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CROSS-REFERENCE TO RELATED APPLICATIONS
U.S. patent application Ser. No. 488,930 entitled "Read Time Fourier Transformer Using One Acousto-Optical Cell" also filed by Applicant is related to this case. A Terminal Disclaimer has been filed in conjunction with the above-referenced Application for the portion of the term of any patent granted on this Application.
BACKGROUND
1. Field of the Invention
The field of the invention in general is an optical signal processor and in particular is an optical Fourier transformer utilizing one acousto-optical cell.
2. Description of the Prior Art
Fourier transforms are used in many fields of technology for converting information from one representation to another. Fourier transformations of time-domain signals are particularly important in signal processing such as in the fields of radar and sonar for which the one-dimensional transformation is given by ##EQU1## The function S(t) is the time-domain signal and S'(f) is the frequency-domain signal which is the Fourier transform of S(t). The conventions used to define Fourier transformations may be somewhat different from those of Eqn. (1) but they only introduce additional constants of proportionality.
For signal processing of arbitrary waveforms, the transformation of Eqn. (1) cannot be performed analytically. One available method to Fourier transform signals involves sampling the signal S(t), digitizing the samples, and then using a computer to numerically transform S(t) to S'(f). Elaborate but efficient computer codes have been written for this task under the generic name of fast Fourier transforms (FFTs). Alternatively electronic chips have been implemented which perform the parallel analog equivalent of the digital FFT.
These FFT methods, although fast, are not nearly fast enough for the requirements of evolving systems. Not only are they throughput or bandwidth limited, but they are not real-time Fourier transformers in the respect that the signal S(t) must, in general, be completed before the transformation procedure is initiated. Furthermore, the fastest electronic FFTs tend to be heavy or power-consuming.
SUMMARY OF THE INVENTION
Accordingly it is an object of this invention to provide a real-time Fourier transformer.
It is a further object of this invention to provide a compact, low-power Fourier transformer.
It is yet a further object of this invention to provide a Fourier transformer that is accurate and free of environmental perturbations.
The invention is an acousto-optical processor for performing Fourier transforms in which a temporally varying signal modulates the intensity of a coherent light source. The resulting beam is split into two beams which are directed onto one face of an acousto-optical cell such as a Bragg cell with corresponding rays of the two beams hitting opposite ends of the Bragg cell upon which is impressed a linear FM or chirp signal. The acousto-optic cell diffracts both beams and the diffracted beams of the same order are recombined with the corresponding rays being coincident such that they interfere. The beams can be split and combined by polarization techniques. Optical detectors integrate the light intensity at points across the combined beam. The spatial distribution of integrated intensity is related to the Fourier transform of the temporally varying signal. Noise and DC background can be eliminated by introducing 180° of additional phase in one of the beams between successive runs and comparing the intensities of the runs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial representation of an optical processor.
FIG. 2 is a schematic representation of a prior art optical Fourier transformer.
FIG. 3 is a schematic cross-section of an embodiment of the invention using non-polarized light.
FIG. 4 is a schematic cross-section of an embodiment of the invention using two beam splitters and polarization discrimination.
FIG. 5 is a schematic cross-section of an embodiment of the invention using one beam splitter and polarization discrimination.
FIG. 6 is a pictorial representation of an embodiment of the invention of multiple Fourier transforms.
FIG. 7 is an oscilloscope trace of output of the embodiment of FIG. 3. The horizontal axis is frequency and the vertical axis is the Fourier transform of the input signal. An additional spatial carrier modulates the Fourier transform.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIG. 1 thereof, computation of the type required by the Fourier transformation of Eqn. (1) can be performed by optical processors. An optical processor of simple but quite general design, shown in schematic representation in FIG. 1, comprises a light source 10, the intensity of which is controlled by a temporally varying input signal S(t). The light source uniformly illuminates an acousto-optical cell 12 which, by one of various mechanisms, affects the light passing through it according to a function h(t,x), which in this general formulation is a function of both time and the distance along the acousto-optical cell 12. There are several types of interactions possible in the acousto-optical cell. For this initial discussion, let the interaction be a modulated photo-elastic interaction which affects the phase of the light passing through the cell.
An optical detector array 14 is positioned to intercept the light passing through the acousto-optic cell 12 and is of a type which integrates the light intensity for a time T to produce the integrated intensity function g(x). It is assumed that each of the array elements can be individually read. For convenience, it is further assumed that there is a direct relationship between the positions x along the acousto-optic cell 12 and the detector array 14 so that the two positions are commonly labeled. The integrated intensity function is then given by ##EQU2##
It can be seen that the optical processor of FIG. 1 acts to transform the function S(t) into the function g(x) according to the kernel h(t,x). The complication that the transformation, such as the Fourier transform of Eqn. (1), is integrated over infinite limits while the integration of Eqn. (2) is limited to a finite time T is not a major problem if the function S(t) is periodic or of negligible value for times longer than T.
The acousto-optic cell 12 having a generalized kernel h(t,x) is difficult to build and operate. A much simplified acousto-optic cell 12 relies on the fact that sound waves propagate through a crystal at a fixed and finite velocity v which is near 6 millimeters per microsecond for most crystals. If a signal h(t) is impressed on one end of an acousto-optic cell 10 by a piezo-electric transducer so as to launch a sound wave of velocity v and if the cell 12 is terminated at its other end so that no reflections occur, then the kernel of the cell assumes the simplified form h(t,x)=h(t-x/v).
A form of kernel found particularly useful in implementing Fourier transforms is a chirp of linear FM in which the signal produced by the transducer is
h(t)=cos(ω.sub.o t+αt.sup.2 /2). (3)
The control circuit producing the chirp can be a linear FM sweep generator. The frequency ω o is the carrier frequency of the acousto-optic cell and may be 1 GHz. However the frequency is swept at a chirp rate α to produce a linear FM signal having a constant envelope. Usually the frequency swept is a small fraction of the carrier frequency.
One type of acousto-optic cell found particularly useful is a Bragg cell in which a wave launched by a transducer on one end of it will affect the refractive properties of the cell according to the local amplitude of the wave in the cell. A multi-wavelength waveform present on the Bragg cell will cause the cell to operate as a diffraction grating and to produce diffraction patterns of order n at an angle θ B according to the Bragg equation
sin θ.sub.B =nλ/2 a . (4)
where a is the period of the wave on the Bragg cell. λ is the wavelength of the incident radiation and θ B is the Bragg angle.
A Fourier transformer using the above concepts has been described by J. N. Lee et al. in Applied Physics Letters, volume 41. pages 131-133, 1982 which is herein incorporated by reference and is shown generally in FIG. 2. A laser 20 produces a beam of coherent light which is expanded but its collimation maintained by a microscope objective 22 and two cylindrical lenses 24 and 26. The relatively large collimated beam is then directed through a first beam splitter 28 which divides the beam into two equal beams. The lower beam is directed through a Bragg cell 30 onto which is applied a chirp signal through a piezo-electric transducer 31. In FIG. 2 is shown an incident upper ray 32 and lower ray 34 of the lower beam passing through the Bragg cell 30 as undiffracted upper and lower rays 36 and 38 respectively (i.e. of order 0) but also creating diffracted upper and lower rays 42 and 44. It will be assumed that the diffracted rays 42 and 44 are of order +1, i.e. n=1 in Eqn. (4). With the correct orientation of the Bragg cell 30, both -1 orders can also be used. For maximum efficiency of conversion of the incident rays 32 and 34 into +1 diffracted rays, the Bragg cell 32 is canted at the lowest order Bragg angle relative to the beam and the +1 diffracted rays will be at twice the Bragg angle relative to the incident rays 32 and 34. The beams containing the diffracted and undiffracted rays 42, 44. 36 and 38 are focussed by a lens 46 onto a mask 48 positioned such that the +1 diffracted rays 42 and 44 pass through a slit 50 in the mask 48 while the undiffracted rays 36 and 38 and all other orders of diffracted rays fall upon the mask 48 and are absorbed. The diffracted rays 42 and 44 are then recollimated by another lens 52. This combination of lenses 46 and 52 and a mask 48 is known as a spatial filter and can be used to select one order of diffracted beam while suppressing the other orders. The rays 42 and 44 are then reflected from a mirror 54 and then enter another beam splitter 55 which will act also as a beam combiner and will direct the beam toward an optical detector array 56.
The other beam resulting from the the first beam splitter 28 is treated in much the same way as the first beam, reflecting from a mirror 57, passing through a second Bragg cell 58 with a transducer 59 on one end, a lens 60, and through a mask 62 positioned to pass +1 diffracted rays, being recollimated by another lens 64 onto the beam splitter 55. However it is required that the beam be oriented such that the ray 66 passing through the end of the Bragg cell 58 nearest the transducer 59 have originated from the same ray that produced the lower ray 34 passing through the end of the other Bragg cell 30 furthest from the transducer 31. It is further required that upon exiting the second beam splitter 55 these two rays be coincident so they can interfere with each other upon arriving at the detector array 56. The apparatus shown in FIG. 2 amounts to a Mach-Zehnder interferometer using the +1 order light diffracted from the Bragg cells 30 and 58. The two Bragg cells 30 and 58 driven in opposite directions by a chirp signal are in the two arms of the Mach-Zehnder interferometer.
Because of the interference between the two beams, many of the lowest order terms of the beams cancel to leave mostly cross-terms between the beams. If the difference in separation of the location in the respective Bragg cells 30 and 58 through which the rays from the respective transducer is denoted by a relative delay τ and if the element on the detector array 56 that detects both these rays is also denoted by τ, then it can shown that the element accumulates a charge after an integration time T of ##EQU3## In Eqn. (5), I(t) is the laser intensity, k 1 and k 2 are proportionality constants, ω o and α are the carrier frequency and the chirp rate respectively of the chirp signal. The first term in Eqn. (5) is a signal dependent direct current (DC) term, which must be eliminated to yield the second term which contains the Fourier transform of S(t) modulating the spatial carrier term exp(-i2ω o τ).
The Fourier transformer of FIG. 2 has been sucessfully tested. However it suffers from numerous problems. It requires careful equilization of the pathlength, especially when the laser 20 is under pulse modulation, in order to ensure good fringe visibility. Furthermore because the optical paths are not common, the interferometer is also sensitive to phase perturbations that the environment introduces in one arm of the interferometer but not in the other. A further practical limitation is that two Bragg cells are required and good quality matched Bragg cells are expensive and difficult to obtain.
The performance of the Mach-Zehnder optical Fourier transformer can be greatly improved if only a single Bragg cell is used. Such an optical Fourier transformer is the subject of a patent application simultaneously filed by this inventor and herein incorporated by reference. This Fourier transformer uses a beam splitter to divide a beam of collimated coherent light into two separate beams. By the use of passive optical components these two beams are directed onto opposing faces of a single acousto-optical cell. Furthermore one of the beams is inverted so that corresponding rays of the two beams pass through opposite ends of the acousto-optical cell. Because of the finite velocity of the chirp signal through the Bragg cell, different wavelength signals simultaneously exist on different parts of the Bragg cell. Both beams upon passing through the acousto-optic cell while it is being chirped produce diffracted beams. Optical components then redirect and invert the diffracted beams so that corresponding rays in the beams are parallel and interfere upon being detected by a photo-detector array. Such an optical Fourier transformer has been successfully tested. However it requires many optical components that need to be carefully maintained in alignment. The many optical paths that need to be kept separate results in a relatively large Fourier transformer and one that is sensitive to misaligment.
In this invention, a Fourier transformation is accomplished by passing beams in one direction through a single acousto-optical cell. This invention has been described by the inventor in the article, S. Lin, "Compact acousto-optical signal processor for real-time Fourier transformation," Applied Optics. volume 21. pages 3227-3229 (1982), herein incorporated by reference. As shown in cross-section in FIG. 3 a diode laser 70 is driven by a combination of bias current i b and the temporally varying signal S(t) which are combined in a bias tee 72 which combines alternating current (AC) and DC signals. A load resistor 74 separates the bias tee 72 from the diode laser 70. The laser 70 as a result produces a beam 76 of coherent light which is spread and collimated into a collimated beam after it passes through a microscope objective 78 and two cylindrical lenses 80 and 82. The central ray 86 of the collimated beam is shown in FIG. 3 although it is to be understood that the beam has substantial width. For clarity in presenting the invention, the central ray will be understood to represent the entire beam. The height of the beam out of the plane is unimportant in this embodiment. The collimated beam 86 is directed to a first beam splitter 88 where the beam 86 is divided into two beams 90 and 92. One beam 90 is reflected back by a first mirror 94 along the same path to the beam splitter 88 in which the beam is at least partially reflected toward a Bragg cell 96. The other beam is reflected by a first inverting reflector 98 such as a roof prism or a cat's eye reflector back through the beam splitter 88 in which the beam is at least partially transmitted toward the Bragg cell 96. The inverting reflector 98 both reflects the beam 92 and inverts its sides, right for left.
If a single offset ray 100 of the collimated beam offset from the beam's central ray 86 is considered, the beam splitter 88 produces two offset rays 102 and 104. The first mirror 94 reflects its ray 102 as a ray 106 back along the same path here shown in FIG. 3 slightly offset for clarity. Ray 106 is then partially reflected in the beam splitter 88 to form ray 108 which is incident on one side of the Bragg cell 96. On the other hand, the ray 104 reflected by the inverting reflector 98 is reflected back as a ray 110 on the opposite side of the central ray 92 from the incident ray 104. As a result, that part of the ray 110 transmitted through the beam splitter 88 will be incident on that end of the Bragg cell 96 which is opposite the end struck by the corresponding ray 108 reflected from the mirror 94.
The Bragg cell 96 may alternately be other types of acousto-optical cells in which there is an optical interaction on light passing through it produced by a signal independently impressed on the cell. In the Bragg cell implementation, a chirp signal of the form cos(ω o τ+αt 2 /2) is impressed on one end of the Bragg cell 96 through a transducer 97 and the resultant wave travels at a finite velocity across the cell 96 before being characteristically terminated at the other end. The Bragg cell 96 produces a diffracted beam 112 of order +1 from both the mirror reflected beam 90 and invertor reflected beam 92. The efficiency of diffraction is maximized for an orientation of the Bragg cell 96 being at the Bragg angle with respect to the beam 92.
The diffracted beam 112 is then directed to a second beam splitter 114 which divides the diffracted beam 112 into two equal beams 116 and 118. One of the split beams 116 is directly reflected by a second mirror 120 onto its original path back into the second beam splitter 114. Therein the split beam 116 is partially reflected into a final beam 122 incident onto an integrating photo-detector array 124 set perpendicularly across the final beam 122. The individual elements of the array 124 thereby time-integrate the intensity of portions of the final beam 122. Similarly the other split beam 118 is reflected from a second inverting reflector 126 back into the second beam splitter 114 and is partially transmitted therethrough into the final beam 122 onto the detector array 124. The final beam 122 is thus composed of rays coming from both the second mirror 120 and the second inverting reflector 126 and the various rays interfere with each other.
The rays resulting from the one offset ray 100 are traced through the second beam splitter 114 in the following manner. The ray 108 reflected from the first mirror 94 is diffracted in the Bragg cell 96 into a diffracted ray 128 which is split in the second beam splitter 114 into two rays 130 and 132. One ray 130 is reflected from the second mirror 120 into a ray 134 back along its same path into the second beam splitter 114 and reflected partially therefrom into a direct-direct final ray 136. The nomenclature direct-direct refers to the fact that this ray resulted from direct reflections on the first and second mirrors 94 and 120. The ray 132 however is inverted on its reflection from the inverting reflector 126 into a direct-inverted ray 138 that is incident on the detector array 124. The nomenclature direct-inverted means that the ray was directly reflected at the first beam splitter 88 but inverted subsequently at the second beam splitter 114. Similar ray tracing of the ray 139 resulting from the first inverting reflector 98 produces an inverted-direct ray 140 that is coincident with the direct-inverted ray 138 as they strike the detector array 124. Also produced is an inverted-inverted ray 142 coincident with the direct-direct ray 136.
The inverted-direct ray 138 and the direct-inverted ray 140 pass through opposing ends of the Bragg cell 96 and interfere with each other to produce an integrated intensity in the detector array 124 proportional to the second term of Eqn. (5). Likewise the direct-direct ray 136 and inverted-inverted ray 142 also produce an integrated intensity proportional to the second term of Eqn. (5). However because the direct-direct ray was reflected twice while the inverted-inverted ray was inverted twice, differential errors are more likely to occur in combining these two rays 136 and 142 rather than the rays 138 and 140 which have similar paths. It is to be further appreciated that the offset ray 100 produces rays that fall on the detector array 124 at two points and that there is the possibility of confusion of results as it would be unknown if the distribution of collected charge on the detector array 124 is caused by the offset ray 100 or another ray 144 on the other side of the collimated beam 86.
The DC term or first term of Eqn. (5) can be eliminated from the Fourier transformer by recording the signal on the individual elements of the detector array 124 and then repeating the signal S(t) for a second run of the Fourier transformer. However on the second run the phase length of one of the separated paths is increased by a total of 180°. One method of accomplishing this is to attach the first mirror 94 to a piezo-electric driver 146 which translates the mirror 94 one-quarter of a wavelength of the laser radiation along the axis of the beam 90. The charge distribution on the detector array 124 from the second run is then compared to the charge distribution from the first run in a data controller such as a computer. Any difference result from contributions of the second term of Eqn. (5) while the constant contribution of the first term cancels. The undiffracted beam 147 can be eliminated by use of a spatial filter.
Many of the disadvantages hitherto described can be eliminated by polarization discrimination as used in a second embodiment of the invention as shown in cross-section in FIG. 4. A collimated beam 86 of coherent light onto which is impressed the signal S(t) is passed through a first polarizer 160 with its polarization vector set at 45° to the plane of the cross-section. There results two coincident beams of equal intensity of vertically and horizontally polarized radiation, called the initial s-beam and the initial p-beam respectively. Both these beams then pass into a first polarization beam splitter 162 wherein the initial s-beam is reflected to a first quarter-wave plate 164 with its fast axis set at 45° to the normal or to the polarization direction of the s-beam. The beam is then reflected by the inverting reflector 98 back through the first quarter-wave plate 164 to the first polarization beam splitter 162. Because of the double pass through the first quarter-wave plate 164 the polarization of the initial s-beam is changed to p-polarization and that inverted beam therefore passes through the first polarizing beam splitter 162 to a second quarter-wave plate 166 with its fast axis at 45°. Similarly the initial p-beam is transmitted through the polarization beam splitter 162 and thence through a third quarter-wave plate 168 also set at 45° to the normal to the mirror 94 and back through the third quarter-wave plate 168 into the first polarizing beam splitter 162. The third quarter-wave plate 168 has changed the initial p-beam into a direct beam with s-polarization so that it reflects within the first polarizing beam splitter 162 toward the second quarter-wave plate 166 and through it. Both the direct and inverted beams in passing through the second quarter-wave plate 166 are converted to circular polarizations of opposite senses. The orientation of the fast axes of the quarter-wave plates 164, 166, and 168 can be easily understood by one skilled in polarization optics keeping in mind the intended light polarizations and the inversion of polarization upon reflection.
Both beams then pass through a Bragg cell 170 on which a shear mode chirp signal is impressed. Both beams being of circular polarization will diffract with equal efficiency and produce diffracted beams of +1 order having circular polarization of opposite sense from that of the incident respective beams. The diffracted beams pass through a fourth quarter-wave plate 172 similarly with its fast axis at 45° wherein the diffracted beam resulting from the initial p-beam is changed from circular to p-polarization. Similarly the initial s-beam produces an s-polarization diffracted beam. Both these beams then pass into a second polarization beam splitter 174. The p-polarized beam is transmitted through the second beam splitter 174 and then passes through a fifth quarter-wave plate 176 set at 45° into a second inverting reflector 178 from which it reflects back through the quarter-wave plate 176 into the second beam splitter 174. Because of the double pass through the fifth quarter-wave plate 176 the initial s-beam has been converted to p-polarization so that it is reflected from the second beam splitter 174 through a second polarizer 180 with an orientation perpendicular to that of the first polarizer 160. Similarly the s-polarized beam is reflected by the second polarizing beam splitter 174 through a sixth quarter-wave plate 182 set at 45° and is reflected by a flat mirror 184 back through the sixth quarter-wave plate 182. Because of its then p-polarization it is transmitted through the second polarizing beam splitter 174 and through the second polarizer 180.
Each of the initial beams eventually is directly reflected once by one of the mirrors 94 and 184 and is also inverted by one of the inverting reflectors 98 and 178 so as to equalize pathlengths and to reduce differential path noise. Both beams after passing the second polarizer 180 have the same polarization so that they interfere. Furthermore the rays that are interfering have passed through opposing ends of the Bragg cell 170. The interfering beams then fall on the photo-detector array 124 which measures a distribution related to the Fourier transform of S(t). Subtraction of background and the DC term is accomplished by changing the phase length of one of the beams by 180° on different runs of S(t) and comparing the distribution on the detector array 124 between runs. One method of accomplishing this is to attach the mirror 94 to a piezo-electric driver 146 that moves the mirror 94 by one-quarter of a wavelength of the laser light between runs.
The number of components can be reduced by making the first polarizing beam splitter 162 work in two directions as shown for a third embodiment presented in cross-section in FIG. 5. The components surrounding the first beam splitter 162 are the same as for the embodiment of FIG. 4 except that a polarization reflector 186 is placed between the first polarizer 160 and first beam splitter 162 with its polarization orientation set to transmit light transmitted by the first polarizer 160. A glass wedge oriented at the Brewster angle to the beam performs such a function as does a dielectric thin film matched to the laser radiation. The other beam splitter is replaced by an inverting reflector such as a combination of a convex lens 188 with its focal point near a third mirror 190. The part of the third mirror 190 where the undiffracted beam is focussed is covered with an optical absorber 192. The beams after being inverted and reflected pass through the Bragg cell 170 without being appreciably diffracted. From thence the beams enter the polarization beam splitter 162 in which the beam which has previously been reflected into the inverting reflector 98 is now reflected into the flat mirror 94. Similarly the beam that previously has been transmitted into the flat mirror 94 is now transmitted to the inverting reflector 98. Both these beams travel toward the polarization reflector 186 which reflects the beams through the second polarizer 180. The combined beams interfere and strike the photo-detector array 124.
The Fourier transformers heretofore described have all had two-dimensional form, i.e. no vertical structure has been described but it has been assumed that they extend only a finite distance in the vertical direction. By stacking such transformers one on top of another in an integrated structure it is possible to compactly transform much data in a parallel operation. An embodiment of a three-dimensional is shown in pictorial representation in FIG. 6 which can simultaneously perform many Fourier transforms on the same signal. This embodiment is the three-dimensional extension of the embodiment of FIG. 3 and is intended to perform the Fourier transformation over a wide frequency range.
A laser on which is impressed the signal S(t) provides a large beam of light that falls upon a first beam splitter 200, On the other side is a first flat mirror 202 mounted on a piezo electric driver 204 which provides phase shifts for DC and background subtraction. On another side of the first beam splitter 200 is positioned an inverting reflector 206. The beams upon exiting the first beam splitter 200 strike a first lens array 208 of cylindrical lenses of focal length f. Spaced a distance f from the first lens array 208 is a multi-channel Bragg cell 210. The channels are positioned on the line foci of the lens array 208. Each channel is controlled by a separate chirp signal having a different chirp bandwidth so that a different frequency range is being analyzed in each channel. A second lens array 212 is placed on the other side of the Bragg cell 210 symmetric to the first lens array 212. The two lens arrays 208 and 212 enhance coupling efficiency and reduce cross-talk between channels. The Bragg cell 210 produces +1 order diffracted beams which after being recollimated by the second lens array 212 enter a second beam splitter 214. Arranged about the second beam splitter 214 are a second flat mirror 216, a second inverting reflector 218, and a two-dimensional photo-detector array 220. The elements of each channel of the detector array 220 integrate the intensity of the beam resulting from the corresponding channel of the Bragg cell 210. Each of the channels represents a different frequency bandwidth. The elements in that channel of the detector array 220 represent frequencies within the bandwidth of that channel.
Other implementations of three-dimensional Fourier transformer are possible. For instance many separate signals can be simultaneously transformed by impressing the signals on separate and parallel sheet beams and passing them all through a tall single-channel Bragg cell that subjects all the sheet beams to the same chirped diffraction pattern.
The use of the invention has been experimentally verified using the embodiment of FIG. 3. An incident sheet beam was produced of dimension about 2.54 cm×1.0 mm. A longitudinal wave Bragg cell of 1 cm aperture was used. The integration time T was 40 ms. The result of the transformation of a sinusoidal signal at 200 Hz is shown in FIG. 7. The trace represents that of the spatial carrier frequency exp(-2ω o τ). The envelope of the carrier is the Fourier transform of S(t).
The Fourier transformers that have been described could also be implemented in other optical technologies such as fiber optics which offer increased miniaturization and rugged operation.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practice otherwise than as specifically described herein. | An optical Fourier transformer comprising an acousto-optical cell such as a Bragg cell upon which is impressed a chirp signal, a laser which is modulated by the signal to be analyzed, optical means for dividing the laser beam into two beams which strike one side of the acousto-optical cell with opposite orientations. The chirped acousto-optical cell diffracts the beams incident thereupon. The two diffracted beams are then recombined with their original orientations reestablished so that they interfere upon striking a time-integrating photo-detector array. The distribution of integrated intensities is related to the Fourier transform of the signal to be analyzed. Polarization discrimination can be used to split and recombine beams and to reduce extraneous beams. Background noise and direct current terms can be eliminated by comparing runs with 180° of phase shift added between runs. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention concerns a method to detect tumorous cell tissue in the gastrointestinal tract with the use of an endocapsule.
[0002] To detect carcinomas of the gastrointestinal tract—for example in the course of a stomach endoscopy—tissue samples are extracted and examined for the presence of a carcinoma. A number of biopsies are frequently required. In order to reduce their number, a procedure known as auto-fluorescence endoscopy is used in which the fluorescence of substances inherent to the body is utilized, which substances occur in an increased concentration in malignant tissue due to increased metabolic activity. An additional possibility for biopsy control is the application of endomicroscopy, i.e. an examination with the aid of a microscope integrated into an endoscope, wherein a contrast agent must be administered to the patient to stain the tissue. However, biopsies continue to be necessary in both cases.
[0003] The extracted tissue samples are histologically examined in a laboratory. For example, slices are produced from the deep-frozen tell tissue samples, which slices are then assessed by the pathologist. A high time cost is necessary for this since not only the sample preparation, but rather also the documentation and the transport require time. Wait times also cannot be avoided. The results are often only present a few days later, which leads to a large psychological stress for the respective patient.
[0004] In addition to the aforementioned assessment of tissue samples, it is also known to conduct a fluorescence cystoscopy for a tumor diagnosis. Tumorous cell tissue is thereby made light-sensitive with suitable chemical substances, and fluorescence at the cells prepared in such a manner is excited upon exposure with light. The light for excitation has a different color than the fluorescence light. However, the substances that are used are strongly phototoxic and can cause necrosis at the correspondingly treated tissue. This can also be utilized for a therapy against carcinomatous tumors, but the knowledge of the positions and the propagation of tumorous cell tissue is required.
[0005] A technique known as 5-ALA induced detection (in which 5-aminolevulinic acid is injected), or methods that are commercially known as Hexvix and TOOKAD and in which other photoactive substances are used, are used to detect tumorous cell tissue.
[0006] It is disadvantageous that substances that are stressful to the respective patient immediately (but also subsequently over a longer time period) must be introduced into the body of the patient. After the injection of the substances, the examinations cannot be implemented immediately afterward since a reaction time (that can vary from patient to patient) must elapse.
[0007] A method for a laser-induced fluorescence of tissue is moreover known from DE 689 25 586 T2, in which method it should be possible to conclude the respective cell tissue type via a fluorescence excitation and the detection of specific characteristic wavelengths in the detected wavelength spectrum of the fluorescence light.
[0008] However, it has been shown that the inherent fluorescence of the body's own chromophores that can be excited to fluorescence in cell tissue (that can be tumorous or healthy) using the occurrence of a wavelength (or possibly also multiple wavelengths) that occur in the fluorescence light spectrum is not unambiguous since a cooperative response of the examined cells cannot be disregarded. These different factors and the biomolecular cell structure have a strong influence, and an association as to whether it is healthy or tumorous cell tissue is not possible with sufficient certainty.
SUMMARY OF THE INVENTION
[0009] An object of the invention is to achieve a detection of tumorous cell tissue in the gastrointestinal tract of a subject in the course of a capsule endoscopy in a shorter amount of time, and with sufficient finding certainty.
[0010] In accordance with the invention, with the use of a radiation source present in an endocapsule, locally defined electromagnetic radiation is emitted toward the cell tissue of the gastrointestinal tract that is to be examined (for example the stomach mucosa), and after a deactivation of the radiation source at the time t 0 , the decay response of the inherent fluorescence intensity of the cell tissue that is excited by the electromagnetic radiation is detected with temporal and spatial resolution. The detection of the inherent fluorescence intensity takes place with one or more known sample rate(s) and is implemented for at least one wavelength. The sample rate is preferably kept constant during the detection.
[0011] With the determined intensity measurement values, the difference autocorrelation function C(t) of the intensity decay response is determined according to Equations (1) and (2), under consideration of the respective known sample rate(s).
[0000] I ( t )= I ( t 0 )−[ I ( t 0 )− I ( t →∞)]*[1− R ( t−t 0 )] (1)
[0000] with
[0000] R ( t−t 0 )=<Δ I ( t )Δ I ( t 0 )> t /<ΔI 2 > t and
[0000] Δ I ( t )= I ( t )− I ( t →∞) (2)
[0000] I(t→∞) is the excited fluorescence light after an infinitely long relaxation that is very small. The relaxation function R(t) results from the correlation function of the fluorescence fluctuations, wherein < > t represents the temporal mean.
[0012] The function C(t)=2[1−R(t)] represents the associated difference correlation function for which the following response can be taken into account given cooperative fluorescence processes:
[0000] C ( t )˜ t 2H (3)
[0013] The exponent H, or the fractal dimension of the stochastic intensity fluctuations D F that can be calculated from this, is a characteristic value for the assessment.
[0014] D F =2−H results and can be used to differentiate healthy and tumorous cell tissue. The exponent H can be determined via linear regression.
[0015] The value D E can be used for a classification with regard to a tumor affliction of the respective exposed cell tissue.
[0016] A comparison with a tumor-specific threshold can be implemented for the classification. However, a specification of a probability of a presence of a tumor can also take place in the classification.
[0017] Under consideration of the specified Equations, the fractal dimension D F is calculated for the respective exposed cell tissue and the value of the determined fractal dimension D F can then be compared with a tumor-specific threshold. Upon exceeding the threshold, the exposed cell tissue of the cell tissue sample is classified as tumorous. Given a shortfall of this threshold, the cell tissue is healthy. The threshold is a numerical value between 1 and 2.
[0018] An exposure, detection and calculation of the fractal dimension D E can thus be implemented at the examined cell tissue in vivo in order to localize healthy tissue and possible tumorous cell tissue. A finding can take place at different positions in that the endocapsule is moved, guided by magnets, to the respective positions. For this an endocapsule includes a magnet system which interacts with an external magnetic field, for example as described in DE 10142253 C1.
[0019] In the evaluation of the intensity decay response, collective electron transitions in cell tissue are described in the invention via an algebraic time response.
[0020] It is preferable to use monochromatic electromagnetic radiation for the inherent fluorescence excitation of the exposed cell tissue. Electromagnetic radiation in the wavelength range between 200 nm and 650 nm are particularly suitable here. Laser light sources can be used as a radiation source. Electromagnetic radiation with a wavelength of 337 nm has proven to be advantageous for the excitation of the inherent fluorescence.
[0021] As already noted, only a selected wavelength is detected from the spectrum of the inherent fluorescence of the cell tissue to be examined and then taken into account. However, two or more wavelengths that deviate from one another and then can be markedly larger or smaller in relation to one another can also be taken into account.
[0022] However, it is advantageous to detect intensity measurement values within an interval around a wavelength of the excited inherent fluorescence, and to determine the difference autocorrelation function of the intensity decay response C(t) of the mean values that have been calculated from the fluorescence intensities detected at the same time for the different wavelengths within the wavelength interval, and to calculate from these the fractal dimension D F for the exposed cell tissue.
[0023] At least 30 wavelengths from the selected wavelength interval should be considered for the mean calculation. The difference of the spacings of the wavelengths from this wavelength interval that are thereby considered should be respectively of equal size. For example, the detection can thus be implemented within a wavelength interval of 421 nm±15 nm.
[0024] The detection can be implemented with a spectrometer at a sample rate ≦1000 ps, preferably ≦100 ps, particularly preferably at approximately 50 ps.
[0025] Examinations of cell tissue can be implemented at multiple positions. However, a respective identical exposure of the selected positions of the cell tissue should thereby be maintained. A respective identically large area should thus be exposed with the same respective energy. For this purpose, the spacing of one or more optical fibers from the surface of the cell tissue that is to be exposed should be constant. For an evaluation and possible consideration in an immediately following operative procedure on a patient (or an operative procedure that is to be implemented later) in which the examination has been implemented in vivo, the knowledge of the respective position at the cell tissue is thus to be detected and documented so that it can be reproduced.
[0026] The examinations of cell tissue can be implemented successively or simultaneously at multiple positions. In the latter cited case, electromagnetic radiation can, for example, be directed—through multiple, correspondingly arranged optical fibers—toward cell tissue or the cell tissue sample at various locations to excite the inherent fluorescence, and after the deactivation of the radiation source the intensity I(t) of the electromagnetic radiation emitted from the cell tissue as a result of the inherent fluorescence of the cell tissue are then directed via optical fibers to a detector.
[0027] With the invention, an examination can be implemented promptly and directly in an operating room. The possibility exists to differentiate tumorous cell tissue from healthy cell tissue with very high probability. With knowledge of the respective extraction location, the invention offers a good basis for decision as to where and how much cell tissue should be operatively removed.
[0028] A device that includes an endocapsule for implementation of the method according to the invention is designed so that living cell tissue, defined locally, is charged with electromagnetic radiation emitted from a radiation source, and a detector for temporally and spectrally resolved detection of the inherent fluorescence intensity of the respective previously exposed cell tissue is connected to an electronic evaluation unit with which the different autocorrelation function C(t) can be determined from the determined intensity measurement values. With the electronic evaluation unit, the fractal dimension D F can be calculated and this value of the fractal dimension D F can be compared with a tumor-specific threshold. An endocapsule can thereby include all required components or only parts of these, as is explained in detail further below.
[0029] A time-consuming preparation of the cell tissue to be examined as it is required in a biopsy is omitted. The physical stress of patients can thereby be reduced since the examination result is present in a markedly shorter amount of time. A very good differentiation can be made between malignant and benign cell tissue.
[0030] No injection of additional substances into the body of patients (with the aforementioned disadvantages) is required either.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a diagram of the intensity decay response given a constant wavelength of 421 nm, acquired with temporal resolution.
[0032] FIG. 2 is a diagram of the intensity decay response acquired with temporal resolution, created with the mean value of multiple wavelengths within a wavelength interval around the wavelength of 421 nm.
[0033] FIG. 3 shows the curve of the difference autocorrelation function over time during decay of the intensity.
[0034] FIGS. 4-10 respectively show devices or endocapsules of different embodiments in accordance with the presence invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The diagrams In FIGS. 1 through 3 are based on examinations that were conducted not in vivo but rather in vitro for reasons of simplification, and for reasons of reproducibility. The cell tissue samples were laid in a groove that represented a receptacle of the cell tissue samples and directed electromagnetic radiation via an optical fiber to specific, predetermined positions of the cell tissue samples. A nitrogen laser was used as a radiation source. The electromagnetic radiation used for the inherent fluorescence excitation of the cell tissue had a wavelength of 337 nm.
[0036] The extracted cell samples were cooled to a temperature of 15° C. to slow necrosis and held at this temperature at least until the end of the examination.
[0037] After deactivation of the radiation source at t 0 , the electromagnetic radiation emitted from the cell tissue as a result of the inherent fluorescence was directed via the same optical fiber to a spectrometer with which a detection in the wavelength interval from approximately 300 nm to approximately 600 nm was possible.
[0038] A characteristic wavelength of 421 nm has been selected at which increased intensities of the inherent fluorescence occurred.
[0039] In the detection, a sampling rate of 50 ps was maintained and a detection of the intensity was made from the point in time t 0 over a time period of 10 ns. An evaluation according to Equations (1) through (3) was made with the intensity measurement values, and the difference autocorrelation function was determined, as shown in FIG. 3 .
[0040] Since a noise was to be recorded at the decay response of the intensity of an individual wavelength, the evaluation was repeated with calculated mean values in analog form. Intensity values were thereby used within a wavelength interval of 421 nm±9.5 nm. FIG. 2 shows the intensity decay response that is thus determined. The mean value calculation thereby took place from 60 wavelengths from this wavelength interval, which 60 wavelengths respectively have a difference of 0.315 nm relative to one another.
[0041] As arises from the diagram shown in FIG. 3 , the value of the fractal dimension D F can be determined with the defined difference autocorrelation function and the slope of a straight line with (t−t 0 ) 2H and given knowledge of the exponent H.
[0042] The determined value D F can be compared with a tumor-specific threshold for the respective examined position of the respective cell tissue sample. For the examined tumors, this threshold was between 1.31 and 1.32.
[0043] However, if the determined value D F is below the threshold, it can be assumed that the examined cell tissue in the respective cell tissue sample is healthy cell tissue free of tumor cells, at least at the location of the sample at which the examination has been conducted.
[0044] However, the invention can also be implemented at at least two elements that can be detectable with the spectrometer, which wavelengths have a larger interval from one another. For example, the temporal intensity decay response can be implemented at the wavelengths 370 nm and 430 nm, possibly also with a described mean value calculation.
[0045] A device with which an examination (of the stomach mucosa 1 , for example) can be made in the manner described above is either formed by an endocapsule 2 that includes all necessary mechanisms or comprises an endocapsule in which only a portion of the necessary mechanisms (but in all cases a radiation source) are included, wherein the remaining portion of the mechanisms are located outside of the endocapsule and outside of the patient body (see FIG. 4-10 ).
[0046] A magnet system 3 that serves for navigation of the endocapsule with the use of an external magnetic field is present in the inner space of an endoscopy 2 . For fluorescence excitation of cell tissue (for example the stomach mucosa 1 ), the endocapsule 2 includes a radiation source 4 , for instance in the form of a laser diode or an LED ( FIG. 4 ). The housing 5 of the endocapsule 2 is penetrated by an opening or, respectively, a window 6 made of radiation-permeable material in the region of the radiation source 4 . The window 6 is arranged at one end of the endocapsule 2 , for example. A battery (not shown) can be present in the endocapsule 2 to supply power to the radiation source 4 . Alternatively, the power supply can take place via a battery or other power source arranged outside of the body, which battery or other power source is connected via a connecting cable 7 with the radiation source 4 . To detect the inherent fluorescence of the examined cell tissue, a detector 11 to detect the fluorescence radiation 8 of the cell tissue is present in the region of the window 8 . For example, the detector can be formed from one or more photodiodes as well as a lens and filter system (not shown), wherein the latter serves for spectral resolution of the inherent fluorescence. For example, a mini-spectrometer that already includes an optical system for spectral resolution can serve as a detector 11 . For example, the spectrometers CM10988MA and CM11009MA that are available from Hamamatsu Deutschland GmbH are suitable. The detector 11 detects the inherent fluorescence intensity of the cell tissue spectrally and with temporal resolution and relays the corresponding data to an electronic evaluation unit 9 which is arranged within the endocapsule 2 , corresponding to FIGS. 4 and 5 . The data calculated by the evaluation unit 9 , which data allow a conclusion about the presence or non-presence of a tumor, are transmitted to a device present outside of the patient body either via a radio interface 10 present in the endocapsule 2 or with a signal line 13 (for example via the connecting cable 7 ). For example, the device comprises a monitor on which a color coding or numerical values for the tumor probability are presented.
[0047] In the endocapsule 2 shown in FIG. 5 , the radiation source is formed by the light exit window 14 of an end of an optical waveguide 15 arranged within the endocapsule 2 . The optical waveguide 15 is directed out of the patient body via a connecting cable 7 connected with the endocapsule 2 , wherein electromagnetic radiation is fed into the other end of the optical waveguide with the aid of an external radiation source 23 .
[0048] In the endocapsule 2 shown in FIG. 6 , the electronic evaluation unit 9 is located outside of the endocapsule 2 and also outside of the patient body. The raw data detected by the detector 11 are transmitted to the external evaluation unit 9 either via a radio interface 10 or via a signal line 16 . The signal line 16 can run in a connecting cable 7 fixed to the endocapsule 2 , wherein this connecting cable 7 can include other additional supply lines, for instance for power supply of the radiation source 4 . However, the radiation emission can also take place via the exit window 14 of an optical waveguide, as in the exemplary embodiment shown in FIG. 5 .
[0049] An additional structural simplification, and therefore also a shrinking of the endocapsule 2 , is achieved if the detector 11 is also arranged outside of the patient body ( FIG. 7 ). Only an optical waveguide 17 that ends in the region of the window 6 is present in the endocapsule 2 , wherein the inherent fluorescence radiation arrives in the optical waveguide 17 via the face 18 of said optical waveguide 17 . The radiation source 4 can be formed by a module and an LED or a laser diode, or by an optical waveguide 15 or by its light exit window 14 . An additional simplification of the endocapsule 2 can take place in that an optical waveguide serving for excitation of the cell tissue and an optical waveguide serving to detect the inherent fluorescence are formed by a single optical waveguide 17 ′ ( FIG. 8 ). Its end arranged outside of the patient body can be associated with a beam splitter 20 . With this the electromagnetic radiation of an external radiation source 23 (thus a radiation source 23 that is arranged outside of the patient body) for the excitation of the inherent fluorescence can be directed via the optical waveguide to the cell tissue, wherein after the deactivation of the radiation source 23 the inherent fluorescence radiation is introduced via the optical waveguide 17 ′ into the detector 11 , and its data are transmitted to the evaluation unit 9 . The optical waveguide 17 ′ as well as the additional aforementioned optical waveguide 15 and 17 can be formed by one or multiple optical fibers. The optical waveguides are advantageously provided with a protective jacket (not shown) or travel within a connecting cable 7 fixed to the endocapsule 2 .
[0050] In all embodiment variants of an endocapsule 2 that are described above, a laser light source 24 operating in the visible range can be present in this. A measurement spot 25 is generated on the examined cell tissue with this laser light source 24 . Furthermore, a camera 26 is present in the endocapsule 2 , such that the measurement spot is visible at the images of the examined tissue and its surroundings that are acquired with the camera and, for example, allows an orientation over the examined area. During the detection of the inherent fluorescence radiation, the distance between the detector 11 and the surface of the examined cell tissue should not change significantly or, respectively, a change of the distance should be accordingly taken into account and corrected in the evaluation. This is done with a distance measurement device described in DE 10 2006 014 857 A1 that—in addition to the laser light source 24 and the camera 26 —comprises an evaluation unit (not shown) that can be integrated into the evaluation unit 9 , for example. The light beam generated by the laser light source generates a distance-independent light marker or, respectively, the measurement spot 25 on the cell tissue. The shape and size of the measurement spot 25 that is transmitted out from the camera 26 (for instance via the radio interface 10 ) is thereby analyzed by the evaluation unit (not shown) with the aid of an image processing software, and the respective distance of the endocapsule 2 or, respectively, of the detector 11 from the cell tissue is determined from the shape and/or size of the measurement spot 25 . A distance varying during the measurement can thus be compensated accordingly by the evaluation unit 9 in the calculation of the fractal dimension D F . The images acquired by the camera 26 are transmitted out via cable or via radio interface 10 .
[0051] A fixed distance of the detector 11 from the cell tissue can be achieved in that a fixing device 27 is present in the endocapsule 2 , with which fixing device 27 this endocapsule 2 can be anchored in the tissue of the gastrointestinal tract. Such a fixing device 27 is described in DE 10 2005 032 290 A1. It comprises an anchor 28 that can be released via a driver device 29 and is connected with the endocapsule 2 via a thread 31 . The anchor 28 , for example, can be found of a material that dissolves after a certain time. In the case of an endocapsule 2 equipped with a fixing device 27 , as well as in other cases, it can be advantageous if radiation source 4 and detector 11 are arranged so as to be spatially variable (for instance are pivotable) within the endocapsule 2 , as this is indicated by the double arrow 30 in FIG. 10 .
[0052] Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted heron all changes and modifications as reasonably and properly come within the scope of their contribution to the art. | In a method and apparatus for detecting tumorous cell tissue in a gastrointestinal tract, electromagnetic radiation is emitted in a locally defined manner from an endoscope onto cell tissue and, after deactivation of the radiation, the decay of the inherent fluorescence intensity of the irradiated cell tissue, excited by the electromagnetic radiation, is detected, with temporal and spectral resolution and with a known scanning rate for at least one wavelength. From the intensity measurement values obtained in this manner, the difference autocorrelation function of the intensity decay is determined, from which a fractal dimension for the irradiated cell tissue is determined. The value of the fractal dimension is used to classify the irradiated cell tissue as to a degree to which the cell tissue is tumorous. | 0 |
FIELD OF THE INVENTION
The present invention relates to new chemical entities and the incorporation and use of the new chemical entities as fragrance materials.
BACKGROUND OF THE INVENTION
There is an ongoing need in the fragrance industry to provide new chemicals to give perfumers and other persons the ability to create new fragrances for perfumes, colognes and personal care products. Those with skill in the art appreciate how differences in the chemical structure of the molecule can result in significant differences in the odor, notes and characteristics of a molecule. These variations and the ongoing need to discover and use the new chemicals in the development of new fragrances allow the perfumers to apply the new compounds in creating new fragrances.
SUMMARY OF THE INVENTION
The present invention provides novel chemicals, and the use of the chemicals to enhance the fragrance of perfumes, toilet waters, colognes, personal products and the like. In addition, the present invention is directed to the use of the novel chemicals to enhance fragrance in perfumes, toilet waters, colognes, personal products and the like.
One embodiment of the invention is directed to a fragrance compound and a method of improving, enhancing or modifying a fragrance formulation through the addition of an olfactory acceptable amount of the following formula:
wherein the dotted line represents a possible single or double bond; wherein R is selected from the group consisting of a C 3 -C 7 hydrocarbon moiety and R 1 and R 2 together can be selected from the group consisting of oxygen and may form a closed ring structure represented by
In another embodiment, the present invention is directed to the fragrance compounds and a method of improving, enhancing or modifying a fragrance formulation through the addition of an olfactory acceptable amount the following formula:
wherein the dotted line represents a possible single or double bond; wherein R is selected from the group consisting of a C 3 -C 7 hydrocarbon moiety, such as C3H and R 1 and R 2 together can be selected from the group consisting of oxygen and may form a closed ring structure represented by
In another embodiment of the invention the use of these materials as a fragrance chemical to enhance fragrance in perfumes, toilet waters, colognes, personal products and the like is also disclosed.
In an additional embodiment of the invention, a method for enhancing a perfume composition by incorporating an olfactory acceptable amount of the compounds provided above is disclosed.
In yet another embodiment of the invention is directed to the following intermediate compounds having the formula:
wherein R 3 is selected from the group consisting of C 3 -C 7 straight chain hydrocarbon moiety and the dotted line may represent a single or double bond.
These and other embodiments of the present invention will be apparent by reading the following specification.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, suitable straight hydrocarbon moieties include ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and the like. Suitable branched hydrocarbon moieties include isopropyl, sec-butyl, tert-butyl, 2-ethyl-propyl, and the like. Suitable hydrocarbon moieties containing double and triple bonds include ethene, propene, 1-butene, 2-butene, penta-1-3-deine, hepta-1,3,5-triene, butyne, hex-1-yne and the like. Suitable cyclic hydrocarbon moieties include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like.
In the preferred embodiment of the invention, the novel compounds of the present invention are represented by the following structures:
Those with skill in the art will recognize that Structure IV is 3-heptylbicyclo[3.2.1]oct-6-en-2-one, Structure VIII is 3-butylbicyclo[3.2.1]oct-6-en-2-one, Structure IX is Bicyclo[3.2.1]octan-2-one, 3-butyl, Structure XVIII is 3-pentylbicyclo[3.2.1]oct-6-en-2-one, Structure XIX is Bicyclo[3.2.1]octan-2-one, 3-pentyl and Structure XIII is 3-hexylbicyclo[3.2.1]oct-6-en-2-one.
In another embodiment of the invention the following compounds of the present invention are represented by the following structure:
Structure XIV is known by one skilled in the art as Spiro[bicyclo[3.2.1]oct-6-ene-2,2′-[1,3]dioxoloane], 3-hexyl.
The intermediate compounds of the present invention are listed below:
Those with skill in the art will recognize that Structure VII is 3-pentylbicyclo[3.2.1]oct-6-en-2-one; Structure XVII is 2-pentylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde, Structure XII is 2-hexylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde and Structure III is 2-heptylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde
Those with skill in the art will recognize that some of the compounds of the present invention have a number of chiral centers, thereby providing numerous isomers of the claimed compounds. It is intended herein that the compounds described herein include isomeric mixtures of such compounds, as well as those isomers that may be separated using techniques known to those having skill in the art. Suitable techniques include chromatography such as high performance liquid chromatography, referred to as HPLC, and particularly gel chromatography and solid phase microextraction, referred to as SPME.
The compounds of the present invention were prepared according to the following general reaction schemes, the details of which are specified in the Examples. The starting materials and catalysts were purchased from Aldrich Chemical Company.
Structure VI, 3-heptylbicyclo[3.2.1]oct-6-en-2-one was prepared according to the following reactions scheme.
First 2-methylene nonanal (II) was prepared as follows,
Then 2-heptylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (III) was prepared accordingly, with dicyclopentadiene (Aldrich Chemicals) used as a catalyst,
3-heptylbicyclo[3.2.1]oct-6-en-2-one (IV) was provided accordingly,
3-pentylbicyclo[3.2.1]oct-6-en-2-one (VIII) and Bicyclo[3.2.1]octan-2-one, 3-butyl (IX) were prepared according to the general reaction scheme below, the details of the reaction are provided in the Examples.
Preparation of 2-methylene hexanal (V)
Preparation of 2-pentylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (VII)
Preparation of 3-butylbicyclo[3.2.1]oct-6-en-2-one (VIII)
Preparation of Bicyclo[3.2.1]octan-2-one, 3-butyl (IX)
3-hexylbicyclo[3.2.1]oct-6-en-2-one (XIII) was prepared according to the following general reaction scheme.
First 2-methylene octanal (X) was prepared,
Then 2-hexylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (XII) was prepared as follows,
Preparation of 3-hexylbicyclo[3.2.1]oct-6-en-2-one (XIII)
Preparation of Spiro[bicyclo[3.2.1]oct-6-ene-2,2′-[1,3]dioxoloane], 3-hexyl (XIV)
3-pentylbicyclo[3.2.1]oct-6-en-2-one (XV) and Bicyclo[3.2.1]ocatn-2-one, 3-pentyl (XVI) were prepared according to the general reaction scheme,
First 2-methylene heptanal (XVI) was prepared,
Then, 2-pentylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (XVII) was prepared,
3-pentylbicyclo[3.2.1]oct-6-en-2-one (XVIII) was prepared as follows,
Finally, Bicyclo[3.2.1]octan-2-one, 3-pentyl (XIX) was prepared accordingly,
The use of the compounds of the present invention is widely applicable in current perfumery products, including the preparation of perfumes and colognes, the perfuming of personal care products such as soaps, shower gels, and hair care products as well as air fresheners and cosmetic preparations. The present invention can also be used to perfume cleaning agents, such as, but not limited to detergents, dishwashing materials, scrubbing compositions, window cleaners and the like.
The compounds of the present invention possess the following fragrance notes:
Structure IV, 3-heptylbicyclo[3.2.1]oct-6-en-2-one, possesses weak, methyl salicylate like and slightly fruity fragrance notes;
Structure VIII, 3-butylbicyclo[3.2.1]oct-6-en-2-one, possesses fruity, slight green, herbal and celery notes;
Structure IX, Bicyclo[3.2.1]octan-2-one, 3-butyl, possesses coconut, lactonic, woody, minty, jasmonic cis like, anisic and tuberose notes;
Structure XIII, 3-hexylbicyclo[3.2.1]oct-6-en-2-one, possesses fruity, floral, sweet and aldehydic fragrance notes;
Structure XVIII, 3-pentylbicyclo[3.2.1]oct-6-en-2-one, possesses anisic, fruity, spicy, mossy, herbal and celery fragrance notes;
Structure XIX, Bicyclo[3.2.1]octan-2-one, 3-pentyl, possesses sweet, slight, anisic, floral and celery notes; and
Structure XIV, Spiro[bicyclo[3.2.1]oct-6-ene-2,2′-[1,3]dioxoloane], 3-hexyl, possesses piney and weak fragrance notes.
In these preparations, the compounds of the present invention can be used alone or in combination with other perfuming compositions, solvents, adjuvants and the like. The nature and variety of the other ingredients that can also be employed are known to those with skill in the art.
Many types of fragrances can be employed in the present invention, the only limitation being the compatibility with the other components being employed. Suitable fragrances include but are not limited to fruits such as almond, apple, cherry, grape, pear, pineapple, orange, strawberry, raspberry; musk, flower scents such as lavender-like, rose-like, iris-like, carnation-like. Other pleasant scents include herbal and woodland scents derived from pine, spruce and other forest smells. Fragrances may also be derived from various oils, such as essential oils, or from plant materials such as peppermint, spearmint and the like.
A list of suitable fragrances is provided in U.S. Pat. No. 4,534,891, the contents of which are incorporated by reference as if set forth in its entirety. Another source of suitable fragrances is found in Perfumes, Cosmetics and Soaps , Second Edition, edited by W. A. Poucher, 1959. Among the fragrances provided in this treatise are acacia, cassie, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, narcissus, freshly-cut hay, orange blossom, orchid, reseda, sweet pea, trefle, tuberose, vanilla, violet, wallflower, and the like.
Olfactory effective amount is understood to mean the amount of compound in perfume compositions the individual component will contribute to its particular olfactory characteristics, but the olfactory effect of the perfume composition will be the sum of the effects of each of the perfumes or fragrance ingredients. Thus the compounds of the invention can be used to alter the aroma characteristics of the perfume composition, or by modifying the olfactory reaction contributed by another ingredient in the composition. The amount will vary depending on many factors including other ingredients, their relative amounts and the effect that is desired.
The level of compound of the invention employed in the perfumed article varies from about 0.005 to about 10 weight percent, preferably from about 0.5 to about 8 and most preferably from about 1 to about 7 weight percent. In addition to the compounds other agents can be used in conjunction with the fragrance. Well known materials such as surfactants, emulsifiers and polymers to encapsulate the fragrance can also be employed without departing from the scope of the present invention.
Another method of reporting the level of the compounds of the invention in the perfumed composition, i.e., the compounds as a weight percentage of the materials added to impart the desired fragrance. The compounds of the invention can range widely from 0.005 to about 70 weight percent of the perfumed composition, preferably from about 0.1 to about 50 and most preferably from about 0.2 to about 25 weight percent. Those with skill in the art will be able to employ the desired level of the compounds of the invention to provide the desired fragrance and intensity.
When used in a fragrance formulation this ingredient provides freshness making the fragrance top notes more desirable and noticeable. It also has a spicy peppery odor which is very commonly used in men's fragrances added for fragrance appropriateness and desirability. The woody part of it is very useful in both men's and women's fragrances adding body and substantivity to the finished product. All of these odor qualities found in this material assist in beautifying and enhancing the finished accord improving the performance of the other materials in the fragrance. The floral of it will beautify as well and makes the fragrance more desirable and add the perception of value. There is also the fruity side of it which is found in many fragrances today which happens to be very trendy, especially for the younger consumer.
The following are provided as specific embodiments of the present invention. Other modifications of this invention will be readily apparent to those skilled in the art. Such modifications are understood to be within the scope of this invention. The chemical materials used in the preparation of the compounds of the present invention are commercially available from Aldrich Chemical Company. As used herein all percentages are weight percent unless otherwise noted, ppm is understood to stand for parts per million, L is understood to be liter, Kg is understood to be kilogram, and g be gram. IFF as used in the examples is understood to mean International Flavors & Fragrances Inc., New York, N.Y., USA.
EXAMPLE I
Process for the Preparation of 3-heptylbicyclo[3.2.1]oct-6-en-2-one (VI)
Preparation of 2-methylene nonanal (II)
A 5-liter flask fitted with an overhead stirrer and condenser was charged with di-N-butyl amine (61 g, 0.47 mol) and acetic acid (56 g, 0.9 mol). Roughly 900 ml of 37% formaldehyde solution in water (351 g formaldehyde, 11.7 mol) was then added and the resulting solution was heated to 50° C. with stirring. After this temperature was reached nonanal (1000 g, 7.0 mol) was fed in over about 2 h. A slight exotherm was noticed during the feed. Monitoring by GC showed the consumption of nonanal and the production of 2-methylene nonanal, finally reaching roughly 95% conversion after the addition was complete. The reaction mixture was allowed to cool to room temperature, poured into a separatory funnel, and washed once with 5% HCl solution. The organic layer was then washed once with saturated sodium bicarbonate, then taken directly on to the next step.
Preparation of 2-heptylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (III)
The material from the previous step (868 g, 5.6 mol) was loaded into a 2-liter stainless steel pressure reactor along with dicyclopentadiene (443 g, 3.4 mol). The pressure reactor was sealed and the mixture was heated to 170° C. with stirring. Samples taken from the reactor showed the generation of a new peak in eventual 60% conversion, along with several smaller peaks. After two hours at this temperature the material was cooled to room temperature and refluxed at 110° C. under vacuum in order to remove lower-boiling impurities. This treatment resulted in 909 g material, of roughly 75% purity. The material was taken on to the next step without further purification.
Preparation of 3-heptylbicyclo[3.2.1]oct-6-en-2-one (IV)
Aluminum chloride (279 g, 2 mol) was dissolved in one liter of methylene chloride in a three liter flask and cooled to 0° C. Structure III (909 g, 4.1 mol) was loaded into an addition funnel and fed into the reaction flask while maintaining this temperature. After two hours the reaction was complete as shown by GC measurements. The reaction mixture was then poured onto ice and 10% sulfuric acid, and the organic layers were separated and washed once with 10% sodium hydroxide solution. The methylene chloride solvent was then removed under reduced pressure, and the resulting oil was purified by simple distillation to yield 260 g (28% yield) of IV. Structure IV, 3-heptylbicyclo[3.2.1]oct-6-en-2-one, possesses weak, methyl salicylate like and slightly fruity fragrance notes.
1 H NMR (CDCl 3 , 500 MHz): 0.87 ppm (t, 3H, J=6.72 Hz), 1.14-1.38 ppm (m, ˜50% of 1H+11H), 1.43-1.50 ppm (m, ˜50% of 1H), 1.75-1.83 ppm (m, ˜50% of 1H+1H), 2.39-2.42 ppm (m, ˜50% of 1H), 2.45-2.49 ppm (m, ˜50% of 1H), 2.62-2.70 ppm (m, ˜50% of 1H), 2.76-2.82 ppm (m, ˜50% of 1H), 2.82-2.85 ppm (m, ˜50% of 1H), 3.00-3.02 ppm (m, ˜50% of 1H), 3.04-3.06 ppm (m, ˜50% of 1H), 5.78-5.82 ppm (m, ˜50% of 1H), 6.03-6.06 ppm (m, ˜50% of 1H), 6.20-6.26 ppm (m, 1H).
EXAMPLE II
Process for the Preparation of 3-pentylbicyclo[3.2.1]oct-6-en-2-one (VIII) and Bicyclo[3.2.1]octan-2-one, 3-butyl (IX)
Preparation of 2-methylene hexanal (V)
A 5-liter flask fitted with an overhead stirrer and condenser was charged with di-N-butyl amine (77 g, 0.59 mol) and acetic acid (72 g, 1.2 mol). Roughly 1100 ml of 37% formaldehyde solution in water (450 g formaldehyde, 15 mol) was then added and the resulting solution was heated to 50° C. with stirring. After this temperature was reached hexanal (1000 g, 10 mol) was fed in over about 2 hours. A slight exotherm was noticed during the feed. Monitoring by GC showed the consumption of hexanal and the production of 2-methylene hexanal, finally reaching roughly 95% conversion after the addition was complete, although only 60% was the desired product. The reaction mixture was allowed to cool to room temperature, poured into a separatory funnel, and washed once with 5% HCl solution. The organic layer was then washed once with saturated sodium bicarbonate, then taken directly on to the next step.
Preparation of 2-pentylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (VII)
The material from the previous step (727 g, 6.5 mol) was loaded into a 2-liter stainless steel pressure reactor along with dicyclopentadiene (511 g, 3.9 mol). The pressure reactor was sealed and the mixture was heated to 170° C. with stirring. Samples taken from the reactor showed the generation of a new peak in eventual 60% conversion, along with several smaller peaks. After two hours at this temperature the material was cooled to room temperature and distilled using a simple distillation apparatus. The final yield of material was 570 g, or 49% yield.
Preparation of 3-butylbicyclo[3.2.1]oct-6-en-2-one (VIII)
Compound VII (570 g, 3.2 mol) was loaded into a 3-liter round bottom flask fitted with a condenser and an overheard stirrer. This was followed by one liter of methylene chloride. The resulting solution was cooled to −50° C. using a dry ice bath. After this temperature was reached, anhydrous aluminum chloride (215 g, 1.6 mol) was added in one portion. The light yellow solution changed color to orange, then dark red with a simultaneous increase in reaction temperature, up to roughly −30° C. A GC sample taken after the addition was complete showed little reaction. The reaction temperature was allowed to gradually increase to 15° C., and GC monitoring showed the complete consumption of start material after one hour at this temperature. The reaction mixture was then poured onto ice and 10% sulfuric acid, and the organic layers were separated and washed once with 10% sodium hydroxide solution. The methylene chloride solvent was then removed under reduced pressure, and the resulting oil was purified by simple distillation to yield 224 g (49% yield) of VIII.
Structure VIII, 3-butylbicyclo[3.2.1]oct-6-en-2-one, possesses fruity, slight green, herbal and celery notes.
1 H NMR (CDCl 3 , 500 MHz): 0.88 ppm (t, 3H, J=7.03 Hz), 1.18-1.38 ppm (m, 5H+˜20% of 1H), 1.44-1.50 ppm (m, ˜80% of 1H), 1.75-1.85 (m, ˜80% of 1H), 1.84 ppm (d, 1H, J=11.1 Hz), 1.94-1.99 ppm (m, ˜80% of 1H), 2.12-2.25 ppm (m, ˜20% of 3H), 2.39-2.52 (m, 1H), 2.64-2.71 (m, ˜80% of 1H), 2.77-2.88 ppm (m, 1H), 3.00-3.07 ppm (m, 1H), 5.78-5.82 ppm (m, ˜20% of 1H), 6.02-6.07 ppm (dd, ˜80% of 1H, J=5.29, 2.82 Hz), 6.19-6.28 ppm (dd, 1H, J=5.55, 2.65 Hz).
Preparation of Bicyclo[3.2.1]octan-2-one, 3-butyl (IX)
Compound VIII (100 g, 0.56 mol) was placed in a stainless steel autoclave with isopropanol (50 g) and palladium on carbon (1 g). The resulting mixture was placed under 300 psi of hydrogen gas, and heated at 100° C. until gas uptake ceased. The resulting material was removed from the autoclave, filtered, and distilled to yield a pure sample of IX.
Structure IX, Bicyclo[3.2.1]octan-2-one, 3-butyl, possesses coconut, lactonic, woody, minty, jasmonic cis like, anisic and tuberose notes
1H NMR (CDCl3, 500 MHz), 0.99 ppm (t, 3H, J=7.11 Hz), 1.11-1.34 ppm (m, 6H), 1.65-1.75 ppm (m, 3H), 1.76-1.88 ppm (m, 3H), 1.90-2.02 ppm (m, 2H), 2.24-2.34 ppm (m, 1H), 2.39-2.44 ppm (m, 1H), 2.70-2.74 ppm (m, 1H).
EXAMPLE III
Preparation of 3-hexylbicyclo[3.2.1]oct-6-en-2-one (XIII)
Preparation of 2-methylene octanal (X)
A 5-liter flask fitted with an overhead stirrer and condenser was charged with di-N-butyl amine (61 g, 0.47 mol) and acetic acid (56 g, 0.9 mol). Roughly 900 ml of 37% formaldehyde solution in water (351 g formaldehyde, 11.7 mol) was then added and the resulting solution was heated to 50° C. with stirring. After this temperature was reached octanal (1000 g, 7.0 mol) was fed in over about 2 h. A slight exotherm was noticed during the feed. Monitoring by GC showed the consumption of octanal and the production of 2-methylene octanal, finally reaching roughly 95% conversion after the addition was complete. The reaction mixture was allowed to cool to room temperature, poured into a separatory funnel, and washed once with 5% HCl solution. The organic layer was then washed once with saturated sodium bicarbonate, then taken directly on to the next step.
Preparation of 2-hexylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (XII)
The material from the previous step (840 g, 5.9 mol) was loaded into a 2-liter stainless steel pressure reactor along with dicyclopentadiene (468 g, 3.5 mol). The pressure reactor was sealed and the mixture was heated to 170° C. with stirring. Samples taken from the reactor showed the generation of a new peak in eventual 60% conversion, along with several smaller peaks. After two hours at this temperature the material was cooled to room temperature and purified via simple distillation. This treatment resulted in 548 g material. The material was taken on to the next step without further purification.
Preparation of 3-hexylbicyclo[3.2.1]oct-6-en-2-one (XIII)
Compound XII (236 g, 1.1 mol) was loaded into a three liter flask and dissolved in one liter of toluene. This mixture was then cooled to −30° C. Aluminum chloride (77 g, 0.56 mol) was then added in one portion. The reaction mixture exothermed moderately and changed color to light orange. The temperature was allowed to rise to −15° C., then held for 3.5 hours. After this time the reaction was complete as shown by GC measurements. The reaction mixture was then poured onto ice and 25% sulfuric acid, and the organic layers were separated and washed once with 10% sodium hydroxide solution. The methylene chloride solvent was then removed under reduced pressure, and the resulting oil was purified by simple distillation to yield 163 g (69% yield) of XIII.
Structure XIII, 3-hexylbicyclo[3.2.1]oct-6-en-2-one, possesses fruity, floral, sweet and aldehydic fragrance notes.
1 H NMR (CDCl 3 , 500 MHz): 0.87 ppm (t, 3H, J=6.25 Hz), 1.15-1.37 ppm (m, 8H), 1.43-1.50 ppm (m, 1H), 1.73-1.85 ppm (m, 2H), 1.93-2.00 ppm (m, 1H), 2.12-2.23 ppm (m, 1H), 2.37-2.50 ppm (m, 1H), 2.62-2.69 ppm (m, 1H), 2.77-2.85 ppm (m, 1H), 2.98-3.04 ppm (m, 1H), 6.02-6.07 ppm (m, 1H), 6.19-6.25 ppm (m, 1H).
Preparation of Spiro[bicyclo[3.2.1]oct-6-ene-2,2′-[1,3]dioxoloane], 3-hexyl (XIV)
Compound XIII (70 g, 0.33 mol) was placed in a 2 liter round bottom flask equipped with a bidwill trap. 500 mL of toluene, 700 mg of pTSA (1 wt %), and ethylene glycol (21 g, 0.33 mol) was added. The mixture was heated to reflux and freed water was removed via the bidwill. After the mixture reached roughly 90% conversion, the material was cooled to room temperature and basified by the addition of 100 mL of 10% NaOH solution. The organic layer was then separated from the water layer, reduced in volume, and the material was purified by fractional distillation to yield a pure sample of XIV.
Structure XIV, Spiro[bicyclo[3.2.1]oct-6-ene-2,2′-[1,3]dioxoloane], 3-hexyl, possesses piney and weak fragrance notes
EXAMPLE IV
Preparation of 3-pentylbicyclo[3.2.1]oct-6-en-2-one (XV) and Bicyclo[3.2.1]ocatn-2-one, 3-pentyl (XVI)
Preparation of 2-methylene heptanal (XVI)
A 3-liter three-neck flask fitted with an overhead stirrer and condenser was charged with di-N-butyl amine (33 g, 0.25 mol) and acetic acid (31 g, 0.5 mol). Roughly 500 ml of 33% formaldehyde solution in water (178 g formaldehyde, 5.9 mol) was then added and the resulting solution was heated to 50° C. with stirring. After this temperature was reached heptanal (500 g, 4.3 mol) was fed in over about 1.5 h. A slight exotherm was noticed during the feed. Monitoring by GC showed the consumption of heptanal and the production of 2-methylene heptanal, finally reaching roughly 95% conversion after the addition was complete. The reaction mixture was allowed to cool to room temperature, poured into a separatory funnel, and washed once with 5% HCl solution. The organic layer was then washed once with saturated sodium carbonate, then taken directly on to the next step.
Preparation of 2-pentylbicyclo[2.2.1]hept-5-ene-2-carbaldehyde (XVII)
The material from the previous step (553 g, 4.3 mol) was loaded into a 2-liter stainless steel pressure reactor along with dicyclopentadiene (343 g, 2.6 mol). The pressure reactor was sealed and the mixture was heated to 170° C. with stirring. Samples taken from the reactor showed the generation of a new peak in eventual 60% conversion, along with several smaller peaks. After two hours at this temperature the material was cooled to room temperature and distilled using a fractional distillation apparatus. The final yield of material was 217 g, or 26% yield.
Preparation of 3-pentylbicyclo[3.2.1]oct-6-en-2-one (XVIII)
Compound XVII (217 g, 1.1 mol) was loaded into a 2-liter round bottom flask fitted with a condenser and an overheard stirrer. This was followed by one liter of methylene chloride. The resulting solution was cooled to 0° C. using a dry ice bath. After this temperature was reached, anhydrous aluminum chloride (153 g, 1.1 mol) was added in one portion. The light yellow solution changed color to orange, then dark red with a simultaneous increase in reaction temperature, up to the boiling point of methylene chloride. A GC sample taken after the reaction began to cool showed the complete consumption of start material and the formation of a new product. The reaction was then poured onto ice, and the organic layers were separated and washed once with 10% sodium hydroxide solution. The methylene chloride solvent was then removed under reduced pressure, and the resulting oil was purified by simple distillation to yield 100 g (46% yield) of XVIII.
Structure XVIII, 3-pentylbicyclo[3.2.1]oct-6-en-2-one, possesses anisic, fruity, spicy, mossy, herbal and celery fragrance notes.
1 H NMR (CDCl 3 , 500 MHz): 0.87 ppm (t, 3H, J=7.05 Hz), 1.16-1.36 ppm (m, 8H), 1.76-1.83 ppm (m, 1H), 2.11-2.24 ppm (m, 3H), 2.44-2.50 ppm (m, 1H), 2.78 (s, 1H), 3.05 ppm (t, 1H, J=3.69 Hz), 5.80 ppm (dd, 1H, J=5.12, 3.31 Hz), 6.24 (dd, 1H, J=5.29, 2.91 Hz).
Preparation of Bicyclo[3.2.1]octan-2-one, 3-pentyl (XIX)
Compound XVIII (130 g, 0.67 mol) was placed in a stainless steel autoclave with 30 g isopropanol and 1.5 g palladium on carbon. The mixture was placed under 300 psi of hydrogen gas. The mixture was then heated at 100° C. until gas uptake ceased. The mixture was then removed from the autoclave, filtered, and distilled to yield a pure sample of XIX.
Structure XIX, Bicyclo[3.2.1]octan-2-one, 3-pentyl, possesses sweet, slight, anisic, floral and celery notes.
1 H NMR (CDCl 3 , 500 MHz): 0.88 ppm (t, 3H, J=6.89 Hz), 1.10-1.18 ppm (m, 1H), 1.19-1.37 ppm (m, 7H), 1.65-1.89 ppm (m, 6H), 1.90-2.03 ppm (m, 2H), 2.25-2.34 ppm (m, 1H), 2.41-2.45 ppm (m, 1H), 2.73 ppm (t, 1H, J=5.62 Hz).
EXAMPLE V
Fragrance Formulation Containing Bicyclo[3.2.1]octan-2-one, 3-butyl (II)
Fragrance ingredient
parts by wt.
Acetald DEA
0.28
Ald C-10
0.70
Allyl amyl glycolate
1.40
Benz acet
0.70
Calone cam 1% dpg
1.40
Coumarin
0.28
Cyclobutanate
0.28
Dihydro myrcenol
6.99
Dimeth benz carb acet
6.99
Eth vanillin
0.14
Eth-2-meth buty
5.59
Fleuranil 10% dpg
1.40
Bicyclo[3.2.1]octan-2-one, 3-butyl (II)
5.00
Galaxolide 50 pct dpg
6.99
Galbascone 10% dpg
0.14
Hexyl buty
1.40
Hexyl cinn ald
6.99
Ionol
0.14
Iso E super
6.99
Koavone
1.40
Mandarin oil hp
2.80
Mango ester 0.01 pct dpg
1.40
Meth anth (USDEA)
0.70
Nebulone
6.99
Orange oil fla
2.80
Prenyl acet
4.20
Trisamber 1% dpg
0.70
Undecalactone gamma
1.40
Undecavertol
2.69
Verdox
13.99
Vertoliff
6.99
Vivaldie
0.14
Total:
100.00
In this case, the presence of the claimed compound enhances the fruity and floral aspects of the fragrance composition.
EXAMPLE VI
Fragrance Formulation Containing Bicyclo[3.2.1]ocatn-2-one, 3-pentyl (IV)
Fragrance Ingredient
parts by wt.
Acalea
3.7
Ald C-8
0.14
Applelide
6.89
Benz acet
3.45
Banz alc
6.89
Benz prop
3.45
Citronellol Coeur
6.89
Cyclamal extra
0.69
Cyclaprop
1.03
Dimeth benz carb buty
8.27
Eth Caproate
0.69
Eth Vanillin
0.07
Eth-2-meth buty
0.14
Floralozone
1.38
Bicyclo[3.2.1]ocatn-2-one, 3-pentyl (IV)
5.00
Geranyl acet pure
2.07
Helional
0.14
Hexalon
0.69
Hexenyl sal, cis-3
0.28
Hexyl cinn ald
4.13
Hexyl sal
0.07
Iso cyclemone E
0.41
Kharismal
4.35
Lilial
6.89
Linalool syn
5.51
Linalyl acet
1.38
Meth cinnamate
0.69
Meth Ionone alpha extra
0.34
Muguesia
2.07
Nerol Coeur
3.45
Neryl acet A
0.14
Ocimene
0.07
Orange oil nova decol
2.76
Peach ald Coeur
0.69
Phen eth alc white extra
1.72
Styralyl acet
0.07
Terpineol Coeur
1.38
Verdox
5.17
Vertenex
6.85
Total:
100.00
In this case, the claimed compound enhances the fruity and floral aspects of the fragrance composition. | The present invention is directed to the fragrance compounds and their intermediates and a method of improving, enhancing or modifying a fragrance formulation through the addition of an olfactory acceptable amount
wherein the dotted line represents a possible single or double bond; wherein R is equal to a C 3 -C 7 hydrocarbon moieties R 1 and R 2 together can be selected from the group consisting of oxygen and may form a closed ring structure represented by | 2 |
FIELD OF APPLICATION
[0001] The present invention relates to the field of chemical industry, notably to the chemical preparations industry for medical, dental and hygienic purposes.
INTRODUCTION
[0002] The present invention relates to a disinfection composition based on chlorhexidine, cationic and/or non-ionic surfactants and xylitol, for lasting disinfection of synthetic fibers, synthetic surfaces, metal surfaces and composite surfaces, and the like. In addition, the present invention relates to a disinfection method of surfaces, a disinfection protocol of toothbrushes and, finally, to a disinfection product.
STATE OF THE ART
[0003] The use of chlorhexidine in disinfection liquid compositions is long known in the state of the art, as demonstrated by, for example, the German patent document DE 203 04 504, disclosing a toothbrush-cleaning composition wherein it comprises cetylpyridinium chloride and/or a mixture of chlorhexidine (including derivatives), optionally comprising dyes and various fragrances and/or plant extracts. Said German document, even though describing a chlorhexidine-based product for cleaning bristles of toothbrushes, neither mentions the time of residual action of the product on the toothbrush after separating it from the bristles, nor refers to the intended disinfection characteristics. There is no mention as to how the proposed composition acts, or to the success of the removal of various residues to which toothbrushes, for instance, are exposed to daily.
[0004] Patent document CH 700 343 discloses a care solution for toothbrushes, specifically intended for the cleaning of bristles of toothbrushes by dipping them in the solution. Said composition can comprise from 80 to 90 wt % vegetable glycerin, from 4 to 10 wt % demineralized water, from 1.00 to 1.40 wt % chlorhexidine digluconate, from 2.0 to 5.0 wt % rosemary extract, from 2.0 to 5.0 wt % mint extract. Just like said German document, CH 700 343 neither mentions the time of residual action of the product on the toothbrush after the separation from the bristles, nor refers to the intended disinfection characteristics. There is no mention as to how the proposed composition acts, or to the success of the removal of various residues to which toothbrushes, for instance, are exposed to daily.
[0005] As for Brazilian patent document PI 0702469-0, it discloses formulation of antiseptic solution for application in dentistry to prevent dental caries and further oral diseases. Even though said formulation exhibits antiseptic solutions containing, among other things, guanidines and biguanidines, surfactants, solvents etc., it is intended specifically to the hygiene of the oral cavity, thus having no reference to its use as a disinfection agent for bristles or other external elements. Again, there is a lack of references as to the time of residual action of the product on the toothbrush after the separation from the bristles and to intended disinfection characteristics. Also, since it is a mouthwash, there is no mention as to how the proposed composition acts, or to the success of the removal of various residues to which toothbrushes, for instance, are exposed to daily.
[0006] The combined use of chlorhexidine and alkylpolyglycosides in antimicrobial compositions is also known in the state of the art, as demonstrated by document WO 2012/034032, which discloses antimicrobial solutions that in certain cases comprise a biguanide and at least one alkylpolyglucoside. The solutions and methods proposed by this document are intended for the elimination or reduction of bacteria, fungi and viruses from the surfaces, for example, of medical equipment, organic surfaces like the skin and sutures, and other inorganic surfaces. There is no mention to the specific treatment of surfaces with the characteristics of toothbrush bristles, as well as there is no mention to the time of residual action of the product on toothbrush bristles, for example, after it is separated from the bristles.
[0007] Another example of the combined use of chlorhexidine and cationic detergents such as alkylpolyglucosides is given by the sanitizing compositions and methods of WO/010345 2010, which discloses sanitizing compositions for use in combination with specific cleaning compositions. In addition to requiring specific protocols for each type of surface to be disinfected, said document does not mention the specific treatment of surfaces with characteristics similar to those of toothbrush bristles.
[0008] Document WO 2009/117299 discloses chlorhexidine-based cleaning, disinfecting, sanitizing and sterilizing preparations and non-ionic surfactants, however, exhibiting the same deficiencies of above-mentioned document WO 2010/010345. The same deficiency occurs with the composition of personal and domestic hygiene disclosed by document PI 0514935-5.
[0009] As can be inferred from the above description, there is room for improvements in formulations of disinfection compositions for lasting disinfecting of synthetic fibers, synthetic surfaces, metal surfaces, composite surfaces, similar surfaces and the like.
[0010] In addition to the compositions and combinations disclosed by the above-mentioned documents, it is also worth mentioning some products that are known in the state of the art and that are also used, both alone and in compositions, as main active principle or as a complement, as compositions for oral hygiene and, eventually, cited for disinfection of surfaces.
[0011] One such product that is worth mentioning is triclosan (in Portuguese, also known as triclosano), also widely used in dentrif ices, which disrupts the bacterial cell membrane, inhibiting its enzymatic function (Torres C R G, Kubo C H, Anido A A, Rodrigues J R. Agentes antimicrobianos e seu potencial de use na Odontologia. Pós Grad Rev Fac Odontol São José dos Campos 2000:3:43-52.). At low concentrations, there is adsorption of microorganisms in the lipid moiety, which causes a drastic change in cellular transport and thereby prevents proper metabolism and cell reproduction, and, accordingly, providing a broad spectrum antimicrobial effect. Despite being a chemical agent capable of providing bacteriostatic action, its anionic charge causes it to have a low substantiality. Its main drawback is the fact that it is anionic, unlike, for example, chlorhexidine and cetylpyridinium chloride, which are cationic. This feature also impairs a synergy action with a cationic surfactant. In addition to being highly toxic to the human body, as well as carcinogenic and also highly polluting to the environment.
[0012] Another product widely used for disinfection is sodium hypochlorite, also known as bleach or javel water. Sodium hypochlorite is a chemical compound with the formula NaClO, typically found in liquid form, in slightly greenish-yellow color, of pungent odor, water soluble, non-flammable, photosensitive (it decomposes when in direct contact with the light), corrosive to metals, having easy oxidation and decomposition, that releases toxic gases when in contact with acids obtained from the reaction of chlorine with a diluted solution of sodium hydroxide (caustic soda). Sodium hypochlorite has germicidal properties and it is widely used for the treatment and purification of water, for disinfection of vegetables and fruits, in the production of industrial disinfectants, in the treatment of swimming pools (disinfection of water), in the composition of conventional pesticides and as an agent of sterilization in the industries of beverages such as beer, wine and cola soft drinks. It is very suitable for sterilization of domestic environments such as bathrooms and kitchens (usually more susceptible to the spread of germs). It can also be used in dental care as an irrigating solution (this use is still not widespread in Brazil, and therefore many dentists use bleach). For being a strong oxidant, it must be handled with care, since the products of its oxidation are corrosive and can cause burns to the skin and eyes, especially when at high concentrations. The reaction of sodium hypochlorite with organic compounds is violent and gives rise to toxic and even carcinogenic substances. For instance, mixtures of hypochlorite and urine should be avoided, since the reaction of this compound with ammonia leads to chloramine, which is toxic to the human body. Accidents involving sodium hypochlorite can result in harmful effects to health. If inhaled, it can cause irritation to the respiratory system, causing cough and dyspnea. If ingested, it causes bloody vomiting, nausea and diarrhea, ulcerations in the esophagus and stomach, in addition to the fact that high concentrations of sodium in the body can lead to dehydration.
[0013] On the other hand, glutaraldehyde has an environmental toxicity above 0.2 ppm/m 3 , also being a carcinogen. It is widely used as a sterilizer and disinfectant for surgical and dental instruments, thermometers, plastic or rubber equipment, veterinary clinics and hospitals (place of consultations and surgeries); various facilities and other materials that cannot be heat sterilized, vehicles for transporting animals, feeders, waterers and eggs. Glutaraldehyde has been widely used for disinfection of certain pieces of equipment such as endoscopes, connections of medical ventilators, respiratory therapy equipment, dialyzers, spirometry tubes and others; to this end the exposure time is 30 minutes. It is not used as a surface disinfectant since it is costly and very toxic.
[0014] Finally, peracetic acid is fairly used in disinfection/sterilization of plastic, polyurethane, polyethylene, PVC, ABS, nylon 6 and 66, optical fiber, viton, silicone, natural and nitrilic rubbers, natural and synthetic fabrics. Plastics, rubber or silicone may experience dryness and/or rigidity depending on their porosity, it is highly flammable and has a strong odor. Peracetic acid (acetyl hydroperoxide or peroxyacetic acid) is a chemical product that presents itself as a colorless liquid, non-colorant, and powerful oxidizing agent with acidic pH, a density close to that of the water and slightly vinegary odor, corrosive to metals (brass, copper, galvanized iron, tin) that, at low concentration, has a fast action against all microorganisms, including bacterial spores. 0.2% peracetic acid can cause respiratory distress, its vapors are irritating, and it requires careful handling. It has low storage stability and low residual effect.
[0015] The other existing antiseptics on the market are indicated (and used), in their overwhelming majority, just as mouthwashes. The products presented and commonly used in the state of the art, either lack a disinfection power strong enough to provide an efficient hygiene of surfaces; or have said disinfection power based on highly toxic products, therefore, inappropriate for application on objects of personal use and hygiene.
[0016] Therefore, as can be inferred from the above description, there is room for improvements in formulations of disinfection compositions for lasting disinfecting of synthetic fibers, synthetic surfaces, metal surfaces, composite surfaces, similar surfaces and the like.
[0017] More specifically, there is room for sanitizing and/or hygiene compositions for objects of personal use having both combined and simultaneous antibacterial, antiseptic and deep cleaning activity with extended action especially for continuous use in toothbrush bristles, but also effective for the disinfection of other synthetic or metallic surfaces (such as, for example, oral hygiene instruments such as tongue scrapers, dental floss bow, among others, in addition to surfaces of oral devices (braces and retainers for instance), prostheses, and even hearing aids, combining minimal toxicity (to the human body) to maximum effectiveness.
[0018] The effectiveness of these compositions still lacking in the state of the art must also be extended to the complementary residues that can be found on the surfaces of objects to be disinfected, for example, fat, dentifrice debris, food debris, organic tissue, saliva, soaps, shampoos, rinses and the like, their continuous and daily use being guaranteed, without restrictions due to a toxic component or which results in human rejection.
[0019] In addition, there is room for a composition having a lasting action on the disinfected surfaces as above-mentioned and which can additionally be beneficial to the health of the user, in a complementary manner. Said composition containing, for instance, compounds having anti-caries efficacy and the like, presenting antimicrobial and also dental plaque inhibiting action, thus achieving a reduction of oral diseases and halitosis, in addition to various conditions related to medical and hearing aids.
OBJECTIVES OF THE INVENTION
[0020] One of the objectives of the present invention is the provision of a disinfection composition according to the features of claim 1 . Another objective of the present invention is the provision of a disinfection method according to the features of claim 9 . Another objective of the present invention is the provision of a disinfection protocol for toothbrushes according to the features of claim 10 . Yet another objective of the present invention is the provision of a disinfection product according to the features of claim 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] A disinfection composition according to the invention must meet three main functions, namely:
disinfection; removal of fat and residues; and additional protection.
[0025] Disinfection
[0026] In a preferred embodiment of the invention, the composition according to the invention has a chlorhexidine gluconate based or chlorhexidine digluconate based disinfection component or simply chlorhexidine.
[0027] Chlorhexidine has antifungal and antibacterial action, in addition to an extremely high capacity of disinfection, bacterial destruction and bacteriostatic action, thus inhibiting bacterial growth (colonies).
[0028] In the form of digluconate, it is an antimicrobial agent exhibiting disinfecting and sanitizing features. It is effective against Salmonella spp., Listeria spp., Clostridium spp., E. Coli, Staphylococcus spp. and Pseudomonas spp. (Chlorhexidine, Technical report, NEOBRAX).
[0029] Its antibacterial mechanism of action is explained by the fact that the cationic molecule of chlorhexidine is quickly attracted to the negatively charged bacterial surface and is adsorbed to the cell membrane by electrostatic interactions, presumably by hydrophobic bonds or hydrogen bridges, this adsorption being concentration-dependent. Thus, at high dosages, it causes precipitation and coagulation of cytoplasmic proteins and bacterial death; and, at lower dosages, the integrity of the cell membrane is altered, resulting in leakage of the bacterial components having low molecular weight (Hjeljord et al. 37 1973; Hugo and Longworth 38 1964; Rolla and Melsen 60 1975).
[0030] In addition, chlorhexidine is stable, is not toxic to tissues, its absorption by the mucosa and skin is minimal and it does not provoke systemic toxic side effects with extended use as well as alterations in the oral microbiota (Davies and Hull 23 1973; Case 15 1977; Rush-ton 62 1977; Winrow 73 1973; Löe et al. 45 1976).
[0031] Chlorhexidine has a substantivity (i.e., active residence time) of approximately 12 hours which is explained by its dicationic nature. Thus, a cationic end of the molecule is attached to the film, which is negatively charged, and the other cationic end is free to interact with bacteria. In this manner, it shall perform an initial bactericidal action, combined with an extended bacteriostatic action (Zanatta F B, Rösing C K. Clorexidina: Mecanismo de ação e Evidências atuais de sua eficácia no contexto do biofilme supragengival , Scientific-A 2007).
[0032] In addition, chlorhexidine is characterized by not developing bacterial resistance, by being non-toxic, non-corrosive and biodegradable (Chlorhexidine, Technical report, NEOBRAX).
[0033] In a preferred embodiment of the invention, the chlorhexidine content of the composition according to the invention is from 0.1 vol % to 20 vol %, preferably from 0.2 vol % to 7 vol %, more preferably from 4 vol % to 6 vol %.
[0034] Removal of Fat and Residues
[0035] Within the scope of the present invention, removal of fat and residues should be understood as the removal of complementary residues that can be found on the surfaces of objects to be disinfected, such as, for example, fat, dentifrice debris, food debris, organic tissue, saliva, soaps, shampoos, rinses and the like.
[0036] In a preferred embodiment of the invention, the composition according to the invention has a cationic surfactant as a component for fat and residues removal.
[0037] Surfactant is a substance or compound capable of reducing the surface tension of the fluid in which it is dissolved; or capable of reducing interfacial tension by preferential adsorption of a vapor-liquid interphase and another interphase.
[0038] The cationic surfactant is the one that, in aqueous solution, is ionized, thus producing positive organic ions which are responsible for the surface activity, having a positively charged radical as the hydrophilic part of the chain. That is, in this type of surfactant, it is one part of the molecule having a positive character that interacts with water, unlike the anionic surfactants. They are not compatible with anionic surfactants, forming an insoluble precipitate with them.
[0039] Cationic surfactants have germicidal properties, are provided with high bactericide power against gram-negative bacteria, as well as being fungicides, acting on certain pathogenic protozoa. They exhibit relatively low toxicity, with the absence of corrosive power (see Technical report: Amaral L et al, Detergente doméstico, Instituto de Tecnologia do Paraná , December 2007).
[0040] In a preferred embodiment of the invention, the composition according to the invention has a non-ionic surfactant as a component for fat and residues removal.
[0041] Non-ionic surfactants are characterized by hydrophilic groups without charges linked to the fat chain. They have as their characteristics the compatibility with most raw materials used in cosmetics, the low irritability to skin and eyes, a high power of surface and interfacial tension reduction, and low detergency and foaming powers.
[0042] In short, the surfactant decreases the surface tension of the liquid, increasing its penetration capability. It binds to and captures fat particles having lipophilic capacity and, at the other molecular end, having hydrophilicity.
[0043] In a preferred embodiment of the invention, the composition according to the invention has an alkylpolyglycoside-based fat removal component.
[0044] Alkylpolyglycosides are a family of relatively new surfactants, synthesized by reacting cornstarch glucose with a fatty alcohol. The resulting molecule is a non-ionic surfactant having good water solubility due to hydroxyl groups. Those are good detergents and have a very high degree of biodegradability. The main surfactants of this class are decyl- and lauryl-polyglucoside with a high degree of polymerization (average number of glucose units per alcohol unit).
[0045] In a preferred embodiment of the invention, the alkylpolyglycosides content of the composition according to the invention is from 0.5 vol % to 12 vol %, preferably 4 vol %.
[0046] In a preferred embodiment of the invention, said alkylpolyglycosides are decylpolyglycosides.
[0047] In another preferred embodiment of the invention, said alkylpolyglycosides are laurylpolyglycosides.
[0048] In yet another preferred embodiment of the invention, said alkylpolyglycosides are decylpolyglycosides mixed with laurylpolyglycosides.
[0049] Additional Protection
[0050] Within the scope of the present invention, additional protection should be understood as the additional protection the user is provided with against caries and oral diseases, various oral conditions and halitosis and various conditions related to medical and hearing aids.
[0051] In a preferred embodiment of the invention, the composition according to the invention has a xylitol-based additional protection component.
[0052] Xylitol is a polyalcohol having as molecular formula C 5 H 12 O 5 (1, 2, 3, 4, 5-pentahydroxypentane), with both inhibition and anti-adhesion actions over certain bacteria. Xylitol is transported via fructose-phosphotransferase system, resulting in intracellular accumulation of xylitol-5-phosphate. This intermediate metabolite is dephosphorylated and excreted as xylitol, without resulting in ATP production. This ‘futile cycle’ consumes energy and results in inhibition of bacterial growth and metabolism, particularly in some bacteria like Streptococcus mutans, Streptococcus pneumoniae, Haemophilus influenzae . (Pereira AFF, 2009) (Almeida LMAG).
[0053] One of the advantages of xylitol, for example over sucrose, is that, due to its high chemical and microbiological stability, it acts as a preservative of food products even at low concentrations, offering resistance to the growth of microorganisms and extending the shelf life of these products (Bar, 1991).
[0054] Since xylitol is a non-toxic substance, as classified by Food and Drug Administration (FDA) as a GRAS-type additive (Generally Regarded as Safe), its incorporation in food is legally permitted.
[0055] Acute otitis media is the second most common infection in children. It is caused by bacteria from the nasopharynx that enter the middle ear via the Eustachian tube (Erramouspe, Heyneman, 2000). According to Kontiokari et al. (1995), xylitol acts to prevent or to combat this disease, inhibiting the growth of Streptococcus pneumoniae bacteria, the main cause of sinusitis and middle ear infections.
[0056] When compared to other sweeteners, xylitol brings about greater benefits for oral health, preventing the incidence of cavities or reducing their formation (Mussatto S I, Roberto I C. Xilitol: Edulcorante com efeitos benéficos para a saúde humana, Revista Brasileira de Ciências Farmacêuticas , vol. 2002).
[0057] In a preferred embodiment of the invention, the xylitol content of the composition according to the invention is from 0.1 vol % to 30 vol %, preferably 10 vol %.
[0058] Other Components
[0059] In a preferred embodiment of the invention, the composition according to the invention comprises various additional components.
[0060] One of the additional components can be, for example, a solution of citric acid, containing 0.01 vol % to 10 vol % qs.
[0061] Other additional component can be, for example, purified water or deionized water, qsp.
[0062] Another additional component can be, for example, a pH stabilizer, in order to maintain the pH between 6.0 and 7.0 composition, in sufficient amount to meet the conditions of the composition according to the invention.
[0063] In addition to these components, preservatives, flavorings, colorings and alcohol may be part of the formulation of the composition according to the invention.
[0064] Application Forms/Pharmaceutical Forms
[0065] In a preferred embodiment of the invention, the compositions according to the invention are used in liquid form and preferably applied in the form of a immersion bath.
[0066] In another preferred embodiment of the invention, the compositions according to the invention can be used and applied respectively in the form of effervescent material (pill, tablet, powder or similar), in the form of aerosol, misting fluid, infusion fluid, vapor and other forms that are suitable for application to surfaces.
[0067] New Technical Effect
[0068] The disinfection composition according to the invention provides a unique synergy that results in a new and unique technical effect.
[0069] Initially, the composition according to the invention has high penetration power in synthetic bristles, especially toothbrush bristles. The penetration occurs even among the tufts, an effect which is primordial to the effective action of the remaining components of the formula.
[0070] As described above, this action occurs due to the reduction of the surface tension of the liquid obtained by surfactant component, being an advantage over all the liquid antiseptics on the market.
[0071] The composition according to the invention eliminates the culture existing in toothbrushes, for example, having an effective action on saliva, fat, dentifrice debris and microorganisms—components which are known to initiate the formation of a biofilm which is responsible for the culture medium.
[0072] Therefore, the composition according to the invention provides the elimination of growth and formation of colonies of microorganisms, the elimination of the medium responsible for the formation of bacterial resistance (resistant bacteria), the elimination of the potential for recontamination and/or transmission of microorganisms to the user, wherein this action is due to the combination of the ability of fat particles sequestration performed by the surfactant plus the chlorhexidine action of disinfection.
[0073] As previously mentioned, the composition according to the invention acts preventively on the inhibition of biofilm formation.
[0074] This effect is due to the action on all the components forming the biofilm and on the entire toothbrush because of the excellent penetration provided by the surfactant that, added to chlorhexidine disinfection capacity, is enhanced by the action of xylitol in inhibiting the growth and metabolism of bacteria.
[0075] The composition according to the invention acts with a disinfectant action, eliminating bacteria, fungi and viruses. The action of chlorhexidine is enhanced for the main etiological agent of dental caries, Estreptococcus mutans , due to combination with xylitol.
[0076] The composition according to the invention has an extended effect (continued disinfection) of at least 7 (seven) days, as a result of the combination of the effects of (i) surfactant provided with excellent penetration in the bristles and the preventive effect against the formation of biofilm, (ii) chlorhexidine disinfection capacity for bacteria, fungi and viruses, wherein chlorhexidine has its residual action of up to 12 hours (Perionews 2011) extended for at least 7 (seven) days within the composition according to the invention.
[0077] The composition according to the invention fights the action of E. mutans through the action enhanced by xylitol.
[0078] Therefore, it is concluded that the actions of disinfection are effective on the entire toothbrush, because of the effective permeability of liquid in addition to the capacity of deep cleaning with dissolution of the fat existing in saliva and residual organic matter.
[0079] As a result of the effects described, in addition to having a disinfected surface, there will be no residual or remaining substrate for the new formation of biofilm and proliferation of bacteria—essential and indispensable condition for high hygiene requirements.
[0080] Composition
[0081] Therefore, one objective of the present invention is the provision of a disinfection composition comprising at least one disinfection component, at least one fat removal component, at least one additional protection component and various additional components.
[0082] In a preferred embodiment of the invention, the composition according to the invention comprises:
at least one chlorhexidine-based disinfection component; at least one alkylpolyglycoside-based fat removal component; at least one xylitol-based additional protection component; and one or more additional components selected from the group consisting of citric acid solution, purified or deionized water qsp, pH stabilizer, preservatives, flavorings, dyes and alcohol.
[0087] In a preferred embodiment of the invention, the composition according to the invention comprises:
a chlorhexidine content from 0.1 vol % to 20 vol %, preferably 0.2 vol %; an alkylpolyglycoside content of 0.5 vol % to 12 vol %, preferably 4 vol %; a xylitol content from 0.1 vol % to 30 vol %, preferably 10 vol %; additional components that can properly complete the formula.
[0092] Disinfection Method
[0093] Another objective of this invention is the provision of a disinfection method, especially for lasting disinfection of synthetic fibers, synthetic surfaces, metallic surfaces, composite surfaces and the like.
[0094] The method according to the invention comprises the following steps:
a) washing the surface to be disinfected with running water; b) washing the surface to be disinfected with saline (optional); c) immersing the surface to be disinfected in the disinfection composition and/or applying the disinfection composition on the surface to be disinfected; d) allowing the action of the disinfection composition during 5 to 15 minutes, preferably 10 minutes; e) emerging the surface to be disinfected in the disinfection composition (considering the immersion of step ‘c’); f) washing the surface to be disinfected with running water; and g) washing the surface to be disinfected with saline (optional).
[0102] Disinfection Protocol for Toothbrushes
[0103] Another objective of this invention is the provision of a disinfection protocol, notably for the lasting disinfection of bristles of toothbrushes.
[0104] The disinfection protocol comprises the following steps:
a) washing hands; b) performing oral hygiene with a toothbrush and a dentifrice or appropriate oral hygiene product; c) washing the toothbrush with running water; d) inserting a disinfection composition according to the invention into a suitable container for partial immersion of the toothbrush; e) immersing the bristles head of the toothbrush in the disinfection composition; f) allowing the action of the disinfection composition during 5 to 15 minutes, preferably 10 minutes or removing the toothbrush only at the time of the next oral hygiene procedure; g) disposing said used disinfection composition after a maximum of 7 days; h) washing the bristles of the toothbrush with running water before the next oral hygiene procedure.
[0113] Product
[0114] Another objective of this invention is the provision of a disinfection product, especially for lasting disinfection of synthetic fibers, synthetic surfaces, metallic surfaces, composite surfaces and the like, comprising a disinfection composition according to the invention.
[0115] In a preferred embodiment of the invention, the product according to the invention is a liquid or fluid for immersion.
[0116] In another preferred embodiment of the invention, the product according to the invention is an effervescent material (pill, tablet, powder or similar) or aerosol, or a misting or infusion fluid, or vapor, or any other form that is suitable for application to surfaces.
[0117] Tests/Results
[0118] In order to test the effectiveness of the disinfection composition according to the invention and its extended action, numerous laboratory tests were conducted, two of which have their results briefly presented below.
[0119] One of the tests performed was the verification of the minimum extended action time of the disinfection composition according to the invention, by dipping toothbrushes infected with Escherichia coli and Pseudomonas aeruginosa separately in a vessel containing the composition according to the invention.
[0120] Contamination of two separate solutions with each of the bacteria was performed, the bristles of a toothbrush being, then, immersed in said contaminated solutions, contaminating them completely.
[0121] Two toothbrushes were infected, each with one of the types of bacteria. Bacteria continued to be inoculated daily and the toothbrushes were kept in their respective fluids kept in an oven at 37° C.
[0122] Said contaminated brushes were then immersed in a disinfection composition according to the invention. The following table (Table 1) shows the result of the presence of bacteria in the infected brushes immersed in those test liquids, for 7 (seven) days, for each bacteria.
[0000]
TABLE 1
7 days laboratory test
DAY 1
DAY 2
DAY 3
DAY 4
DAY 5
DAY 6
DAY 7
Bacterium: Escherichia Coli
TOOTHBRUSH 1
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
TOOTHBRUSH 2
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
Bacterium: Pseudomonas Aeruginosa
TOOTHBRUSH 1
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
TOOTHBRUSH 2
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
NEGATIVE
[0123] Taking into consideration Table 1 above, one concludes that the qualitatively tested disinfection composition has an extended action during at least seven days, without being replaced or replenished throughout the testing period. The composition according to the invention was successful considering the extended period criterion, even with daily inoculation of bacteria.
[0124] Another test performed was the one for efficacy of elimination of microorganisms strains added to different liquids, including the composition according to the invention, by measuring the residual content of the strains in those fluids.
[0125] The microorganism strains used are recited in the results table below (Table 2).
[0126] The disinfection liquids prepared and tested are also recited in the results table below (Table 2).
[0127] Antimicrobial activities of three liquids were analyzed, namely: (i) Purified water (reference) (ii) Solution A (1 vol % chlorhexidine, 4 vol % alkylpolyglycosides, 10 vol % xylitol and purified water qsp pH 6.0) and Solution B (5 vol % chlorhexidine, 4 vol % alkylpolyglycosides, 10 vol % xylitol and purified water qsp pH 6.0).
[0128] Methodology: inoculation of each microorganism at 10 6 in each respective disinfection liquid, individually. Keeping it in each liquid for a disinfection action for 10 minutes. Then, the respective cultures were carried out in which there was quantitative analysis with a counting method after 48 hours in an oven.
[0129] Table 2 results, referring to residual activity, prove the effectiveness of compositions according to the invention.
[0000]
TABLE 2
antimicrobial activity by contact time
Candida
Klebsiella
E. Coli
Samonella
S. Mutans
S. aureus
P. Aeruginosa
Lactobacillus
Decimal
Inoculum
Inoculum
Inoculum
Inoculum
Inoculum
Inoculum
Inoculum
Inoculum
Reduction
5.3 × 10 5
1.1 × 10 6
5.0 × 10 6
4.6 × 10 6
2.1 × 10 6
4.0 × 10 6
4.7 × 10 6
4.5 × 10 5
(% DR)
Product
CFU
CFU
CFU
CFU
CFU
CFU
CFU
CFU
Bacteria
Purified
2.2 × 10 5
6.7 × 10 5
3.4 × 10 6
2.9 × 10 6
2.1 × 10 6
4.7 × 10 6
4.0 × 10 6
2.8 × 10 5
No
water
reduction
Solution A
<10
<10
<10
<10
<10
<10
<10
<10
99.99
Solution B
<10
<10
<10
<10
<10
<10
<10
<10
99.99
[0130] Final Considerations
[0131] As can be inferred from the description above, the composition according to the invention provides lasting disinfection of synthetic fibers, synthetic surfaces, metal surfaces, composite and similar surfaces, and the like, avoiding contamination and re-contamination of said elements.
[0132] More specifically, the composition according to the invention exhibits both combined and simultaneous antibacterial, antiseptic and deep cleaning activity with extended action (of at least seven days) especially for continuous use in toothbrush bristles, but also effective for the disinfection of other synthetic or metallic surfaces (such as, for example, oral hygiene instruments such as tongue scrapers, dental floss bow, among others), in addition to surfaces of oral devices (braces and retainers for instance), prostheses, and even hearing aids, combining minimal toxicity (to the human body) to maximum effectiveness.
[0133] The effectiveness of the composition according to the invention also extends to the complementary residues that can be found on the surfaces of objects to be disinfected, for example, fat, dentifrice debris, food debris, organic tissue, saliva, soaps, shampoos, rinses and the like, their continuous and daily use being guaranteed, without restrictions due to its non-toxic components.
[0134] In addition, there is room for a composition having a lasting action on the disinfected surfaces as above-mentioned and which can additionally be beneficial to the health of the user, in a complementary manner. Said composition containing, for instance, compounds that have anti-caries efficacy and the like, presenting antimicrobial and also dental plaque inhibiting action, thus achieving a reduction of oral diseases and halitosis, in addition to various conditions related to medical and hearing aids.
CONCLUSION
[0135] Those skilled in the art will easily understand that modifications can be made to the present invention without straying from the concepts exposed in the above description. These modifications are to be considered comprised by the scope of the present invention. Consequently, the particular embodiments previously described in detail are only illustrative and exemplary as well as non-restrictive with regards to the scope of the present invention, to which the full extent of the appended claims and of each and every equivalent should be given. | The present invention relates to a disinfection composition, particularly for lasting disinfection of synthetic fibres, synthetic surfaces, metallic surfaces and composite surfaces, and similar surfaces, said disinfection composition comprising at least one disinfectant, at least one fat- and residue-removing component, at least one additional protection component and additional components which are compatible with the above components and have low or no toxicity. The invention further relates to a disinfection method, to a specific tooth brush disinfection protocol and finally, to a corresponding disinfection product. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to means for preventing over fusing, and more particularly to means of this type especially adapted for use with cartridge fuses having a notched terminal blade.
Electric cartridge fuses rated 100 Amperes and higher are provided with blade-type terminals adapted for insertion into a fuse holder comprising a spaced pair of fuse clips fastened to an insulating base. Conventionally, spring means are used to bias the jaws of each clip together to reliably contact and hold the terminal blade within the clip jaws. For one particular class of fuses having a relatively low range of rated currents, a notch is formed partially through the width of one of the flat terminal blades. Another particular class of fuse, having relatively higher rated current, is provided with flat terminal blades without notches.
The conventional fuse clip accepts the terminal blade of either class of cartridge fuse. A circuit having a relatively high current rating may have a fuse of lower rated current installed within its terminal clips to protect a load device having a current rating less than the circuit rating. Conversely, if a cartridge fuse having a current rating in excess of the circuit current rating is installed in a conventional fuse clip, an overcurrent fault hazard is present and the fuse will not provide current interruption and protection in the event of an overcurrent fault of magnitude sufficient to damage the circuit but less than the current rating of the fuse.
It is therefore desirable to provide means for use with a spring-bias terminal clip to facilitate installation of a notched terminal blade while preventing installation of a cartridge fuse having a higher current rating and an unnotched terminal blade. The rejection means must be capable of being field installed in a relatively simple manner in a fuse clip, preferably without requiring the use of tools, and must be extremely difficult to remove once installed to prevent subsequent unauthorized removal.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention, a fuse clip having a pair of spaced parallel clip jaws adapted to receive a flat terminal blade of a cartridge fuse, and having a U-shaped spring member with its free arms pressing the clip jaws of the terminal resiliently toward each other, is provided with a rejector pin passing through aligned apertures in both free arms of the spring and the underlying portions of both clip jaws. The diameter of the rejector pin is selected to enter a considerable distance into the notch formed in the terminal blade of a relatively low current rating cartridge fuse.
A one-piece rejector pin has a tapering neck converging toward a head portion having a greater diameter than the exterior diameter of the remaining rejector pin portion. A C-spring is installed around the tapering neck to have a normally-expanded outer diameter greater than the pin diameter. The apertures have a diameter greater than the pin diameter but less than the outer diameter of the expanded C-spring to allow the spring to be compressed for insertion through a single clip arm and spring arm. The C-spring is then released to expand to prevent withdrawal of the pin, while the rejection member head prevents passage of the rejector pin completely through the aligned apertures. The C-spring is located in an area of the fuse clip inaccessible to normal tools and cannot be removed unless the fuse clip is rendered completely unusable.
The notch in the terminal blade of a cartridge fuse having a relatively lower current rating fits around the rejector pin to allow proper insertion and retention of the notched terminal blade in the fuse clip. The pin is positioned in the fuse clip to interfere with the edge of a normal, unnotched terminal blade to prevent its insertion into the fuse clip, thus providing rejection means for preventing the installation of a cartridge fuse of higher current rating.
It is, therefore, one object of the present invention to provide a terminal blade clip with means for accepting only notched terminal blades to prevent installation of a cartridge fuse having a detrimentally high current rating.
It is another object of the present invention to provide such rejection means capable of being field installed in the terminal clip without the use of tools.
It is a further object of the present invention to provide such rejection means which is incapable of being removed from the terminal clip with ordinarily available tools.
These and other objects of the present invention will be understood upon a reading of the following detailed description and the drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a high current-rating cartridge fuse having unnotched terminal blades; a relatively low current-rating cartridge fuse having one notched terminal blade; and of conventional spring-reinforced terminal clip for forming an electrical connection to the terminal blades of either fuse;
FIG. 2 is a side view of a rejector pin having its keeper spring in the compressed condition;
FIG. 3 is a side view of a rejector pin having its keeper spring in the expanded condition; and
FIG. 4 is a cross-section of the spring-reinforced terminal clip with the rejector pin installed in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a relatively high rated-current fuse 10 is comprised of a cylindrical body 11 of insulating material enclosing a fusible element (not shown for purposes of simplicity). An end cap 12 of conductive material is suitably fastened to enclose each end of body 11 and to electrically contact one of the opposed ends of the fusible element. A flat terminal blade 14 extends from each end cap 12 in a direction away from insulating body 11. Terminal blades 14, 14 lie in a common plane and each terminal blade has a pair of parallel, unbroken edge surfaces 14a, 14b.
Another cartridge fuse 20 of relatively lower rated-current is comprised of an insulating portion 21 having conductive end caps 22a and 22b at opposed ends thereof. A flat and unnotched terminal blade 23 extends from a first end cap 22a in a direction away from insulating portion 21. Another flat terminal blade 24 extends from the remaining conductive end cap 22b in a direction opposite that of terminal blade 23. Terminal blades 23 and 24 are aligned in the same plane and each has a pair of parallel edges 23a, 23b and 24a, 24b, respectively. Terminal blade 24 has a substantially rectangular notch 25 formed into one edge 24a thereof and extending a significant distance toward the remaining edge 24b.
A conventional terminal clip 30 comprises a web portion 31 including means (not shown) for mounting web 31 to a flat surface, and a pair of clip arms 32 and 33 extending transverse to the plane of web 31. Each clip arm 32 and 33 includes a flat portion 32a and 33a parallel to the flat portion of the other clip arm and a canted portion 32b, 33b disposed at and diverging from the end of parallel flat portions 32a, 33a, respectively, furthest from web 31. Terminal clip 30 is conventionally formed of a high-conductivity metallic substance, such as metallic copper and the like, which material advantageously possesses a natural resiliency tending to force spaced parallel clip portions 32a and 33a towards each other to define a narrow blade-receiving gap 35 therebetween. A U-shaped reinforcing spring 37 has a web 38 and a pair of parallel arms 39, with each arm extending from an opposite side of web 38. Reinforcing spring 37 is advantageously formed of a very resilient material, such as spring steel or the like, and has a distance between facing interior surfaces of arms 39 less than the normal distance between the parallel exterior faces of arms 32a and 33a of clip 30 to resiliently force their interior surfaces even closer together to narrow gap 35.
An aperture 40 is formed approximately through the center of each flat clip arm portion 32a and 33a. The axes of apertures 40, 40 are in alignment parallel to the plane of web 31 (FIG. 4). Each reinforcing spring 39 has a corresponding aperture 41 of diameter D formed therethrough. Apertures 41 are formed by piercing arms 39 from their exterior surfaces inwardly towards gap 39 in a manner to cause a swaged portion 42 to be formed, which swaged portion 42 enters an associated clip arm aperture 40 to resiliently lock reinforcing spring 37 to terminal clip 30.
In accordance with the invention, a rejector member 50 (FIG. 2) has a cylindrical pin portion 51 of substantially constant outer diameter D 1 from which portion a tapering neck 52 converges toward a head portion 53 having an outer diameter D 2 greater than the diameter D 1 of pin portion 51. A C-shaped keeper spring 55 is resiliently retained about neck 52.
Rejector member 50 is installed in blade clip 30 by initially positioning face 51a of pin portion 51 within one aperture 41 of a spring arm 39. The aperture diameter D is greater than pin outer diameter D 1 and less than head outer diameter D 2 . Rejector member 50 is pressed in the direction of arrow A while C-shaped spring 55 is compressed about the narrow portion of conical neck 52 to close the spring to an outer diameter allowing pin portion 51 and compressed spring 55 to pass through both the first aperture 41 and the underlying clip aperture 40 until pin portion 51 enters and passes through the clip aperture 40 and overlying spring aperture 41 in the opposite blade (FIG. 4). Keeper spring 55 is then released to expand to its normal outer diameter which is selected to be greater than spring aperture diameter D. Head 53, having a diameter D 2 greater than aperture diameter D, prevents passage of rejector pin 50 completely through the passage formed by aligned apertures 40, 40 and 41, 41. The length of rejector pin 50 is established to prevent removal of pin portion 51 from spring arm aperture 41 for all normal widths of gap 35.
Attempted removal of rejector pin 50 requires the application of force to the rejector member in the direction of arrow B. Movement in this direction causes keeper spring 55 to ride up along the tapering face of conical neck 52 to expand to a final outer diameter D 3 greater than the diameter of spring arm aperture 41 to prevent removal of rejector member 50 from the spring arm while simultaneously preventing removal of reinforcing spring 37 from terminal clip 30. Thus, rejector member 50 is modified by keeper spring 55 to be a device initially capable only of limited axial movement through apertures 40 and 41 in a single direction when spring 55 is compressed and, upon insertion, the normal expansion of the keeper spring prevents movement in either axial direction.
Keeper spring 55 is normally positioned in or adjacent to one of clip arm apertures 40 to prevent access to spring 55 with conventional tools, thus defeating attempts to compress and remove the keeper spring from the rejector member.
Notch 25 in blade 24 of low rated-current fuse 20 cooperates with rejector pin 50 to allow blade 24 to fully enter gap 35, whereby the interior surfaces of parallel clip arms 32a and 33a resiliently bear against the exterior opposed faces of the terminal blade to assure proper electrical contact thereto. The unnotched blade 14 of the relatively high rated-current fuse 10 cannot enter gap 35 to a sufficient depth to be permanently retained therein against the force of reinforcing spring 37 tending to narrow gap 35, and the unnotched blade is expelled therefrom in a direction away from web 31 to prevent its installation therein.
There has just been described a novel field installable fuse rejector member for use with a terminal clip having a spring member between its clip jaws. The novel rejector member is not only field installable without requiring installation tools, but also cannot be removed from the terminal with ordinary tools.
The present invention has been described with reference to one preferred embodiment thereof; many variations and modifications will now become apparent to those skilled in the art. I do not wish, therefore, to be limited by the specific disclosure herein, but only by the scope of the appended claims. | A rejector pin member is field installable between the spring-loaded clip jaws of a terminal clip receiving a terminal blade of a cartridge fuse. The rejector pin allows the terminal clip to only accept a notched terminal blade of a fuse having a relatively low current rating and rejects the unnotched terminal blade of a cartridge fuse having a relatively high current rating, to prevent formation of an overcurrent heating hazard in the circuit protected by the fuse. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement of 3-way switched lamp holders. Typical lamp holders utilize two methods of connection for electrical wires, soldering or screw type connections. However, both of these methods are labor intensive, have poor reliability, and require particular tools. Whereas in the instant invention, the electrical wires are simply inserted through the holes formed in the top of the lamp holder body to allow the springs to engage the respective wires.
2. PRIOR ART
Switched 3-way medium base lamp holders are well known in the art. The best prior art known to the Applicant include U.S. Pat. Nos. 2,576,856; 2,283,405; 3,125,392; 2,713,668; and, 4,257,664, West German Pat. Nos. 1911887 and 2250456, and Great Britain Pat. No. 2040608. These references however do not disclose a turn-knob 3-way switch medium base lamp holder having the novel combination of elements as disclosed herein.
SUMMARY OF THE INVENTION
The main objective of the invention is to provide an improvement of the push-in type electrical connection for a 3-way turn-knob switched medium base lamp holder. The holes formed in the top of the lamp holder body provide a guide for the electric wires which are inserted therein and then subsequently pinched and clamped by the bent springs disposed within the lamp holder. The bent springs provide sufficent spring force to firmly pinch the electric wires, making the electrical connection without deforming the wires.
The second objective of the invention is to provide an improved push-in connector for use with the 3-way turn-knob switch. The switch includes a U-shaped contact spring as an electrical conductor, which is installed without the use of tools.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the lamp holder; FIG. 2 is a bottom plan view of the lamp holder; FIG. 2-1 is a top plan view of the lamp holder; FIG. 3 is a sectional view of the lamp holder taken along the section line 3--3 of FIG. 2; FIG. 4 is a sectional view of the lamp holder taken along the section line 4--4 of FIG. 1; FIG. 5 is a sectional view of the lamp holder taken along the section line 5--5 of FIG. 2; FIG. 5-1 is a perspective view of the spring connector 5; FIG. 6 is a sectional view of the lamp holder taken along the section line 6--6 of FIG. 2; FIG. 6-1 is a perspective view of the L-shaped spring connector; FIG. 7 is a sectional view of the lamp holder taken along the section line 7--7 of FIG. 2; FIG. 8 is a sectional view of the lamp holder taken along the section line 8--8 of FIG. 7; and, FIG. 8-1 is a perspective view of the U-shaped spring of the lamp holder assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, there is shown, the body 1 of the turn-knob 3-way switched medium base lamp holder according to the invention. The lamp holder includes an insulating disk 2 disposed between the metal shell 3 and the body 1. A turn-knob 4 is disposed on one side of the assembly to provide switch control, and a pair of holes 11 and 12 are formed on the top of body 1. Within the holes 11 and 12 there is located respective spring connectors for coupling with respective electric wires which are inserted into the body through the holes.
On the opposing end of the lamp holder a pair of symmetrically located holes 13 and 14 are provided for receiving rivets which couple the body 1, insulating disk 2, and metal screw shell 3 together. The insulating disk 2 is provided with a rectangular slot 21 through which the rectangular tongue spring 7 is received, and a square hole 22 is also provided for passage of the square contact terminal 63 therethrough.
Referring to FIG. 3, there is shown, the structure of the body 1 wherein there is formed a pair of guiding slots 15 and 16. The spring connector 5 is received within the guiding slot 15, and the spring 6 is received within guiding slot 16. The tongue spring 7 is riveted to the central portion of insulating disk 2. The contact spring 71 is electrically coupled to tongue spring 7 by means of the rivet which couples tongue spring 7 to the insulating disk 2, or in the alternative, contact spring 71 is integrally formed with tongue spring 7 and is folded back upon itself and riveted in position, thereby improving the ease of assembly, and insuring a good electrical path.
The 3-way switch coupled to turn-knob 4 includes contact springs 51, 61 and 71 for forming a switched electrical path from the spring connector 5 to either one or both of spring 6 and tongue spring 7, responsive to the rotation of the disk 41 coupled to turn-knob 4. Contact spring 51 is electrically coupled to spring connector 5 by means of a compressive fit within the guide slot 15. Contact spring 51 is positioned and retained relative to contact spring connector 5 by means of a hole 511 formed in contact spring 51 for receiving a nipple 52 formed in spring connector 5. Similarly, contact spring 61 is electrically coupled to spring 6 by means of a compressive fit within the guide slot 16. Contact spring 61 is located and maintained relative to spring 6 by means of a hole 611 formed in contact spring 61 for receiving a nipple 62 formed in spring 6.
The switch function is achieved by means of an electrical contact 411 having three contact surfaces wherein each contact surface is substantially orthogonal to at least one of the other two contact surfaces, and two of the contacts are separated by approximately 180° . Using 90° rotational steps, the electrical contact 411 provides a circuit path from contact spring 51 to either contact spring 71 or contact spring 61, both contact springs 71 and 61, or neither contact springs 71 and 61. Thus achieving the standard 3-way switch function.
Referring to FIG. 4, there is shown the opposing side of the turn-knob 4. As shown, a deep slot is formed in the body 1 for receiving the L-shaped spring connector 8, which extends to an opening 17 formed in one side of body 1. Opening 17 is provided for insertion of the U-shaped spring 9 for making an electrical connection with a rivet 131, as will be described in following paragraphs.
Referring to FIG. 5, a sectional view of the structure is shown wherein the spring connector 5 is shown with its oblique U-shape portion extending within the slot 15. Spring connector 5 is notched at the edge disposed adjacent the hole 11, as shown in FIGS. 5 and 5-1. The notched end of spring connector 5 extends and contacts the inside wall 111 of hole 11 such that when an electrical wire is inserted into hole 11 the spring connector 5, by virtue of the notch, is displaced from the wall and exerts a spring force to pinch the wire firmly and prevent its breaking free therefrom.
As shown in FIGS. 6, 6-1, 7 and 8-1, the L-shaped spring connector 8 is notched at the tip 121, the tip 21 normally located in contact with the inside wall of hull 12, prior to insertion of a wire. When an electric wire is inserted into hull 12, the L-shaped spring connector 8 firmly grasps the wire with the notched edge.
To provide an electrical path between the L-shaped spring connector 8 and the rivet 131, which is coupled to the metal screw shell 3, a U-shaped spring 9 is provided. The U-shaped spring 9 is inserted through the opening 17 formed in the body 1 and under compressive force contacts the lower portion 81 of L-shaped spring connector 8 and the body of rivet 131. Thus, an electrical path is formed from the wire lead "B" through the L-shaped spring connector 8 to the screw shell 3 by means of the U-shaped spring 9 and rivet 131.
The electrical path from lead "A" is made through the spring connector 5 to the contact spring 51 for coupling with the electrical contact 411. Responsive to the position of disk 41 electrical contact 411 provides an electrical path to contact spring 71, which in turn is coupled to the tongue spring 7, or to contact spring 61 for providing a path to the spring 6 having an end 63 for contacting the respective lamp terminal, or both contact springs 71 and 61, creating the two circuit paths, as previously described.
Referring to FIGS. 8 and 8-1, the spring connector 5 and the spring 6 are each individually inserted into respective slots 15 and 16 where they are stably held along with respective contact springs 51 and 61. The respective dimensions between the spring connector 5, spring 6 and slots 15 and 16 have been predetermined to provide a tight fit to prevent displacement of the springs when the turn-knob 3-way switch is operated.
Thus, a lamp holder assembly is constructed in a simple manner without the requirement for soldering tools or screwdriving tools. Electrical paths are made within the assembly by the interface between spring parts which are forced one against the other due to the structural relationship of those parts within the lamp holder body 1. Of particular importance, is the means by which the screw shell 3 is electrically coupled to the L-shaped contact spring 8. This connection is simply made by the insertion of the U-shaped spring 9 through the opening 17, wedging the U-shaped spring 9 between the lower portion 81 of L-shaped spring connector 8 and the rivet 131, as shown in FIG. 2.
Although this invention has been described in connection with specific forms and embodiments thereof, it will be appreciated that various modifications other than those discussed above may be resorted to without departing from the spirit or scope of the invention. For example, equivalent elements may be substituted for those specifically shown and described, certain features may be used independently of other features, and in certain cases, particular locations of elements may be reversed or interposed, all without departing from the spirit or scope of the invention as defined in the appended claims. | This invention is directed to an improved connector for turn-knob 3-way switched medium base lamp holders. By means of the improved structures forming the connecting holes, through which the electrical wires are inserted, to match the spring force of the connecting springs located within the lamp holder body. The electrical connection is made by the pinching action of the connecting spring against the electric wire through the holes on the top of the lamp holder body. Improved performance of this electrical connection is achieved by the grooves and bends formed in the connecting spring for applying sufficient force to provide a good electrical connection without deformation of the wire. | 7 |
BACKGROUND OF THE INVENTION
[0001] (a) Technical Field of the Invention
[0002] The present invention relates to a reel, and in particular, a reel which allows single positioning of cord or multiple positioning of cord.
[0003] (b) Description of the Prior Art
[0004] Conventional type of positioning a cord within a reel is the application of steel beads. As shown in FIGS. 5 and 6 , the reel A 10 comprises a front cover A 1 , a spiral spring A 2 , a sliding seat A 3 , a transmission cord A 4 , a positioning steel bead A 5 and a rear cover A 6 . In this conventional structure, the sliding seat A 3 contains the spiral spring to restore the transmission cord A 4 to its original position. The steel bead A 5 slides within the sliding seat A 3 so as to position the cord A 4 . The bottom section of the sliding seat A 3 has a passage A 3 1 so that the steel bead A 5 could roll, engage and disengage within the passage A 3 1 .
[0005] The drawback of the conventional reel are as follows:
[0006] 1. The constant engagement disengagement and high speed rolling of the steel bead causes wear to the passage. When a gap forms between the passage and the steel bead, the function for engagement is lost.
[0007] 2. In view of the above, noise will occur when the gap is widen. The precision of engagement and disengagement is depending on the precision of the gap formed between the steel bead and the passage. Due to wear of the passage, precision control may not be possible.
[0008] Accordingly, it is an object of the present invention to provide a positioning rod structure for a reel which could mitigate the above-mentioned drawback.
SUMMARY OF THE INVENTION
[0009] The primary purpose of the present invention is to provide a positioning rod structure of an unidirectional reel comprising a top cover, a spiral spring, a reeling disc having an upper and lower frame and a railing groove, a leading cord, a bottom cover and a positioning rod, characterized in that the leading cord winds around the lower and upper frame of the reeling disc and the leading cord is wound in a way that the cord has one side being loose and the other side being tight and the upper flame positions the leading cord for pulling and the lower flame positions the leading cord ready to rotate but the leading cord is positioned by the positioning rod, the positioning rod structure is arranged to be mounted at the external side of the lower Frame of the bottom cover to correspond to the railing grooves provided at the bottom section of the reeling disc and the positioning rod structure includes a positioning rod and a positioning plate, wherein the positioning plate covers the top portion of the positioning rod and is engaged using a peg, the center of the positioning plate is a pivot hole for pivotally mounting with the positioning rod, and the positioning plate has an exposed front end mounted with a sliding protruded section to correspond with the railing groove which rotates in accordance with the operation of the reel disc which engaging and disengaging alternately.
[0010] The advantages of the present invention are that
[0011] 1. Wearing process is slow with respect to positioning rod structure, the positioning rod structure of the present invention has a better longevity.
[0012] 2. Even wear is occurred, the engaging and disengaging function of the positioning rod structure shall never be lost, in addition, there is no noise problem with respect to the present structure.
[0013] 3. Disengagement as found in the conventional steel bead type of positioning will not be happened as the positioning rod is swinging to engage and disengage.
[0014] 4. The cost of operation is low as the engaging and disengaging do not need to be very precise.
[0015] 5. The operation of the positioning rod structure is simple and convenient.
[0016] The foregoing object and summary provide only a brief introduction to the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and drawings identical reference numerals refer to identical or similar parts.
[0017] Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view a positioning rod of an unidirectional reel in accordance with the present invention.
[0019] FIG. 2 is an exploded perspective view of the unidirectional reel of the present invention.
[0020] FIG. 3 is an exploded perspective view of the positioning rod, shown as component A in FIG. 2 , in accordance with the present invention.
[0021] FIG. 4 is a schematic view showing the relative positioning between the positioning rod and the railing groove of the present invention.
[0022] FIG. 5 is an exploded perspective view of a conventional reel.
[0023] FIG. 6 is a schematic view showing the bottom section structure of the sliding seat of the conventional reel employing steel bead for positioning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The following descriptions are of exemplary embodiments only, and are not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. Various changes to the described embodiments may be made in the function and arrangement of the elements described without departing from the scope of the invention as set forth in the appended claims.
[0025] Referring to FIGS. 1 and 2 , the positioning rod structure comprises a top cover 1 , a spiral spring 2 , a reeling disc 3 , a leading cord 4 , a bottom cover 5 and a positioning rod 6 . The center end 21 of the spiral spring 2 is engagingly secured to an engaging slot 52 formed at the center shaft 51 at the interior of the bottom cover 5 . The external end of the spiral spring 2 is engaging at the engaging slot 31 of the reeling disc 3 . When the reeling disc 3 rotates clockwise or anti-clockwise, the spiral spring 5 at the interior of the reeling disc 3 is urged to become loose or tight and the tightness of the spiral spring 2 provides a power source for restoration of the reel.
[0026] Along the edge wall of the reeling disc 3 , an engaging plate 32 is provided such that the leading cord 4 passes through the clipping opening 33 to the bottom frame of the reeling disc 3 . That is, the reeling disc 3 is a turning point such that the leading cord 4 can be divided into two sections in accordance with the reeling disc 3 and the cord 4 surrounds the upper fame at the upper and lower frame position of the reeling disc 3 . In accordance with the present invention, the upper frame is the pulling cord 4 , and the lower frame position is the ready to rotate cord 4 .
[0027] When the pulling cord 4 at the upper frame position and the ready to rotate cord 4 at the lower frame urge the cord 4 , the reeling disc 3 will rotate unidirectionally, and the ready to rotate cord 4 will rotate at same direction but the cord 4 will become loose or right in accordance with the number and length of the cord 4 being pulled. If the cord 4 is restored to its original position, the ready to rotate cord 4 will similarly rotate counterclockwise and the cord 4 becomes tight to correspond to the number of rotation of the cord and the length of the cord. Thus, the ready to rotate cord 4 will not be fully affected by the pulling of the cord 4 and the end of the cord 41 and the end of the ready to rotate cord 42 are respectively connected to the connector of the terminals.
[0028] In accordance with the present invention, the reeling disc 3 is matching with a positioning structure mounted within the inner edge of the bottom cover 5 to form into an engaging and a disengaging mechanism. As shown in FIG. 3 , the positioning rod structure 6 includes a positioning rod 61 and a positioning plate 62 , wherein the positioning plate 62 covers the top section of the positioning rod 61 and the two lateral sides of the positioning plate 62 is engaged by a peg 60 . The positioning plate 62 has a center pivot hole 621 for pivotally mounting of a positioning pivot shaft 611 such that the positioning shaft 61 forms a positioning plate 62 to position and to pivot the structure. Furthermore, the front end exposed from the rod body of the positioning plate 62 is a sliding protruded section 612 for correspondingly slide with the railing grooves 34 at the bottom section of the rotating disc 3 .
[0029] As shown in FIG. 4 , the bottom section of the reeling disc 3 has a railing grooves 34 and the positioning rod 41 engages or disengages alternately based on the railing grooves 35 . Thus, when the cord 4 is pulled, the reeling plate 3 is rotated, and the positioning rod 61 corresponding to the railing groove 34 , provides a swinging movement, and the swinging operation allows the pulling of the cord 4 and then the cord 4 is positioned, and another pulling of the cord 4 is allowed when the cord 4 is disengaged with the positioning rod 61 .
[0030] In another occasion, which is known as gradually positioning mechanism, the cord 4 is pulled and positioned and before the cord 4 is fully retracted, the cord 4 is pulled again, the cord 4 is then engaged. Thus, the positioning rod structure provides one time positioning of cord 4 or multiple positioning of cord controls.
[0031] It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above.
[0032] While certain novel features of this invention have been shown and described and are pointed out in the annexed claim, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. | A positioning rod structure for a reel is disclosed. The reel is positioning upon pulling out of cord from the reel and will restore to its original position if the cord is pulled for a second time. When the cord is pulled for one round, a positioning of the cord is done, and the pulling of the cord provides multi control of the cord, accordingly, the pulling of cord is precisely controlled. | 1 |
FIELD OF THE INVENTION
[0001] This invention generally relates to fuel/water separators and more particularly to drain valves associated therewith.
BACKGROUND OF THE INVENTION
[0002] Fuel/water separation filters are commonly used in contemporary internal combustion engines. As fuel flows through the filter, water and other contaminants are separated from the fuel and collect in a chamber of the filter. Periodically, the water and other contaminants must be drained from the filter. As a result, the above filters often include drain valves to effectuate drainage of the water and other contaminants. One such filter incorporating a drain valve can be found at U.S. Pat. No. 5,144,978 to Brown et al., the entire disclosure of which is incorporated herein by reference. Embodiments of the present invention generally relate to improvements in the design and function of the aforementioned filters.
BRIEF SUMMARY OF THE INVENTION
[0003] In view of the above, embodiments of the present invention provide a filter with a drain valve assembly that overcomes existing problems in the art. More particularly, embodiments of the present invention provide a drain valve assembly that incorporates a mechanical lock between a knob and a valve member thereof. With such a configuration, there is a reduced likelihood that the knob will become dislodged from the valve member in the field.
[0004] In one claimed aspect, a filter having a drain valve is provided. A filter according to this embodiment includes a filter housing having media therein. The filter housing has a threaded opening with a valve seat surrounding the opening. The filter also has a valve assembly that includes a valve member and a knob. The valve member has a valve head adapted to seal against the valve seat. The valve member also has a valve stem positioned within the threaded opening. The valve stem has at least one tab projecting from an end thereof. The at least one tab of the valve stem engages the knob to fixedly retain the knob on the valve stem.
[0005] In another claimed aspect, a filter having a drain valve is provided. The filter according to this embodiment includes a housing having a canister with an opening and a valve seat surrounding the opening. The filter also includes a valve assembly carried by the canister. The valve assembly has a rotatable valve member adapted to seal against the valve seat. The rotatable valve member has an outer periphery defining a lip. A knob having an aperture for receipt of a portion of the rotatable valve member is also provided. The aperture has an inner periphery radially spaced apart from the outer periphery of the portion of the rotatable valve member by a clearance gap. A locking structure is disposed between the knob and the rotatable valve member and axially extends across the clearance gap. The locking structure is operable to bias an abutting surface of the knob against the lip such that the knob is fixedly positioned along the rotatable valve member.
[0006] In yet another claimed aspect, a filter is provided. A filter according to this embodiment includes a filter housing having filter media therein. The filter housing has an opening with a valve seat surrounding the opening. A valve assembly extends through the opening. The valve assembly has an axially movable valve member and a knob. The axially movable valve member is adapted to move toward and away from the valve seat and seal against the valve seat in a closed position. The knob is mounted to the axially movable valve member with a deformed portion of the valve assembly.
[0007] Other aspects, objectives and advantages 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
[0008] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
[0009] FIG. 1 is a partial perspective view of a filter with a drain valve according to the teachings of the present invention;
[0010] FIG. 2 is a partial front cross section of the filter of FIG. 1 with the drain valve in a closed position;
[0011] FIG. 3 is a partial front cross section of the filter of FIG. 1 with the drain valve in an open position.
[0012] FIG. 4 is on an exploded perspective view of a valve stem and a knob of the drain valve of FIG. 1 ; and
[0013] FIG. 5 is a partial front cross section of the knob installed on the stem of the drain valve of FIG. 1 .
[0014] While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Turning now to the drawings, there is illustrated in FIG. 1 an exemplary embodiment of a filter 10 incorporating a drain valve assembly 12 mounted to a housing 14 of the filter 10 according to the present invention. As will be discussed in greater detail in the following, the drain valve assembly 12 allows for periodic draining of water and other contaminants collected within the housing 14 during filtration. With reference to FIG. 2 , the housing 14 has a canister portion that carries filter media 16 within a chamber 18 therein. During the filtration process, water and other contaminants will collect in a bottom of the chamber 18 as illustrated. Periodically, the water and other contaminants within the chamber 18 must be drained to ensure the efficient and effective operation of the filter 10 . As will be discussed in greater detail below, a user of the filter 10 can selectively open and close the drain valve assembly 12 by hand to facilitate such drainage.
[0016] Still referring to FIG. 2 , the drain valve assembly 12 is positioned within an opening 20 of the housing 14 . The drain valve assembly 12 includes a rotatable valve member 22 with a knob 24 connected thereto by a deformed portion therebetween. The deformed portion may be part of the valve and/or part of the knob, and in one embodiment, is shown taking the form of locking structures or tabs 50 . The knob 24 is configured for hand manipulation, and rotation of the knob 24 will also result in rotation of the rotatable valve member 22 . The valve member 22 has a valve head 26 that moves linearly towards and away from a valve seat 28 that surrounds the opening 20 upon rotation of the knob 24 and valve member 22 . When the valve head 26 , and more particularly a sealing surface 30 thereof, is in contact with the valve seat 28 , the drain valve assembly 12 is in a closed position such that water and other contaminants cannot drain out of the chamber 18 .
[0017] Turning now to FIG. 3 , the drain valve assembly 12 is illustrated in the open position. When in the open position, air is permitted to flow from the exterior of the filter 10 through a vent 32 of the valve member 22 and into the chamber 18 of the housing 14 . When this occurs, the water and other contaminants contained within the chamber 18 will flow out of the housing 14 through a drain 34 formed in the valve member 22 . As such, the drain valve assembly 12 generally moves along direction line 42 to facilitate the periodic draining of water and other contaminants contained within the chamber 18 of the housing 14 .
[0018] Movement along direction line 42 is provided in part by a threaded nut 40 mounted to the housing and in threaded engagement with the valve member 22 . As a user rotates the knob 24 , the valve member 22 will move into and out of engagement with the valve seat 28 . Although illustrated as incorporating a threaded nut 40 , it is recognized that the opening 20 of the housing 14 can be threaded to allow for the linear movement of the valve member 22 relative to the housing 14 without the use of an additional threaded nut 40 .
[0019] The valve seat 28 is situated within the chamber 18 of the housing 14 and surrounds the opening 20 thereof. In the illustrated embodiment, the valve seat 28 is a compressible gasket. The gasket is held in place by the threaded nut 40 .
[0020] Turning now to FIG. 4 , the valve member 22 has a valve stem 44 that extends away from the valve head 26 . The valve stem 44 has threads 36 formed on an outer surface 38 of the valve stem 44 . The threads 36 engage the threaded nut 40 (see FIGS. 2 and 3 ) to allow for the selective engagement and disengagement of the sealing surface 30 of the valve head 26 with the valve seat 28 .
[0021] The valve stem 44 also includes a lip 46 for location of the knob 24 . As illustrated in FIGS. 2 and 3 , when the knob 24 is fully installed on the valve member 22 , the knob 24 is in abutted contact with the lip 46 . The valve stem 44 also has a keyed portion 48 that matches a keyed aperture 60 of the knob 24 . As will be discussed in greater detail below, the keyed portion 48 and knob 24 maintain a keyed relationship when fully assembled such that the knob 24 cannot rotate relative to the valve member 22 .
[0022] Still referring to FIG. 4 , one or more locking structures 50 extend away from the keyed portion 48 . The locking structures 50 are located at an outer peripheral edge 52 of the keyed portion 48 . The locking structures 50 may be intermittently situated around the outer peripheral edge 52 , as illustrated, or can be provided by a continuous lid or edge extending from the outer peripheral edge 52 of the keyed portion 48 .
[0023] Referring now to FIGS. 4 and 5 , the locking structures 50 are deformable generally in direction 58 such that they engage a relief 54 formed into a top surface 56 of the knob 24 . The locking structures 50 are deformed against the relief 54 of the knob 24 such that the knob 24 is biased against the lip 46 (see FIG. 3 ) formed on the valve stem 44 of the valve member 22 . As such, the knob 24 is advantageously fixed to the valve member 22 such that the knob 24 is generally prevented from axial displacement along the valve member 22 .
[0024] Turning back to FIG. 4 , the locking structures 50 are illustrated as a deformed portion of the valve stem 22 that generally extends across a clearance gap formed between the valve member 22 and the knob 24 . The locking structures 50 can be deformed in a variety of ways including but not limited to, swaging, punching or similar processes.
[0025] Referring back to FIGS. 2 and 3 , the locking structures 50 hold the knob 26 in place along the valve member 22 and against the lip 46 thereof. As the knob 24 is rotated by hand, there is reduced likelihood that the knob 24 will become dislodged from the valve member 22 . As such, the filter 10 generally presents a more robust construction with a reduced failure mode in the field.
[0026] As described herein, the filter 10 incorporates a drain valve assembly 12 that overcomes existing problems in the art by providing a reliable assembly that can be repeatedly opened and closed with a reduced likelihood that the knob 24 will fall off of the valve member 22 .
[0027] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0028] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0029] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. | A filter with a drain valve is provided. The drain valve mounts within an opening of a housing of the filter. The drain valve has a knob mounted to a valve member thereof. At least one locking structure is disposed between the knob and the valve member to mechanically lock the knob to the valve member. Such a configuration reduces the likelihood that the knob will become inadvertently dislodged during operation. | 1 |
This application is a divisional application of U.S. patent application Ser. No. 08/850,171, filed May 2, 1997, now abandoned.
FIELD OF THE INVENTION
The present invention relates to the detection of specific nucleic acid sequences in a target test sample.
In particular, the present invention relates to the automated detection of specific nucleic acid sequences which are either unamplified or amplified nucleic acid sequences (amplicons).
In addition, the present invention relates to the use of automated amplification, methods and compositions for monitoring successful amplification, improved methods for reducing the chance for contamination, and the use of unified reaction buffers and unit dose aliquots of reaction components for amplification.
Finally, the present invention also relates to unique constructs and methods for the conventional or automated detection of one, or more than one different nucleic acid sequences in a single assay.
THE BACKGROUND OF THE INVENTION
The development of techniques for the manipulation of nucleic acids, the amplification of such nucleic acids when necessary, and the subsequent detection of specific sequences of nucleic acids or amplicons has generated extremely sensitive and nucleic acid sequence specific assays for the diagnosis of disease and/or identification of pathogenic organisms in a test sample.
Amplification of Nucleic Acids
When necessary, enzymatic amplification of nucleic acid sequences will enhance the ability to detect such nucleic acid sequences. Generally, the currently known amplification schemes can be broadly grouped into two classes based on whether, the enzymatic amplification reactions are driven by continuous cycling of the temperature between the denaturation temperature, the primer annealing temperature, and the amplicon (product of enzymatic amplification of nucleic acid) synthesis temperature, or whether the temperature is kept constant throughout the enzymatic amplification process (isothermal amplification). Typical cycling nucleic acid amplification technologies (thermocycling) are polymerase chain reaction (PCR), and ligase chain reaction (LCR). Specific protocols for such reactions are discussed in, for example, Short Protocols in Molecular Biolog , 2 nd Edition, A Compendium of Methods from Current Protocols in Molecular Biology , (Eds. Ausubel et al., John Wiley & Sons, New York, 1992) chapter 15. Reactions which are isothermal include: transcription-mediated amplification (TMA), nucleic acid sequence-based amplification (NASBA), and strand displacement amplification (SDA).
U.S. Patent documents which discuss nucleic acid amplification include U.S. Pat. Nos. 4,683,195; 4,683,202; 5,130,238; 4,876,187; 5,030,557; 5,399,491; 5,409,818; 5,485,184; 5,409,818; 5,554,517; 5,437,990 and 5,554,516 (each of which are hereby incorporated by reference in their entirety). It is well known that methods such as those described in these patents permit the amplification and detection of nucleic acids without requiring cloning, and are responsible for the most sensitive assays for nucleic acid sequences. However, it is equally well recognized that along with the sensitivity of detection possible with nucleic acid amplification, the ease of contamination by minute amounts of unwanted exogenous nucleic acid sequences is extremely great. Contamination by unwanted exogenous DNA or RNA nucleic acids is equally likely. The utility of amplification reactions will be enhanced by methods to control the introduction of unwanted exogenous nucleic acids and other contaminants.
Prior to the discovery of thermostable enzymes, methods that used thermocycling were made extremely difficult by the requirement for the addition of fresh enzyme after each denaturation step, since initially the elevated temperatures required for denaturation also inactivated the polymerases. Once thermostable enzymes were discovered, cycling nucleic acid amplification became a far more simplified procedure where the addition of enzyme was only needed at the beginning of the reaction. Thus reaction tubes did not need to be opened and new enzyme did not need to be added during the reaction, allowed for an improvement in efficiency and accuracy as the risk of contamination was reduced, and the cost of enzymes was also reduced. An example of a thermostable enzyme is the polymerase isolated from the organism Thermophilus aquaticus.
In general, isothermal amplification can require the combined activity of multiple enzyme activities for which no optimal thermostable variants have been described. The initial step of an amplification reaction will usually require denaturation of the nucleic acid target, for example in the TMA reaction, the initial denaturation step is usually ≧65° C., but can be typically ≧95° C., and is used when required to remove the secondary structure of the target nucleic acid.
The reaction mixture is then cooled to a lower temperature which allows for primer annealing, and is the optimal reaction temperature for the combined activities of the amplification enzymes. For example, in TMA the enzymes are generally a T7 RNA polymerase and a reverse transcriptase (which includes endogenous RNase H activity). The temperature of the reaction is kept constant through out the subsequent isothermal amplification cycle.
Because of the lack of suitable thermostable enzymes, some isothermal amplifications will generally require the addition of enzymes to the reaction mixture after denaturation at high temperature, and cool-down to a lower temperature. This requirement is inconvenient, and requires the opening of the amplification reaction tube, which introduces a major opportunity for contamination.
Thus, it would be most useful if such reactions could be more easily performed with a reduced risk of contamination by methods which would allow for integrated denaturation and amplification without the need for manual enzyme transfer.
Amplification Buffer and Single Reaction Aliquot of Reagents
Typical reaction protocols require the use of several different buffers, tailored to optimize the activity of the particular enzyme being used at certain steps in the reaction, or for optimal resuspension of reaction components. For example, while a typical PCR 10×amplification buffer will contain 500 mM KCl and 100 mM Tris HCl, pH 8.4, the concentration of MgCl 2 will depend upon the nucleic acid target sequence and primer set of interest. Reverse transcription buffer (5×) typically contains 400 mM Tris-Cl, pH 8.2; 400 mM KCl and 300 mM MgCl 2 , whereas Murine Maloney Leukemia Virus reverse transcriptase buffer (5×) typically contains 250 mM Tris-Cl, pH 8.3; 375 mM KCl; 50 mM DTT (Dithiothreitol) and 15 mM MgCl 2 .
While such reaction buffers can be prepared in bulk from stock chemicals, most commercially available amplification products provide bulk packaged reagents and specific buffers for use with the amplification protocol. For example, commercially available manual amplification assays for detection of clinically significant pathogens (for example Gen-Probe Inc. Chlamydia, and Mycobacterium tuberculosis detection assays) requires several manual manipulations to perform the assay, including dilution of the test sample in a sample dilution buffer (SDB), combination of the diluted sample with amplification reaction reagents such as oligonucleotides and specific oligonucleotide promoter/primers which have been reconstituted in an amplification reconstitution buffer (ARB), and finally, the addition to this reaction mixture of enzymes reconstituted in an enzyme dilution buffer (EDB).
The preparation and use of multiple buffers which requires multiple manual additions to the reaction mixture introduces a greater chance for contamination. It would be most useful to have a single unified buffer which could be used in all phases of an amplification protocol. In particular, with the commercially available TMA assays described above, the requirement for three buffers greatly complicates automation of such a protocol.
Bulk packaging of the enzyme or other reaction components by manufacturers, may require reconstitution of the components in large quantities, and the use of stock amounts of multiple reagents, can be wasteful when less than the maximal number of reactions are to be carried out, as some of these components may be stable for only a short time. This process of reconstitution also requires multiple manipulations by the user of the stock reagents, and aliquoting of individual reaction amounts of reagents from stocks which creates a major opportunity for contamination.
Methods and compositions for the preparation of bulk quantities of preserved proteins are known, see for example, U.S. Pat. Nos. 5,098,893; 4,762,857; 4,457,916; 4,891,319; 5,026,566 and International Patent Publications WO 89/06542; WO 93/00806; WO 95/33488 and WO 89/00012, all of which are hereby incorporated by reference in their entirety. However, the use of pre-aliquoted and preserved reagent components in single reaction quantities/dose is both very useful and economical. Single aliquots of enzyme reagent avoids multiple use of bulk reagents, reducing waste, and greatly reducing the chance of contamination. Further, such single reaction aliquots are most suitable for the automation of the reaction process.
The requirement for many changes of buffer and the multiple addition of reagents complicates the automation of such reactions. A single dose unit of reaction buffer mixture, and a unified combination buffer will both simplify automation of the process and reduce the chance of contamination.
Automation of nucleic Acid Detection with or without Amplification
Nucleic acid probe assays, and combination amplification/probe assays can be rapid, sensitive, highly specific, and usually require precise handling in order to minimize contamination with non-specific nucleic acids, and are thus prime candidates for automation. As with conventional nucleic acid detection protocols, it is generally required to utilize a detection probe oligonucleotide sequence which is linked by some means to a detectable signal generating component. One possible probe detection system is described in U.S. Pat. No. 4,581,333 hereby incorporated by reference in its entirety.
In addition, automation of a nucleic acid detection system targeting unamplified or amplified nucleic acid, or a combined automated amplification/detection system will generally be adaptable to the use of nucleic acid capture oligonucleotides that are attached to some form of solid support system. Examples of such attachment and methods for attachment of nucleic acid to solid support are found in U.S. Pat. No. 5,489,653 and 5,510,084 both of which are hereby incorporated by reference.
Automation of amplification, detection, and a combination of amplification and detection is desirable to reduce the requirement of multiple user interactions with the assay. Apparatus and methods for optically analyzing test materials are described for example in U.S. Pat. No. 5,122,284 (hereby incorporated by reference in its entirety). Automation is generally believed to be more economical, efficient, reproducible and accurate for the processing of clinical assays. Thus with the superior sensitivity and specificity of nucleic acid detection assays, the use of amplification of nucleic acid sequences, and automation at one or more phases of a assay protocol can enhance the utility of the assay protocol and its utility in a clinical setting.
Advantage of Internal Control Sequences
Nucleic acid amplification is highly sensitive to reaction conditions, and the failure to amplify and/or detect any specific nucleic acid sequences in a sample may be due to error in the amplification process as much as being due to absence of desired target sequence. Amplification reactions are notoriously sensitive to reaction conditions and have generally required including control reactions with known nucleic acid target and primers in separate reaction vessels treated at the same time. However, internal control sequences added into the test reaction mixture would truly control for the success of the amplification process in the subject test reaction mixture and would be most useful. U.S. Pat. No. 5,457,027 (hereby incorporated by reference in its entirety) teaches certain internal control sequences which are useful as an internal oligonucleotide standard in isothermal amplification reactions for Mycobacterium tuberculosis.
However it would be extremely useful to have a general method of generating internal control sequences, that would be useful as internal controls of the various amplification procedures, which are specifically tailored to be unaffected by the nucleic acid sequences present in the target organism, the host organism, or nucleic acids present in the normal flora or in the environment. Generally, such internal control sequences should not be substantially similar to any nucleic acid sequences present in a clinical setting, including human, pathogenic organism, normal flora organisms, or environmental organisms which could interfere with the amplification and detection of the internal control sequences.
Detection of More than one Nucleic Acid Sequence in a Single Assay
In general, a single assay reaction for the detection of nucleic acid sequences is limited to the detection of a single target nucleic acid sequence. This single target limitation increases costs and time required to perform clinical diagnostic assays and verification control reactions. The detection of more than one nucleic acid sequence in a sample using a single assay would greatly enhance the efficiency of sample analysis and would be of a great economic benefit by reducing costs, for example helping to reduce the need for multiple clinical assays.
Multiple analyte detection in a single assay has been applied to antibody detection of analyte as in for example International Patent Publication number WO 89/00290 and WO 93/21346 both of which are hereby incorporated by reference in their entirety.
In addition to reducing cost, time required, the detection of more than one nucleic acid target sequence in a single assay would reduce the chance of erroneous results. In particular multiple detection would greatly enhance the utility and benefit using internal control sequences and allow for the rapid validation of negative results.
SUMMARY OF THE INVENTION
The present invention comprises methods for the automated isothermal amplification and detection of a specific nucleic acid in a test sample to be tested comprising:
a) combining a test sample to be tested with a buffer, a mixture of free nucleotides, specific oligonucleotide primers, and optionally thermostable nucleic acid polymerization enzyme, in a first reaction vessel and placing the reaction vessel in an automated apparatus such that;
b) the automated apparatus heats the first reaction vessel to a temperature, and for a time sufficient to denature, if necessary, the nucleic acid in the sample to be tested;
c) the automated apparatus cools the first reaction vessel to a temperature such that oligonucleotide primers can specifically anneal to the target nucleic acid;
d) the automated apparatus transfers the reaction mixture from the first reaction vessel to a second reaction vessel, and brings the reaction mixture in contact with themmolabile nucleic acid amplification enzyme;
e) the automated apparatus maintains the temperature of the second reaction vessel at a temperature which allows primer mediated amplification of the nucleic acid;
f) the automated apparatus contacts the amplified nucleic acid in the second reaction vessel with a capture nucleic acid specific for the nucleic acid to be tested such that they form a specifically-bound nucleic acid-capture probe complex;
g) the automated apparatus optionally washes the specifically captured amplified nucleic acid such that non-specifically bound nucleic acid is washed away from the specifically-bound nucleic acid-capture probe complex;
h) the automated apparatus contacts the specifically-bound nucleic acid-capture probe complex with a labeled nucleic acid probe specific for the amplified nucleic acid such that a complex is formed between the specifically amplified nucleic acid and the labeled nucleic acid probe;
i) the automated apparatus washes the specifically-bound nucleic acid-capture probe-labeled probe complex such that non-specifically bound labeled probe nucleic acid is washed away from the specifically bound complex;
j) the automated apparatus contacts the specifically bound complex with a solution wherein an detection reaction between the labeled nucleic acid probe is effected between the solution and the label attached to the nucleic acid such that a detectable signal is generated from the sample in proportion the amount of specifically-bound amplified nucleic acid in the sample;
wherein the steps h, i, and j may occur sequentially or simultaneously;
k) the automated apparatus detects the signal and optionally displays a value for the signal, or optionally records a value for the signal.
As used herein, the term test sample includes samples taken from living patients, from non-living patients, from surfaces, gas, vacuum or liquids, from tissues, bodily fluids, swabs from body surfaces or cavities, and any similar source. The term buffer as used here encompasses suitable formulations of buffer which can support the effective activity of a label, for example an enzyme placed into such buffer when treated at the appropriate temperature for activity and given the proper enzymatic substrate and templates as needed. The term specific oligonucleotide nucleic acid primers means an oligonucleotide having a nucleic acid sequence which is substantially complementary to and will specifically hybridize/anneal to a target nucleic acid of interest and may optionally contain a promoter sequence recognized by RNA polymerase. The term reaction vessel means a container in which a chemical reaction can be performed and preferably capable of withstanding temperatures of anywhere from about −80° C. to 100° C.
The instant invention further provides for the method described above, wherein the reaction buffer is a unified buffer and as such is suitable for denaturation nucleic acids and annealing of nucleic acids, and is further capable of sustaining the enzymatic activity of nucleic acid polymerization and amplification enzyme. Further encompassed by the invention is the method wherein the nucleic acid amplification enzyme is administered in the second reaction chamber as a single assay dose amount in a lyophilized pellet, and the reaction chamber is sealed prior to the amplification step.
The invention teaches an apparatus for the automated detection of more than one nucleic acid target sequences or amplicons comprising a solid phase receptacle (SPR® pipet-like devise) coated with at least two distinct zones of a capture nucleic acid oligonucleotide.
The invention teaches a method for the automated detection of more than one nucleic acid target sequence comprising contacting a solid phase receptacle (SPR® pipet-like devise) coated with at least two distinct capture nucleic acid oligonucleotides in a single or multiple zones to a sample to be tested and detecting a signal(s) from specifically bound probe. In one embodiment of the invention, the SPR® is coated with two distinct zones of capture nucleic acid oligonucleotides which are specific for different nucleic acid sequence targets. In another embodiment of the invention, the SPR® is coated with at least one capture probe for a target nucleic acid sequence, and one capture probe for an amplification control nucleic acid sequence which when detected confirms that amplification did take place.
The present invention also comprises an internal amplification positive control nucleic acid having the nucleic acid sequence of RIC1 and a second internal amplification positive control nucleic acid having the nucleic acid sequence of RIC2.
The present invention further comprises a method for generating an internal amplification positive control nucleic acid consisting of:
generating random nucleic acid sequences of at least 10 nucleotides in length, screening said random nucleic acid sequence and selecting for specific functionality, combining in tandem a number of such functionally selected nucleic acid sequences, and screening the combined nucleic acid sequence and optionally selecting against formation of intra-strand nucleic acid dimers, or the formation of hairpin structures.
BRIEF DESCRIPTION OF THE DRAWINGS
Presently preferred embodiments of the invention will be described in conjunction with the appended drawings, wherein like reference numerals refer to like elements in the various views, and in which:
FIG. 1 is a graph illustrating single dose reagent pellet temperature stability;
FIG. 2 illustrates the general TMA protocol;
FIG. 3A is a schematic representation of a disposable dual chamber reaction vessel and the heating steps associated therewith to perform a TMA reaction in accordance with one possible embodiment of the invention;
FIG. 3B is a schematic representation of alternative form of the invention in which two separate reaction chambers are combined to form a dual chamber reaction vessel;
FIG. 3C is a schematic representation of two alternative embodiments of a dual chamber reaction vessel that are snapped into place in a test strip for processing with a solid phase receptacle and optical equipment in accordance with a preferred embodiment of the invention;
FIG. 4 is a schematic representation of an alternative embodiment of a dual chamber reaction vessel formed from two separate chambers that are combined in a manner to permit a fluid sample in one chamber to be transferred to the other chamber, with the combined dual chamber vessel placed into a test strip such as illustrated in FIG. 3C;
FIG. 5 is a perspective view of a stand-alone amplification processing station for the test strips having the dual chamber reaction vessels in accordance with a presently preferred form of the invention;
FIG. 6 is a perspective view of one of the amplification modules of FIG. 4 / 31 , as seen from the rear of the module;
FIG. 7 is a perspective view of the front of the module of FIG. 5 / 32 ;
FIG. 8 is another perspective view of the module of FIG. 7;
FIG. 9 is a detailed perspective view of a portion of the test strip holder and 95° C. Peltier heating subsystems of the module of FIGS. 6-8;
FIG. 10 is an isolated perspective view of the test strip holder of FIG. 9, showing two test strips installed in the test strip holder;
FIG. 11 is a detailed perspective view of the test strip holder or tray of FIG. 7;
FIG. 12 is a block diagram of the electronics of the amplification processing station of FIG. 7;
FIG. 13 is a diagram of the vacuum subsystem for the amplification processing station of FIG. 6; and
FIG. 14 is a graph of the thermal cycle of the station of FIG. 6 .
FIG. 15 illustrates a schematic of the operation of the multiplex VIDAS detection.
FIG. 16 illustrates the production of SPR® with two distinct capture zones;
FIG. 17 illustrates the VIDAS apparatus strip configuration for multiplex detection;
FIG. 18 illustrates and graphs the results of verification of the VIDAS multiplex protocol detecting only NG target;
FIG. 19 A/ 46 A is a graph showing the results when 1×10 12 CT targets were mixed with 0, 1×10 9 , 1×10 10 , 1×10 11 , or 1×10 12 , NG targets, and detected with the VIDAS instrument using the multiplex protocol and SPRs coated with CT capture probes on the bottom zone of the SPR®, and NG capture probes on the top zone of the SPR®.
FIG. 19 B/ 46 B illustrates the results when 1×10 12 NG targets was mixed with 0, 1×10 9 , 1×10 10 , 1×10 11 , or 1×10 12 , NG targets, and detected with the VIDAS instrument using the multiplex protocol and SPR® coated with CT capture probes on the bottom zone of the SPR®, and NG capture probes on the top zone of the SPR®.
FIG. 20A is a graph showing detection of Mtb nucleic acid by VIDAS apparatus after amplification.
FIG. 20B is a graph showing detection of Mtb nucleic acid by VIDAS apparatus.
FIG. 21 is a graph showing detection of Mtb nucleic acid by VIDAS apparatus after amplification.
FIG. 22 is a graph showing detection of Mtb nucleic acid by VIDAS apparatus after amplification using the binary/dual chamber protocol.
FIG. 23 illustrates the results generated by the method described showing a collection of strings of nucleic acid sequences and screening for specific functional parameters.
FIG. 24 shows the nucleic acid sequence of Random Internal Control 1 (RIC1) with the possible oligonucleotide primers/probes for amplification and detection of the control sequence.
FIG. 25 shows an analysis of the possible secondary structural components of the RIC1 sequence.
FIG. 26 shows the nucleic acid sequence of Random Internal Control 2 (RIC2) with the possible oligonucleotide primers/probes for amplification and detection of the control sequence.
FIG. 27 shows an analysis of the possible secondary structural components of the RIC2 sequence.
FIG. 28 illustrates results from detection of RIC1 DNA, where the ran21 was the capture probe and ran33 was an enzyme-linked detector-probe, and shows that amplification and detection occurs under standard assay conditions.
FIG. 29 shows that RIC1 RNA, amplified by TMA and the chemically activated signal detected on a VIDAS instrument (bioMérieux Vitek, Inc.) using the enzyme-linked detection system, has a limit of sensitivity of about 1000 molecules of RIC1 RNA (without optimization of conditions).
DESCRIPTION OF THE INVENTION
The following examples are provided to better illustrate certain embodiments of the present invention without intending to limit the scope of the invention.
EXAMPLE 1
Single Dose Reagents and Unified Buffer
The implementation of a TMA reaction (see U.S. Pat. No. 5,437,990) on-line in a VIDAS or off-line in a separate instrument (with detection occurring on a VIDAS instrument) requires modification of the chemistry used to perform the reaction manually. First, bulk packaged reagents must be modified into single aliquot doses, and second, the buffer components of the reaction has been altered to form a single comprehensive multifunctional unified buffer solution.
Under the current manual technology, the reagents are prepared as lyophilized “cakes” of multiple-assay quantities. The amplification and enzyme reagents thus must be reconstituted in bulk and aliquoted for individual assays.
Thus the automated form of TMA on the VIDAS system improves on the above manual method by utilizing single dose pellets of lyophilized reaction components that can be resuspended in a single unified buffer which will support sample dilution, denaturation of nucleic acids, annealing of nucleic acids, and desired enzymatic activity.
A) Unified Buffer and Single Dose Reagents
To test the feasibility of single dose amplification reagents, standard Chlamydia TMA Amplification and Enzyme reagents (Gen-Probe Inc.), the bulk reagents were reconstituted in 0.75 ml of water. 12.5 μl of either the water reconstituted amplification or enzyme reagent (i.e. a single dose aliquots) were aliquoted into microcentrifuge tubes. These tubes were placed in a vacuum centrifuge with low heat to remove water. The end result of this procedure was microcentrifuge tube containing a small, dry cake of either enzyme or amplification reagent at the bottom of the tube.
The combined Unified Buffer used in this example, consists of a combination of standard commercially available Gen-Probe Inc. Sample Dilution Buffer (SDB), Amplification Reconstitution Buffer (ARB), and Enzyme Dilution Buffer (EDB) in a 2:1:1 ratio. To each dried amplification reagent microfuge tube was added 100 μl of the combined Unified Buffer, and positive control nucleic acid (+), and overlaid with 100 μl of silicone oil. The tube was then heated to 95° C. for 10 minutes and then cooled to 42° C. for 5 minutes. The 200 μl total volume was then transferred to a tube containing the dried enzyme reagent. This was then gently mixed to resuspend the enzyme reagent, and the solution was heated for one hour at 42° C.
Control reactions were prepared using Gen-Probe Control reagents which were reconstituted in the normal 1.5 ml of ARB or EDB according to instructions provided in the Gen-Probe kit. In each control reaction 25 μl of the reconstituted amplification reagent was combined with 50 μl or the SDB with the positive control nucleic acid (+). The mixture was also heated to 95° C. for 10 minutes and then cooled to 42° C. for 5 minutes. To this was added 25 μl of the reconstituted enzyme reagent and incubated at 42° C. for one hour. Negative control had no nucleic acid.
Both the test Unified Buffer (Unified) reactions and the standard Control 15 (Control) reactions were then subjected to the Gen-Probe Inc. standard Hybridization Protection Assay (HPA) protocol. Briefly, 100 μl of a Chlamydia trachomatis specific nucleic acid probe was added to each tube and allowed to hybridize for 15 minutes at 60° C. Then 300 μl of Selection Reagent was added to each tube and the differential hydrolysis of hybridized and unhybridized probe was allowed to occur for 10 minutes. The tubes were then read in a Gen-Probe Inc. Leader 50 luminometer and the resultant data recorded as Relative Light Units (RLU) detected from the label, as shown in Table 1 below. Data reported as RLU, standard C. Trachomatis TMA/HPA reaction.
TABLE 1
Unified single dose aliquot of amplification and enzyme reagents
Control (+)
Unified (+)
Control (−)
Unified (−)
2,264,426
2,245,495
6,734
3,993
2,156,498
2,062,483
3,484
3,765
1,958,742
2,418,531
5,439
5,836
2,451,872
2,286,773
2,346,131
1,834,198
The data in Table 1 demonstrates that comparable results are obtained when using the single dose aliquots of dried amplification and enzyme reagent. In addition, the data shows that the results were comparable using three separate buffers (ARB, EDB and SDB) and one unified combined buffer (SDB, ARB and EDB combined at a ratio of 2:1:1) to resuspend the reagents and run the reactions.
B) Pellitization of Single Dose Reagents
In order to simplify the single dose aliquoting of reagents, methods which will allow for pelletization of these reagents in single dose aliquots were used. Briefly, reagent pellets (or beads) can be made by aliquoting an aqueous solution of the reagent of choice (that has been combined with an appropriate excipient, such as D(+) Trehalose (α-D-Glucopyranosyl-α-D-glucopyranoside, purchased from Pfanstiehl Laboratories, Inc., Waukegan, Ill.) into a cryogenic fluid, and then using sublimation to remove the water from the pellet. Once the reagent/trehalose mixture is aliquoted into the cryogenic fluid, it forms a spherical frozen pellet. These pellets are then placed in a lyophilizer where the frozen water molecules sublimate during the vacuum cycle. The result of this procedure is small, stable, non-flaking reagent pellets which can be dispensed into the appropriate packaging. Single dose aliquot pellets of reagents which contained RT, T7 and sugar were subjected to a wide range of temperatures to examine pellet stability. After being subject to a test temperature for 10 minutes, the pellets were then used for CT amplification. The results are graphed in FIG. 1 . The results show that the single dose reagent pellet remains stable even after to exposure to high temperatures for 10 minutes.
The extraordinary stability of enzymes dried in trehalose has been previously reported (Colaco et al., 1992, Bio/Technology, 10, 1007) which has renewed interest in research on long-term stabilization of proteins has become a topic of interest (Franks, 1994, Bio/Technology, 12, 253). The resulting pellets of the amplification reagent and enzyme reagents were tested by use in C. Trachomatis TMA/PA reactions.
The prepared amplification pellets were placed in a tube to which was added 75 μl of a mixture of ARB and SDB (mixed in a 1:2 ratio) with positive control nucleic acid. This sample was then heated to 95° C. for 10 minutes and then cooled to 42° C. for 5 minutes. To this was added 25 μl of enzyme reagent, which had been reconstituted using standard Gen-Probe Inc. procedure. This mixture was allowed to incubate for one hour at 42° C. The reactions were then analyzed by the HPA procedure, as described above. The results of this test are reported as RLU in Table 2, and labeled AMP Pellets(+). As above, negative control reactions were run without nucleic acid (−).
The prepared enzyme pellets were tested by heating 100 μl of a combination of SDB with positive control nucleic acid, EDB, and the standard reconstituted amplification reagent (in a 2:1:1 ratio) at 95° C. for 10 minutes and then cooled to 42° C. for 5 minutes. The total volume of the reaction mix was added to the prepared enzyme pellet. After the pellet was dissolved, the reaction was heated to 42° C. for one hour and then subjected to HPA analysis as above. The results of this test are reported as RLU in Table 2 below, labeled Enzyme Pellet (+). Control reactions were prepared using standard Gen-Probe Inc. reagents following standard procedure. Data reported as RLU, standard C. Trachomatis TMA/HPA reaction.
TABLE 2
Single dose aliquot of pelleted amplification and enzyme reagents
Amp Pellets
Amp Pellets
Enzyme
Enzyme
Control (+)
(+)
(−)
Pellets (+)
Pellets (−)
2,363,342
2,451,387
2,619
2,240,989
3,418
2,350,028
2,215,235
2,358
3,383,195
1,865
2,168,393
2,136,645
3,421
2,596,041
2,649
2,412,876
2,375,541
2,247
2,342,288
1,653
The data in Table 2 demonstrates that there was no significant difference when using the standard Gen-Probe Inc. reagents, or the dried, prepared, single dose amplification reagent pellet, or the enzyme reagent pellet. Thus the single dose aliquots of reagents are suitable for use with a single unified buffer for application to automation using a VIDAS system.
EXAMPLE 2
Automated Isothermal Amplification Using Thermolabile Enzymes
In order to automate the isothermal amplification assay reaction for use with clinical assay apparatus, such as a VIDAS instrument (BioMérieux Vitek, Inc.), a novel dual-chamber reaction vessel has been designed to implement the use of the unified buffer and single reaction aliquot reagent pellets described above in isothermal amplification assay of test samples which can be further used in combination with a stand alone processing station.
A) Dual Reaction Chambers
The use of two chambers will facilitate keeping separate the heat stable sample/amplification reagent (containing the specific primers and nucleotides) from the heat labile enzymatic components (i.e. RNA reverse transcriptase, RNA polymerase RNase H). FIG. 3A is a schematic representation of a disposable dual chamber reaction vessel 10 and the heating steps associated therewith to perform a TMA reaction in accordance with one possible embodiment of the invention. Chamber A contains the amplification mix, namely deoxynucleotides, primers, MgCl 2 and other salts and buffer components. Chamber B contains the amplification enzyme that catalyzes the amplification reaction, e.g., T7 and/or RT. After addition of the targets (or patient sample) into chamber A, heat is applied to chamber A to denature the DNA nucleic acid targets and/or remove RNA secondary structure. The temperature of chamber A is then cooled down to allow primer annealing. Subsequently, the solution of chamber A is brought into contact with chamber B. Chambers A and B, now in fluid communication with each other, are then maintained at the optimum temperature for the amplification reaction, e.g., 42 degrees C. By spatially separating chamber A from chamber B, and applying the heat for denaturation to chamber A only, the thermolabile enzymes in chamber B are protected from inactivation during the denaturation step.
FIG. 3B is a schematic representation of an alternative form of the invention in which two separate reaction chambers 12 and 14 are combined to form a dual chamber reaction vessel 10 . Like the embodiment of FIG. 3A, Chamber A is pre-loaded during a manufacturing step with an amplification mix, namely nucleotides, primers, MgCl 2 and other salts and buffer components. Chamber B is pre-loaded during manufacturing with the amplification enzyme that catalyzes the amplification reaction, e.g., T7 and/or RT. Fluid sample is then introduced into chamber A. The targets are heated for denaturation to 95° C. in chamber A. After cooling chamber A to 42° C., the solution in chamber A is brought into contact with the enzymes in chamber B to trigger the isothermal amplification reaction.
If the reaction vessel is designed such that, after having brought the contents of chambers A and B into contact, the amplification chamber does not allow any exchange of materials with the environment, a closed system amplification is realized that minimizes the risk of contaminating the amplification reaction with heterologous targets or amplification products from previous reactions.
FIG. 3C is a schematic representation of two alternative dual chamber reaction vessels 10 and 10 ′ that are snapped into place in a test strip 19 for processing with a solid phase receptacle and optical equipment in accordance with a preferred embodiment of the invention. In the embodiments of FIG. 3, a unidirectional flow system is provided. The sample is first introduced into chamber A for heating to the denaturation temperature. Chamber A contains the dried amplification reagent mix 16 . After cooling, the fluid is transferred to chamber B containing the dried enzyme 18 in the form of a pellet. Chamber B is maintained at 42° C. after the fluid sample is introduced into Chamber B. The amplification reaction takes place in Chamber B at the optimum reaction temperature (e.g., 42° C.). After the reaction is completed, the test strip 19 is then processed in a machine such as the VIDAS® instrument available from bioMérieux Vitek, Inc., the assignee of the present invention. Persons of skill in the art are familiar with the VIDAS® instrument.
The steps of heating and cooling of chamber A could be performed prior to the insertion of the dual chamber disposable reaction vessel 10 or 10 ′ into the test strip 16 , or, alternatively, suitable heating elements could be placed adjacent to the left hand end 24 of the test strip 19 in order to provide the proper temperature control of the reaction chamber A. The stand alone amplification processing station of FIGS. 4-14, described below, incorporates suitable heating elements and control systems to provide the proper temperature control for the reaction vessel 10 .
FIG. 4 is a schematic representation of an alternative embodiment of a dual chamber reaction vessel 10 ″ formed from two separate interlocking vessels 10 A and 10 B that are combined in a manner to permit a fluid sample in one chamber to flow to the other, with the combined dual chamber vessel 10 ″ placed into a test strip 19 such as described above in FIG. 3 A. The fluid sample is introduced into chamber A, which contains the dried amplification reagent mix 16 . Vessel A is then heated off-line to 95 degrees C, then cooled to 42 degrees C. The two vessels A and B are brought together by means of a conventional snap fit between complementary locking surfaces on the tube projection 26 on chamber B and the recessed conduit 28 on chamber A. The mixing of the sample solution from chamber A with the enzyme from chamber B occurs since the two chambers are in fluid communication with each other, as indicated by the arrow 30 . The sample can then be amplified in the combined dual chamber disposable reaction vessel 10 ″ off-line, or on-line by snapping the combined disposable vessel 10 ″ into a modified VIDAS® strip. The VIDAS® instrument could perform the detection of the amplification reaction in known fashion.
B) Amplification Station
FIG. 5 is a perspective view of a stand-alone amplification processing system 200 for the test strips 19 having the dual chamber reaction vessels in accordance with a presently preferred form of the invention. The system 200 consists of two identical amplification stations 202 and 204 , a power supply module 206 , a control circuitry module 208 , a vacuum tank 210 and connectors 212 for the power supply module 206 . The tank 210 has hoses 320 and 324 for providing vacuum to amplification stations 202 and 204 and ultimately to a plurality of vacuum probes (one per strip) in the manner described above for facilitating transfer of fluid from the first chamber to the second chamber. The vacuum subsystem is described below in conjunction with FIG. 14 .
The amplification stations 202 and 204 each have a tray for receiving at least one of the strips and associated temperature control, vacuum and valve activation subsystems for heating the reaction wells of the strip to the proper temperatures, transferring fluid from the first chamber in the dual chamber reaction wells to the second chamber, and activating a valve such as a thimble valve to open the fluid channel to allow the fluid to flow between the two chambers.
The stations 202 and 204 are designed as stand alone amplification stations for performing the amplification reaction in an automated manner after the patient or clinical sample has been added to the first chamber of the dual chamber reaction vessel described above. The processing of the strips after the reaction is completed with an SPR takes place in a separate machine, such as the VIDAS® instrument. Specifically, after the strips have been placed in the stations 202 and 204 and the reaction run in the stations, the strips are removed from the stations 202 and 204 and placed into a VIDAS® instrument for subsequent processing and analysis in known fashion.
The entire system 200 is under microprocessor control by an amplification system interface board (not shown in FIG. 5 ). The control system is shown in block diagram form in FIG. 12 and will be described later.
Referring now to FIG. 6, one of the amplification stations 202 is shown in a perspective view. The other amplification station is of identical design and construction. FIG. 7 is a perspective view of the front of the module of FIG. 6 .
Referring to these figures, the station includes a vacuum probe slide motor 222 and vacuum probes slide cam wheel 246 that operate to slide a set of vacuum probes 244 (shown in FIG. 7) for the thimble valves up and down relative to a vacuum probes slide 246 to open the thimble valves and apply vacuum so as to draw the fluid from the first chamber of the reaction vessel 10 to the second chamber. The vacuum probes 244 reciprocate within annular recesses provided in the vacuum probes slide 246 . Obviously, proper registry of the pin structure and vacuum probe 244 with corresponding structure in the test strip as installed on the tray needs to be observed.
The station includes side walls 228 and 230 that provide a frame for the station 202 . Tray controller board 229 is mounted between the side walls 228 and 230 . The electronics module for the station 202 is installed on the tray controller board 229 .
A set of tray thermal insulation covers 220 are part of a thermal subsystem and are provided to envelop a tray 240 (FIG. 7) that receives one or more of the test strips. The insulation covers 220 help maintain the temperature of the tray 240 at the proper temperatures. The thermal subsystem also includes a 42° C. Peltier heat sink 242 , a portion of which is positioned adjacent to the second chamber in the dual chamber reaction vessel in the test strip to maintain that chamber at the proper temperature for the enzymatic amplification reaction. A 95° C. heat sink 250 is provided for the front of the tray 240 for maintaining the first chamber of the reaction well in the test strip at the denaturation temperature.
FIG. 8 is another perspective view of the module of FIG. 7, showing the 95° C. heat sink 250 and a set of fins 252 . Note that the 95° C. heat sink 250 is positioned to the front of and slightly below the tray 240 . The 42° C. heat sink 242 is positioned behind the heat sink 250 .
FIG. 9 is a detailed perspective view of a portion of the tray 240 that holds the test strips (not shown) as seen from above. The tray 240 includes a front portion having a base 254 , a plurality of discontinuous raised parallel ridge structures 256 with recessed slots 258 for receiving the test strips. The base of the front 254 of the tray 240 is in contact with the 95° C. heat sink 250 . The side walls of the parallel raised ridges 256 at positions 256 A and 256 B are placed as close as possible to the first and second chambers of the reaction vessel 10 of FIG. 3A so as to reduce thermal resistance. The base of the rear of the tray 240 is in contact with a 42° C. Peltier heat sink, as best seen in FIG. 8 . The portion 256 B of the raised ridge for the rear of the tray is physically isolated from portion 256 A for the front of the tray, and portion 256 B is in contact with the 42° C. heat sink so as to keep the second chamber of the reaction vessel in the test strip at the proper temperature.
Still referring to FIG. 9, the vacuum probes 244 include a rubber gasket 260 . When the vacuum probes 244 are lowered by the vacuum probe motor 222 (FIG. 6) the gaskets 260 are positioned on the upper surface of the test strip surrounding the vacuum port in the dual chamber reaction vessel so as to make a tight seal and permit vacuum to be drawn on the second chamber.
FIG. 10 is an isolated perspective view of the test strip holder or tray 240 of FIG. 9, showing two test strips installed in the tray 240 . The tray 240 has a plurality of lanes or slots 241 receiving up to six test strips 19 for simultaneous processing. FIG. 10 shows the heat sinks 242 and 250 for maintaining the respective portions of the tray 240 and ridges 256 at the proper temperature.
FIG. 11 is a detailed perspective view of the test strip holder or tray 240 as seen from below. The 95° C. Peltier heat sink which would be below front portion 254 has been removed in order to better illustrate the rear heat sink 242 beneath the rear portion of the tray 240 .
FIG. 12 is a block diagram of the electronics and control system of the amplification processing system of FIG. 5 . The control system is divided into two boards 310 and 311 , section A 310 at the top of the diagram devoted to amplification module or station 202 and the other board 311 (section B) devoted to the other module 204 . The two boards 310 and 311 are identical and only the top section 310 will be discussed. The two boards 310 and 311 are connected to an amplification station interface board 300 .
The interface board 300 communicates with a stand alone personal computer 304 via a high speed data bus 302 . The personal computer 304 is a conventional IBM compatible computer with hard disk drive, video monitor, etc. In a preferred embodiment, the stations 202 and 204 are under control by the interface board 300 .
The board 310 for station 202 controls the front tray 240 which is maintained at a temperature of 95° C. by two Peltier heat sink modules, a pair of fans and a temperature sensor incorporated into the front portion 254 of the tray 240 . The back of the tray is maintained at a temperature of 42° C. by two Peltier modules and a temperature sensor. The movement of the vacuum probes 244 is controlled by the probes motor 222 . Position sensors are provided to provide input signals to the tray controller board as to the position of the vacuum probes 244 . The tray controller board 310 includes a set of drivers 312 for the active and passive components of the system which receive data from the temperature and position sensors and issue commands to the active components, i.e., motors, fans, Peltier modules, etc. The drivers are responsive to commands from the amplification interface board 300 . The interface board also issues commands to the vacuum pump for the vacuum subsystem, as shown.
FIG. 13 is a diagram of the vacuum subsystem 320 for the amplification processing stations 202 and 204 of FIG. 5 . The subsystem includes a 1 liter plastic vacuum tank 210 which is connected via an inlet line 322 to a vacuum pump 323 for generating a vacuum in the tank 210 . A vacuum supply line 324 is provided for providing vacuum to a pair of pinch solenoid valves 224 (see FIG. 6) via supply lines 324 A and 324 B. These vacuum supply lines 324 A and 324 B supply vacuum to a manifold 226 distributing the vacuum to the vacuum probes 244 . Note the pointed tips 245 of the vacuum probes 244 for piercing the film or membrane 64 covering the strip 19 . The vacuum system 320 also includes a differential pressure transducer 321 for monitoring the presence of vacuum in the tank 210 . The transducer 321 supplies pressure signals to the interface board 300 of FIG. 12 .
FIG. 14 is a representative graph of the thermal cycle profile of the station of FIG. 5 . As indicated in line 400 , after an initial ramp up 402 in the temperature lasting less than a minute, a first temperature T 1 is reached (e.g., a denaturation temperature) which is maintained for a predetermined time period, such as 5-10 minutes, at which time a reaction occurs in the first chamber of the reaction vessel. Thereafter, a ramp down of temperature as indicated at 404 occurs and the temperature of the reaction solution in the first chamber of the reaction vessel 10 cools to temperature T 2 . After a designated amount of time after cooling to temperature T 2 , a fluid transfer occurs in which the solution in the first chamber is conveyed to the second chamber. Temperature T 2 is maintained for an appropriate amount of time for the reaction of interest, such as one hour. At time 406 , the temperature is raised rapidly to a temperature T 3 of 65° C. to stop the amplification reaction. For a TMA reaction, it is important that the ramp up time from time 406 to time 408 is brief, that is, less than 2 minutes and preferably less than one minute. Preferably, all the ramp up and ramp down of temperatures occur in less than a minute.
Other embodiments of reaction vessels and amplification station components are also envisioned, and certain examples of such alternative embodiments are described in copending U.S. patent application of Luigi Catanzariti et al., serial no. hereby incorporated by reference in the entirety.
EXAMPLE 3
Automated VIDAS Test for Non-amplified and Amplified Detection of Mycobacterium tuberculosis (Mtb)
Using the VIDAS instrument (BioMérieux Vitek, Inc.), modified to 42° C., we have developed an in-line simple rapid nucleic acid amplification and detection assay for the clinical laboratory for the detection of Mtb in test samples which can be completed in a short time. The entire assay is designed to take place on a single test strip, minimizing the potential for target or amplicon contamination. The amplification based assay is capable of detection of Mtb where the sample contains only 5 cells similar to the sensitivity achieved by the Gen-Probe commercial kit.
The amplification based assay utilizes isothermal transcription-mediated amplification (TMA) targeting unique sequences of rRNA, followed by hybridization and enzyme-linked fluorescent detection of nucleic acid probe in the VIDAS instrument.
The amplification/detection assay can detect approximately 1 fg of Mtb rRNA, or less than one Mtb organism per test, and is specific for all members of the Mtb complex. Specific probes for the detection of Mtb can be found in C. Mabilat, 1994, J. Clin. Microbiol. 32, 2707.
Standard smears for acid-fast bacilli are not always reliable as a diagnostic tool, and even when positive may be a mycobateria other than Mtb. Currently, standard methods for diagnosis of tuberculosis requires culturing the slow-growing bacteria, and may take up to 6 weeks or longer. During this time, the patient is usually isolated. Initial results are that this automated test matches or exceeds the clinical sensitivity of the culture method, and offers a highly sensitive method to rapidly (in less than three hours) detect Mtb in infected samples, thereby aiding rapid diagnosis, isolation and treatment.
A) Sample Preparation
A 450 μl volume of specimen is added to 50 μl of specimen dilution buffer in a lysing tube containing glass beads, sonicated for 15 minutes at room temperature to lyse organisms, heat inactivated for 15 minutes at 95° C. Where required, isothermal S amplification was conducted as per a commercially available manual assay kit (Gen-Probe Inc.) following the kit instructions using standard kit reagents. However, similar assays can be conducted using the modified components as described in the Examples above.
B) Detection
In order for the automated detection assay to operate, the detection system requires hybridization of the target nucleic acid or amplicon to a specific capture nucleic acid bound to a solid support, (in the VIDAS system called a “solid phase receptacle” SPR® pipet-like devise), and to a labeled detection probe nucleic acid (for example where the label can be alkaline phosphatase, a chemiluminescent signal compound, or other reagent that will allow for specific detection of bound probe).
In an automated system such as the VIDAS, after several wash steps to remove unbound probe, the SPR® transfers the probe-target hybrid to an enzyme substrate, whereby the detectable signal is triggered from the bound probe and detected by the assay instrument. In one embodiment, the probe is conjugated to alkaline phosphatase, and once placed in contact with substrate of methyl umbelliferyl phosphate (MUMP), the substrate is converted into 4-methyl umbelliferone (4-MU) by the alkaline phosphatase. The 4-MU produces fluorescence which is measured and recorded by the standard VIDAS instrument as relative fluorescence units (RFU). When target nucleic acid is not present, no probe is bound, and no substrate is converted, thus no fluorescence is detected.
C) Analytical Sensitivity: Controls
Generally controls are prepared in a matrix of specimen dilution buffer with positive controls containing 5 fg of Mtb rRNA, or the equivalent rRNA of approximately 1 M. tb cell. Sensitivity of the automated probe assay can be determined by testing dilutions of lysed M tb cells. The cell lysates can generally be prepared with a 1 μl loop of cells (the assumption being that there are approximately 1×10 9 colony forming units (CFU) per 1 μl loop-full, based upon previous titration and CFU experiments). Dilutions of the Mtb lysates can then be tested with the automated probe assay.
FIG. 20A is a graph showing detection of Mtb amplicons according to the Gen-Probe kit. FIG. 20B is a graph showing detection of Mtb amplicons from the same reactions as in FIG. 20A by the VIDAS instrument.
FIG. 21 is a graph showing amplification and detection of Mtb nucleic acids on to the modified VIDAS apparatus. Enzyme was used in liquid form and amplification was performed in-line with VIDAS assay instrument.
FIG. 22 is a graph showing amplification and detection of Mtb nucleic acids on the modified VIDAS apparatus using the binary/dual chamber disposable reaction vessel. The denaturation step was performed off-line of the VIDAS instrument, amplification and detection was performed in-line with VIDAS instrument.
EXAMPLE 4
Automated VIDAS Test for Amplified Detection of Chlamydia trachomatis (CT)
Using the VIDAS instrument (BioMérieux Vitek, Inc.), we have developed a simple, fully automated, highly specific assay for the rapid detection of Chlamydia trachomatis (CT) from test samples. The test utilizes isothermal TMA targeting unique sequences of the rRNA followed by hybridization and enzyme-linked fluorescence detection. The automated test specifically detects all the clinically important serovars of Chlamydia trachomatis (CT) from urogenital specimens in less than two hours. We obtained an analytical sensitivity of 0.5 fg of rRNA, or the equivalent of approximately {fraction (1/10)} th of an elementary body of Chlamydia trachomatis (CT). Agreement between the automated test and Gen-Probe's Amplified CT test for 207 clinical endocervical swabs and urines showed complete agreement. Chlamydia trachomatis (CT) infection is the leading cause of sexually transmitted disease in the United States and Europe. It is currently estimated that about four million new CT infection occur each year in the United States.
Chlamydia trachomatis (CT) is a small obligate intracellular parasite that causes infections in both females and males, adults and newborns. The greatest challenge to the control of CT infection is that as many as 75% of infected women and 50% of infected men are asymptomatic. This results in a large reservoir of unrecognized infected individuals who can transmit the CT infection. The rapid and simple detection of CT infection would greatly assist identification infected individuals.
A) Patient Specimens and Sample Preparation
Coded samples (207) were obtained from patients with symptoms consistent with CT infection. The cervical samples were collected with a Gen-Probe sample collection kit containing Gen-Probe transport medium; the urine samples were collected into standard urine collection devices. All samples were stored at 4° C.
Cervical swabs were centrifuged at 425 ×g for 5 minutes to bring all liquid to the bottom of the tube. The swabs were then treated with 40 μl Gen-Probe Specimen Preparation Reagent and incubated at 60° C. for 10 minutes. 20 μl of the treated sample was then pipetted into 400 μl of sample dilution buffer (SDB).
Two ml of each urine sample was warmed to 37° C. for 10 minutes and microfuged at 12,000 ×g for 5 minutes. The supernatant was discarded and 300 μl of sample dilution buffer was added to each specimen. All 15 serovars of CT were used for inclusive samples, specimens were quantified and 20 μl of specimens containing 4×10 2 LFU/ml (inclusion forming unit per ml) of each serovar was added to 400 μl of SDB. A panel of exclusive urogenital micororganisms was obtained and quantified and 20 μl of 2×10 9 /ml microorganisms were pipetted into 400 μl of SDB. Positive control containing 0.5 fg rRNA or the equivalent of 0.1 CT elementary body was diluted in SDB.
B) Sample Amplification and VIDAS Detection
Samples were amplified using the TMA protocol, and rRNA targets were hybridized to oligomer conjugated to AMVE copolymer and an oligomer conjugated to alkaline phosphatase. See for example U.S. Pat. No. 5,489,653 and 5,510,084. As described above, the solid phase receptacle (SPR® pipet-like devise) carries the hybrids through successive wash steps and finally into the substrate 4-MUP. The alkaline phosphatase converts the substrate to fluoresence 4-MU, which is detected by the VIDAS assay machine and recorded as relative fluorescence units.
Table 2B below illustrates detection of CT by VIDAS automated assay following amplification as RFV (RFV=RFU—Background RFU) against concentration of CT rRNA. Dilutions of C. trachomatis purified rRNA from 0 to 200 molecules were amplified (n=3) and detected in the VIDAS automated probe assay. Detection limit is 20 molecules of purified rRNA.
TABLE 2B
CT Detection by VIDAS
rRNA Input Molecules
VIDAS RFV
0
1
2
121
20
3260
200
8487
C) Analytical Specificity and Results
Amplifications and detection were carried out in the presence of each of the following ATCC organisms with detections reported as RFV in Table 3 below.
TABLE 3
Exclusivity panel for CT
Bacillus subtilis
Branhamella
Candida albicans
Chlamydia
Chlamydia
33
catarrhalis
26
pneumoniae
psittaci
15
39
11
Escherichia coli
Klebsiella
Lactobacillus
Neisseria
Neisseria
11
pneumoniae
acidophilus
elongata
lactamica
13
27
44
18
Neisseria
Neisseria
Propionibacterium
Pseudomonas
Staphylococcus
meningitidis-D
meningitidis-Y
acnes
aeruginosa
aureus
61
52
14
13
13
Streptococcus
Streptococcus
Streptococcus
Yersinia
Chlamydia
agalactiae
bovis
pneumoniae
enterolitica
trachomatis
16
45
34
11
10673
Negative Control
12
Analytical specificity for Chlamydia serovars data reported as RFV is shown in Table 4 below.
TABLE 4
Inclusivity Panel for CT
Serovar A
Serovar B
Serovar Ba
Serovar C
Serovar D
5421
7247
9626
8066
10849
Serovar E
Serovar F
Serovar G
Serovar H
Serovar I
4608
9916
10082
7769
9733
Serovar J
Serovar K
Serovar L1
Serovar L2
Serovar L3
9209
2423
10786
1812
5883
Positive
Negative
Control 3775
Control 9
Table 5 below illustrates the results of clinical cervical swab specimen testing for CT comparing results from the Gen-Probe manual AMP-CT assay and the VIDAS automated probe assay.
TABLE 5
Amplified Clinical Cervical Specimen Detection of CT
Gen-Probe manual AMP-CT assay
VIDAS off-line
+
−
automated probe
+
35
0
assay
−
0
85
Table 6 below illustrates the results of clinical urine specimen testing comparing the results of manual AMP-CT assay and the VIDAS automated probe assay.
TABLE 6
Amplified Clinical Urine Specimen detection of CT
Gen-Probe manual AMP-CT assay
VIDAS off-line
+
−
automated probe
+
25
0
assay
−
0
62
Thus there was perfect agreement in assay results between the automated probe assay using the VIDAS instrument and the manual Gen-Probe AMP-CT assay.
EXAMPLE 5
Multiplex (Multiple Sequence) Nucleic Acid Detection
The value of diagnostic tests based on nucleic acid probes can be substantially increased through the detection of multiple different nucleic acid targets, and the use of internal positive controls. An automated method has been devised for use with the VIDAS instrument (BioMérieux Vitek, Inc.) which can discretely detect at least two different nucleic acid target sequences in one assay reaction, and is termed the Multiplex protocol. Thus a nucleic acid amplification procedure, or a processed test sample may be screened for more than one amplified nucleic acid target in the same assay. This method relies on the spatial separation of discrete nucleic acid probes which can capture different target nucleic acid sequences, on the Solid Phase Receptacle (SPR® pipet-like devise) of the VIDAS instrument. The SPR® is a disposable pipet-like tip which enables fluid movements as well as acting as the solid support for affinity capture. The multiplex capture by SPR® is demonstrated using capture probes specific for Chlamydia trachomatis (CT) and Neisseria gonorrhoeae (NG).
FIG. 15 illustrates a schematic of the operation of the multiplex VIDAS detection. Solid phase receptacles (SPR® pipet-like devise) are coated with two distinct zones of oligonucleotides with nucleic acid sequences which are used to specifically capture target nucleic acid sequences with their corresponding specific reporter probe nucleic acids labeled with alkaline phosphatase (AKP). Following washes to remove unbound reporter probes, AKP localized to the SPR® bottom is detected with the fluorescent substrate 4-MUP. The AKP is stripped from the bottom of the SPR® with NaOH. The enzyme reaction well is emptied, washed, and re-filled with fresh 4-MUP. To ensure the removal of AKP from the bottom of the SPR®, the new substrate is exposed to the bottom of the SPR® and residual fluorescence is measured. Finally, target bound to the top of the SPR® is detected by immersing the SPR® in the 4-MUP.
FIG. 16 illustrates the production of SPR® with two distinct capture zones. The SPR® is inserted tip-first into a silicon plug, which are held in a rack. Differential pressure is used to uniformly draw a 1 μg/ml solution of a specific capture probe, conjugated to AMVE copolymer, into all SPR®s at one time. Attachment of the conjugate to the SPR® surface is activated by passive adsorption for several hours at room temperature. After washing, and drying, the SPR®s are capped with a small adhesive disc and inserted into new racks in a tip-down orientation. The lower portion of the SPR® is then similarly coated with a second capture probe conjugate. SPR®s are stable when stored dry at 4° C.
FIG. 17 illustrates the VIDAS apparatus strip configuration for multiplex detection. The strip can be pre-filled with 200 μl of AKP-probe mix (about 1×10 12 molecules each) in hybridization buffer in well X 1 , 600 μl of wash buffer in wells X 3 , X 4 , X 5 , 600 μl of stripping reagent in wells X 6 and X 7 , and 400 μl of AKP substrate in X 8 and sealed with foil. A foil-sealed optical cuvette (XA) containing 300 μl of 4-MUP is snapped into the strip, and the strips are inserted into the VIDAS instrument at 37° C. The multiplex VIDAS protocol is then executed using SPR®s coated with two capture probes in distinct zones.
The VIDAS multiplex protocol can involve many steps. For example the validation test protocol contained 13 steps as follows:
1. Transfer 203 μl target from X 0 to AKP-probes in X 1 ,
2. Hybridize and capture to SPR®),
3. Wash SPR® (316 μl) twice with PBS/TWEEN (X 3 , X 4 ),
4. 4-MUP to SPR® bottom (89.6 μl) in XA for 5.3 minutes then read,
5. 4-MUP to SPR® bottom (89.6 μl) in XA for 14.8 minutes then read,
6. Transfer used substrate from XA to X 2 (5×67.1 μl),
7. Strip AKP from SPR® bottom (112.6 μl) with NaOH (X 7 ),
8. Wash XA with fresh NaOH (3×112.6 μl; X 6 to XA to X 6 ),
9. Wash XA with PBS/TWEEN (3×112.6 μl; X 5 to XA to X 5 ),
10. Transfer fresh 4-MUP from X 8 to XA (6×48 μl),
11. 4-MUP to SPR® bottom (89.6 μl) in XA for 10.7 minutes then read,
12. 4-MUP to SPR® top (294 μl) in XA for 5.5 minutes then read,
13. 4-MUP to SPR® top (294 μl) in XA for 15 minutes then read.
Hybridization, substrate, wash and stripping steps all involve multiple cycles of pipeting the respective solution into the SPR®, holding the solution for a defined period of time, and pipeting the solution out of the SPR®. Hold times for hybridization, substrate and washing or stripping are 3.0, 0.5 and 0.17 minutes respectively. “Read” means the fluorescence is detected by the apparatus. Total assay time for the research protocol was about 1.75 hours but can be reduced to 75 minutes.
FIG. 18 illustrates and graphs the results of verification of the VIDAS multiplex protocol executed as described above, wherein the SPR® was homogeneously coated with only a single capture probe for Neisseria gonorrhoeae (NG). The number of NG oligonucleotide targets in the test sample was varied from 0, 1×10 10 , or 1×10 11 molecules in the test sample. The data shown are averages of replicate samples. The graph as illustrated is divided into two parts; the left and right halves show the results of two fluorescent measurements from the lower and the upper zones of the SPR®, respectively. The measurements taken from the bottom zone after stripping the lower area of bound nucleic acid, and exposure for about 11 minutes in fresh 4-MUP substrate was approximately 46 RFU for all samples tested, and was equivalent to background fluorescence measured. This measurement is shown by the 0 time point in the center of the graph. Thus the graph illustrates two sequential sets of measurements of fluorescence from a single SPR®, the first set of measurements being taken from the bottom half of the
SPR® (left half of the graph), and a second set of measurements taken from the top of the SPR® (the right of the graph).
FIG. 19 illustrates Multiplex detection of CT and NG oligonucleotide targets at different input amounts. FIG. 19A is a graph showing the results when 1×10 12 CT targets were mixed with 0, 1×10 9 , 1×10 10 , 1×10 11 , or 1×10 12 , NG targets, and detected with the VIDAS instrument using the multiplex protocol and SPR®s coated with CT capture probes on the bottom zone of the SPR®, and NG capture probes on the top zone of the SPR®. FIG. 19B illustrates the results when 1×10 12 NG targets was mixed with 0, 1×10 9 , 1×10 10 , 1×10 11 , or 1×10 12 , CT targets, and detected with the VIDAS instrument using the multiplex protocol and SPR®s coated with CT capture probes on the bottom zone of the SPR®, and NG capture probes on the top zone of the SPR®. The data is graphed as above where the graph illustrates two sequential sets of measurements of fluorescence from a single SPR®, the first set of measurements being taken from the bottom half of the SPR® (left half of the graph), Stripped and verified (the center of the graph) and a second set of measurements taken from the top of the SPR® (the right of the graph).
Table 7 below summarizes the data obtained by Multiplex VIDAS detection of CT and NG in a sample at various target levels, reported in RFUs.
TABLE 7
Detection of CT and NG targets in sample
RFUs A
none B
1 × 10 9
1 × 10 10
1 × 10 11
1 × 10 12
1 × 10 13
none C
43 D /40 E
43/116
46/693
62/7116
174/11817
273/12136
1 × 10 9
189/41
246/118
169/773
220/5750
422/12522
399/11401
1 × 10 10
1736/41
2258/125
1937/734
1931/6639
2128/12390
2371/11180
1 × 10 11
10339/48
9815/145
9858/760
9369/4571
9784/11825
10252/10312
1 × 10 12
12149/49
13520/148
12940/796
13593/4397
11239/11786
10158/9900
1 × 10 13
11545/57
11713/121
10804/815
12805/5404
12305/12326
11416/10490
A Data is reported in RFUs, after ˜5 minute exposure of 4-MUP to bound AKP-probe
B Columns are data for that number of NG targets in sample
C Rows are the data for that number of CT targets in sample
D The first value reported is RFU detected from the CT assay portion
E The second value reported is RFU detected from the NG assay portion
Thus the multiplex VIDAS protocol is clearly operative and enables the rapid and discrete detection of more than one different nucleic acid signal in a sample. This protocol, and the SPR® coating can be manipulated in many formats to present coating zones of different surface area with different sized gaps between detection zones. The SPR® can be coated with nucleic acids which are designed to capture different regions of the same nucleic acid sequence to detect, for example, truncated gene expression, different alleles or alternatively spliced genes. The SPR® can be coated to capture internal control nucleic acid sequences which can be used to detect and confirm successful nucleic acid amplification reactions. Thus the VIDAS protocol is a flexible method for detection of more than one nucleic acid sequence in the same sample, in a single assay.
EXAMPLE 6
Internal Control Sequence and Method
The construction of internal control sequences composed of functional building blocks of sequences chosen by random generation of nucleic acid sequences for use as amplification reaction internal positive controls ideally requires that the control sequences be specifically designed to be used for the various nucleic acid amplification protocols including but not limited to PCR, LCR, TMA, NASBA, and SDA. The internal control nucleic acid sequence, in combination with the appropriate sequence specific oligonucleotide primers or promoter-primers will generate a positive amplification signal if the amplification reaction was successfully completed.
Ideally, the internal control nucleic acid is useful regardless of the nucleic acid sequences present in the target organism, the host organism, or nucleic acids present in the normal flora or in the environment. Generally, the internal control sequences should not be substantially similar to any nucleic acid sequences present in a clinical setting, including human, pathogenic organism, normal flora organisms, or environmental organisms which could interfere with the amplification and detection of the internal control sequences.
The internal control sequences of the instant invention are comprised of functional blocks of sequences chosen from a list of randomly generated nucleic acid sequences. The functional blocks are segments which provide for a special property needed to allow for amplification, capture, and detection of the amplification product. For example, in a TMA reaction, the internal control sequences are most useful when the functional blocks meet certain functional requirements of the amplification protocol, such as: a) a primer binding site on the anti-sense strand; b) a capture site; c) a detector probe binding site; d) a T7-promoter containing primer binding site on the sense strand. Each of these functional elements has its own particular constraints, such as length, %G-C content, Tm, lack of homology to known sequences, and absence of secondary structural features (i.e. free from dimer formation or hairpin structures) which can be used to select the appropriate sequence. Thus randomly generated functional blocks of sequences can be screened for the desired functional properties before use in constructing internal control sequences.
In order to construct a internal control sequences having the desired properties comprising a specified number of functional blocks and satisfying the desired constraints within each block, a random sequence generator was used to generate strings of numbers; each number being limited to the range from 0.000 to 4.000. The length of the strings is flexible and chosen based upon the desired lengths of the functional blocks.
Each number in the string (i.e. n 1 , n 2 , n 3 , n 4 . . . nx where x is the length of the string) was then assigned a corresponding nucleotide as follows: guanosine (G) if 0<n≦1; adenosine (A) if 1<n≦2; thymidine (T) if 2<n≦3; and cytosine (C) if 3<n≦4. A large collection of such strings was produced and screened for those meeting the sequence and structural requirements of each functional block. FIG. 23 illustrates the results generated by the method described showing a collection of strings of nucleic acid sequences and screening for specific functional parameters.
Potential internal control (IC) sequences were then constructed by assembling the functional blocks (selected at random) in the proper order. Finally, the assembled internal control sequences were then examined to insure that overall sequence and structural constraints were maintained. For example, in a TMA internal control sequence the two primer binding sites should not have a significant base-pairing potential or form stable 3′ dimer structures. Those internal control sequences which pass thorough these layers of screening were then physically produced using overlapping oligonucleotides and tested for performance in actual amplification/detection assays.
Although any one function block may have some homology to sequences present in a clinical setting (a perfect match of 21 nucleotide block is expected at a random frequency of 1 in every 4e12 sequences or about 4×10 21 ; generated sequences were screened against GenBank data base) it is highly unlikely that all functional blocks will be found to have substantial homology. Since the internal control nucleic acid sequences are constructed of a group of functional blocks placed in tandem, the chance possibility that a natural nucleic acid sequence will have an identical string of nucleic acid sequence blocks in the same tandem organization is remote.
Two specific internal control sequences have been constructed using the method described above. Random Internal Control 1 (RIC1) is shown in FIG. 24 with the possible oligonucleotide primers/probes for amplification and detection of the control sequence. FIG. 25 shows an analysis of the possible secondary structural components of the RIC1 sequence. RIC1 was constructed using randomly generated strings ran16, ran 19, ran21 and ran33. The functional blocks requiring primer binding were met by ran16 and ran19, while the capture site was satisfied by ran21 and the detector probe binding site was met by ran33.
Random Internal Control 2 (RIC2) is shown in FIG. 26 with the possible oligonucleotide primers/probes for amplification and detection of the control sequence. FIG. 27 shows an analysis of the possible secondary structural components of the RIC2 sequence. Similarly to RIC1, RIC2 was constructed using randomly generated strings ran27, ran32, ran39 and ran51. Thus, illustrating that it is also possible that the functional blocks requiring primer binding, capture site, detector probe binding site can be met by alternative random sequences generated by the method described above. FIG. 28 illustrates results from detection of RIC1 DNA, where the ran21 was the capture probe and ran33 was an enzyme-linked detector-probe, and shows that detection occurs under standard assay conditions with expected fluorescence intensities. FIG. 29 shows that RIC1 RNA, amplified by TMA and detected on a VIDAS instrument (BioMérieux Vitek, Inc.) using the enzyme-linked detection system, has a limit of sensitivity of about 1000 molecules of RIC1 RNA (without optimization of conditions). Similar analysis of RIC2 sequences was performed and found to be similar to RIC1. It is significant that the amplification and detection system of the internal control functioned effectively under the conditions optimized for the selected target.
As an alternative approach for multiplex detection using internal controls (IC), SPR®s can be homogeneously coated with a mixture of different capture nucleic acid sequences in a single, whole-SPR® zone. For example, two capture nucleic acid sequences can be combined in one zone, one specific for a target test sequence, and one specific for an internal control sequence. Target amplicons, if present, and internal control amplicons are simultaneously hybridized to the SPR® by the capture probes. In the presence of labeled probe nucleic acid sequences specific for the target test nucleic acid sequence. Following washing, a first read is done to so that the presence or absence of label on the SPR® is determined to ascertain the presence of the test target. A second hybridization is then done (sequential hybridization) to the SPR® using a detection label nucleic acid sequence specific for the internal control. The SPR® is washed to remove excess unbound detection probe, and the second label is measured to indicate the presence or absence of the internal control. If the first signal is negative, a positive signal from the IC second read confirms the functionality of the amplification/detection system. In this case, one can conclude that the test target nucleic acid sequence was truly absent (true negative). If the first signal is positive, this alone is enough to confirm functionality of the amplification and detection system, and the second signal is immaterial (positive result). In the special case where the first the first and second label are the same, an additive signal will result from the positive first read and the positive second IC read. If both the first signal is negative and the second IC signal is also negative, then the amplification/detection functionality failed, which could be due to for example, sample interference or mechanical failure. In this case the test result is reported invalid (false negative) and re-testing is recommended.
There is great interest in the use of internal controls, the underlying rational being that “. . . if the sample will not support the amplification of the internal control, it is unlikely to support the amplification of the target nucleic acid sequence.” (NCCLS Document MM3-A, Molecular Diagnostic Methods for Infectious Diseases; Approved Guideline, p. 55, March 1995).
Using a sequential hybridization approach with multiple detector probes, it has been possible to design protocols which allow for the discrete detection of first read signal (ie. pure CT signal) and an additive “mixed” second read (ie. additive CT and discrete signal for negatives; see Table 7A below). This protocol will not need stripping with NaOH. For example, Table 7A shows the results when different mixtures of synthetic targets were first captured with homogeneously coated SPR®s (CT and IC capture probes) and hybridized with the CT detector probe. After the first read, hybridization was performed with the IC detector probe, followed by a second read (same substrate).
This type of protocol can also be used for a combined GC/CT/intemal control assay, if a screening approach is allowed (no discrimination between GC and/or CT positives during the first read). GC and CT specific signals have to be resolved by running the CT and GC specific assays on screen positive samples (5-10% of cases, depending on prevalence) SPR®s would be coated homogeneously with 3 capture probes (CT/GC/internal control).
TABLE 7A
Homogeneous Coated SPR ® Detection of multiple signals
Target
CT 1 st Read
IC 2 nd Read
Bkg. RFU
10 10 CT
7077
8608
58
10 10 IC
58
4110
56
10 10 IC/CT
5594
8273
57
10 10 IC/CT
5712
8317
57
no target
66
89
57
Thus internal control sequences described above are useful for application with VIDAS apparatus with coated SPR® and the use of the Multiplex system to provide for combined assay detection of a nucleic acid and monitoring control for successful reaction. | The present invention relates to the detection of specific nucleic acid sequences after an amplification process, or directly without amplification. In particular, the invention provides for the automation of the amplification and detection process, the amplification and detection of one or more specific nucleic acid sequences, the use of internal controls, reduced potential for contamination caused by the manual manipulation of reagents, and improved reagent compositions to better control assay performance and provide for further protection against contamination. | 2 |
BACKGROUND OF THE DISCLOSURE
After a well borehole has been drilled to a specified depth, a perforating shaped charge is used to form a jet perforation extending radially outwardly which punctures casing in the well, cement on the exterior and adjacent formations with the view of initiating fluid flow from the formation of interest. It is an important sequential step, which if misfired, creates a great deal of risk in the well completion procedures.
A typical procedure is to support an assembly on a wireline which incorporates one or more (typically several) jet perforating shaped charges. A detonator is included to trigger operation of the various shaped charges. In one approach, the shaped charges are supported on an open carrier which has the form of a lengthwise metallic strip or the like. The shaped charges are exposed to well fluids. A detonator supported on the carrier is also exposed to the well fluids and must operate with impunity to the surrounding environment. The detonator (sometimes called a blasting cap) starts detonation at one end of a detonating cord which extends the length of the apparatus. The resulting shock wave formed by the detonator travels along the cord and initiates the multiple attached shaped charges to perforate the well. The detonator is ordinarily constructed of a primary explosive material. The terms "primary" and "secondary" refer to the relative sensitivity of explosive materials. A typical primary explosive material is lead azide, and another is lead styphnate. Such primary explosive materials are normally extremely sensitive to any stimuli, including heat, sparks, friction, shock, and electrical current. To the measure that they are somewhat sensitive to various stimuli, a safety hazard is created in light of the fact that any stimuli may trigger premature detonation. This type of sensitivity associated with well known primary explosives shows them to be sensitive to premature or unintended shock, static electricity discharge, high ambient temperature normally associated with downhole conditions and other causes of detonation. For instance, electromagnetic radiation is a serious factor including RF (Radio Frequency) radiation at any wave length. Electrical static and mechanical agitation can also cause premature triggering. Detonation may occur at the wrong depth in the well and place the perforations at the wrong location. It may also occur near the well head, and possibly injure personnel near the well head.
The term "secondary explosive" refers to explosive materials which are not as sensitive as primary explosive materials. Typical examples of secondary explosives are RDX, HNS, PYX and others. In general terms, they are much more stable for handling and are relatively insensitive to detonation initiation. This lack of sensitivity makes them much safer to use. They are much safer to handle and are not as likely to explode prematurely. Secondary explosive detonators are much safer from inadvertent operation. In fact, they are so difficult to detonate that it requires special effort to provide proper detonation shock. In detonators made of primary explosives, the current for detonation is typically less than one ampere. This is so small as to run the risk of detonation with stray currents in the firing circuit. This also suggests that these detonators are sensitive to heat, impact, and unintended static discharge. With a secondary explosive, a significantly greater current flow (or other external stimuli) is required for detonation.
The present invention sets forth a means and method of detonating secondary explosives in a detonator which particularly protects against unintended stray currents, static electricity discharges, and the like. It also protects against RF detonation. It additionally protects against unintended shock detonation. The present apparatus contemplates the use of an electrically operated detonator which is provided with a sizable current over a long interval of time. While it is possible for a static discharge to ignite a secondary explosive, it is highly unlikely. Secondary explosives in the detonator inevitably require a much larger electric current for initiation. The present apparatus incorporates a system whereby a large AC current is applied through a wireline to a circuit which forms a proper detonation signal. The signal is delivered in the form of AC current flow which is stored on a charging capacitor through a voltage multiplying circuit. Only when the current forms an adequate charge is the capacitor able to form a discharge ideally through a gas discharge tube, or spark gap. This circuit cooperatively yields a charging sequence which forms an adequate charge, a charge having a voltage exceeding a required minimum and sustains the current on discharge for at least a specified interval. The circuit protects against stray or static discharges. Static which occurs in random fashion may create a momentary charge on the capacitor but that is reduced to zero by a bleed circuit incorporating a resistor connected to ground. As the circuit operates protectively, no preliminary inadvertent triggering event can occur whereby premature detonation occurs. Thus, the safer secondary explosives used in the detonator are much more difficult to detonate but this is used to advantage to assure that random events do not trigger detonation.
The present apparatus further incorporates an exploding wire foil and flyer combination for forming the necessary shock. The exploding wire foil is connected across the electrical circuit which forms the requisite output current. The output current must have a substantial current flow for a minimum interval. It flows through a wire foil which has a narrow neck. In the region of the neck, the current typically vaporizes that portion of the wire foil. When this occurs, the wire foil is exploded. It is arranged so that the foil explosion shears a small disc, called a flyer, which traverses a specified distance to impinge on secondary explosive materials and thereby initiate explosion. This distance is important in providing a safety interlock in the present apparatus. The value of this will be understood on description of the problem set forth below.
The present apparatus is particularly useful in a sealed housing which encloses a set of shaped charges. The sealed container is intended to be leakproof and is constructed in this fashion. It is impossible to know whether it does leak when downhole. When leakage occurs, the leakage will fill the lower part of the closed and sealed housing. When sequential detonation of the shaped charges is started, pressures within the housing rise rapidly. When a noncompressible fluid, partially or wholly, fills the housing, the case will quickly split resulting in destruction of the entire structure and may very well abort the perforating sequence. When this occurs, it may be impossible to retrieve the shattered tool and other equipment on the wireline. It is difficult to know how many of the perforations will be formed. The present detonator is a detonator adapted to be installed at the lower end of the tool. If there is no leakage, there is no fluid in the lower portion of the tool and detonation is triggered through the detonator which sets off the explosive sequence in a detonating cord propagated to the several shaped charges. By contrast, assume that leakage has occurred and that the detonator is then submerged in well fluids. The detonator of the present apparatus is constructed so that well fluids in the tool will prevent electrical firing. First of all, the circuit which provides the necessary current flow to the exploding wire foil has exposed terminals which are fluid shorted to thereby prevent detonation. In addition, the fluid which accumulates in the tool is permitted to come into the detonator to fill the gap between the exploding wire foil and the secondary explosive. This prevents detonation. At the surface, when this occurs, operating personnel will have sufficient information to know that the explosive sequence has not occurred and that the detonator has been prevented from firing. This also enables the entire structure to be retrieved. It is retrieved in an armed, but completely safe, condition since the detonator has been properly prevented from operation by means of the fluid accumulation in the tool.
The present apparatus provides an alternate detonator which has sealed electrical leads. Thus, it can be used fully submerged in well fluids and yet still operate. This particular version of the detonator is desirable when used with perforating shaped charges that are not enclosed in a sealed housing. These are known as "exposed" perforating guns, and any detonator used with them must be fluid tight.
The alternate apparatus similarly contemplates the use of the firing circuit which is an AC Voltage multiplier having a ladder circuit accumulating an increased charge on a charging capacitor. A bleed resistor to ground is included to prevent accumulation of stray or static events. Moreover, the output is through a pair of terminals which are controllably exposed to well fluids. These terminals in turn connect to an exploding wire foil which has the shape of an hourglass so that the narrow portion literally explodes when the current flow is directed through the narrow neck. The exploding wire foil shears a flying disc which is in spaced relationship to a secondary explosive charge. Initiation of the explosive is prompted by impact of the flying disc. The foil end flyer combination is included within a housing which has an internal shoulder abutting the detonating cord so that it is prevented from pumping into the housing by ambient pressure conditions. The housing is sealed at respective spaced ends by means of tapered boots fitting over the exterior. The explosives in the detonator are only secondary explosives thereby providing a significantly safer detonating system.
DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, 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 shows a shaped charge carrier incorporating a detonator in accordance with the present invention operated by the charging circuit to be described;
FIG. 2 is a shaped charge carrier similar to that of FIG. 1 wherein the shaped charges are enclosed in a sealed housing to exclude well fluids and further including a detonator located at the lower portion of the sealed housing;
FIG. 3 shows a firing circuit connected to a cooperative detonator having an exploding foil element and including a space wherein well fluids may enter to prevent detonation;
FIG. 4 is a sectional view along the line 4--4 of FIG. 3 showing the shape of the exploding wire foil;
FIG. 5 is an exploded view of the components including the exploding wire foil; and
FIG. 6 is an alternative embodiment of the detonator which is designed to exclude entry of well fluids and further incorporating means connecting with the detonating cord.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is first directed to FIG. 1 of the drawings where the numeral 10 identifies a perforating gun assembly adapted to be lowered in a well for conducting perforating operations with shaped charges. This includes a wireline 11 of substantial length which includes a current conducting member as well as a strength member. The wireline 11 is connected to a cable head 12. In turn, that is connected with a collar locator 13. The collar locator 13 locates collars in the casing and thereby provides an electrical signal of the location of the shaped charge perforating gun assembly 10 to the surface to enable proper positioning of the apparatus in the borehole. A casing collar locator is well known in the art. The apparatus further includes a firing sub 14 connected below the collar locator 13 and in turn that is connected with a firing head 15. The firing sub and firing head combination incorporates the circuitry to be described in conjunction with FIG. 3 of the drawings. The system further includes an elongate carrier member 16 which supports a number of shaped charges 17 therealong. The several shaped charges are all detonated by means of an explosive signal provided over a detonating cord 18. The detonating cord is initiated with a detonating signal from a detonator 20. The several shaped charges are fired to form perforations through the surrounding casing and into the adjacent formations.
FIG. 2 is a structure similar to that of FIG. 1 except in certain details as will be noted. To this end, a similar wireline 11 is shown in FIG. 2 and connects with similar cable head 12 and a similar collar locator 13. The arrangement shown in FIG. 2 also includes a firing sub 14 which is connected with a firing head 15. Rather than a carrier, this arrangement of apparatus utilizes an elongate cylindrical sealed housing 21 which is closed with a bull plug 22 at the lower end. The several detonating cord, which in turn detonates the shaped charges 17 are again included and are detonated for forming perforations by a detonator cord 18. In this arrangement, the detonator is located at the lower end. A wire 23 provides an electrical current flow to the detonator 24. The detonator 24 triggers the shaped charges for operation from bottom to top. The detonator 24 is located at the lower end of the tool for reasons to be described. The detonators 20 and 24 are shown in the accompanying drawings and will be described beginning with FIG. 3 where the detonator 24 is illustrated.
Attention is now directed to FIG. 3 of the drawings where the numeral 24 identifies the detonator that is adapted to be used as a fluid-disabled device. Moreover, FIG. 3 also illustrates a firing circuit generally identified at 25 which is physically located in the firing sub 13. The circuit includes a conductor 26 which extends to the wireline 11 for receiving current flow from the surface. The circuit incorporates the following significant structural elements. The conductor 26 is the input conductor to a blocking capacitor 27. This prevents DC from feeding through the circuit. In like fashion, there is a suitable ground connection indicated at 28. The input AC signal is applied to a ladder circuit including reversed diodes 29 and 30 which connect to a capacitor 31. This is repeated successively by incorporation of the additional diode 32 which is connected across the capacitor 33 in the same fashion as the capacitor 31. This sequence is repeated where the diodes alternate direction and the respective capacitors 31 and 33 are duplicated along the ladder. The number of diodes and capacitors in the ladder can be increased. The various capacitors are preferably fabricated with equal peak voltages and equal capacitance. The ladder circuit forms a high voltage rectified current which flows through a connecting resistor 34 to charge a capacitor 35 connected to ground. Charge on the capacitor 35 is accumulated by application of AC current for several seconds. The charge on the capacitor 35 is reduced continuously by means of a bleed resistor 36 connected to ground.
Assume that stray or random static events occur. For instance, assume that a very large voltage spike passes through the circuitry. Even assuming that it is a very large voltage level, because it is not repeated, it will not form the necessary charge accumulation on the capacitor 35. The capacitor 35 does not change voltage instantaneously so that no output firing signal can be formed. Assume that a leakage current exists somewhere in the system. While the charge on the capacitor might otherwise accumulate, any leakage current is reduced by bleeding to ground through the resistor 36. Therefore, long term leakage currents and short term voltage spikes can not provide a triggering event to the system whereby the detonator is discharged. The charge capacitor 35 accumulates the needed large charge from AC current applied to the voltage ladder. This large current forms a significant charge accumulation which is finally sufficient to operate the voltage discharge tube 38. When this occurs, a very substantial current flow is delivered to the detonator 24 and operation is then assured. An important factor is that the voltage be sufficiently high and the current have sufficient duration to trigger proper operation. The spark gap tube 38 is a gas filled tube which does not conduct unless a particular voltage level across the tube is experienced whereupon a current surge does then occur. At this time, the current surge is sufficient to trigger operation of the detonator. It is desirable to locate the spark gap tube 38 as close as reasonably possible to the detonator which is connected to it.
The voltage which triggers the detonator is delivered over a conductor and provided to an electrical lead 40. A similar ground lead 41 is likewise included to complete the circuit. The leads 40 and 41 secure aligned voltage conductor pins 42 and 43. They extend through a sealed body 44 which is surrounded by a shell or housing 45. The housing is crimped or rolled at the end 46 to fasten the housing around the base 44. The leads 40 and 41 are adapted to be exposed to well fluids. Well fluids are conductive at least to some measure. In effect, well fluid contact with the leads 40 and 41 forms an equivalent resistor 47 across the leads 40 and 41. The resistor 47 is equivalent to the fluid contact resistance. In other words, fluid which surrounds the pins 40 and 41 has an equivalent resistance. This resistance is sufficient to reduce firing current applied to the system as will be described.
The base 44 is drilled with a pair of holes which position the pins 42 and 43. The pins extend fully through the base. The base 44 is shown in FIG. 4 in the end view after disassembly to expose the end of the base. A metal foil 48 is placed across the circular end face of the base. It extends across and contacts against the ends of the pins 42 and 43. The foil 48 is shaped with a narrow neck 49, the neck 49 being in the form or shape of an hour glass. The neck 49 is a narrower region which is centered on the circular support surface. The metal foil is made of conductive material, copper being a suitable material. It is relatively thin and measures less than 0.001 inches in thickness. The narrow neck 49 is reduced by perhaps seventy-five percent of the width of the foil strip 48. This reduction in width assures that the current flow between the two pins is constrained in the region of the neck. This deployment of components directs the current flow through the hour glass shape at 49 and thereby assures that the foil is exploded by the current flow. Going now to FIG. 5 of the drawings, the numeral 50 identifies a thin sheet plastic disc which is placed over the foil. The disc 50 is quite thin, perhaps 0.001 inches in thickness. It is made of plastic but it can be made of other non-conductive materials also. Primarily, it is included to form a flyer disc which travels through an opening 51 in a cap 52 fitted over the exploding wire foil 48 shown in FIG. 4. The vaporization of the foil 48 is so violent that a divit is sheared out of the disc 50 and is propelled violently through the passage 51. The flyer drives into the secondary explosive 53. This cylindrical plug of explosive material is detonated by the impact of the flyer driven by the exploding wire foil.
The secondary explosive material is captured in a sleeve 54. In turn, the sleeve 54 is on the interior of the housing 45. The housing has an internal shoulder at 56 which is abutted against the secondary explosive charge 53 to fasten that charge and prevent movement. The housing is drilled with a number of ports 57. The ports 57 introduce well fluid into a chamber 58. The chamber 58 is filled with well fluid should any be in the near vicinity. Fluid disrupts the secondary explosive charge 53 from transferring detonation to a detonating cord 60 located an appropriate distance away.
The shoulder 56 on the interior of the housing 45 contacts and abuts against a detonating cord 60. The cord is prevented from further entry by the internally directed shoulder 56. The housing 45 is serrated with a crimp at 61 that grips the jacket 62 around the detonating cord 60 to assure sound mechanical connection. It prevents the detonating cord 60 from pulling free. The detonator as described and illustrated in FIG. 3 is thus an apparatus which is able to provide detonation to the detonating cord 60 only if proper fluid isolation has occurred.
Recall that the detonator 24 is installed within the sealed housing 21. If no fluid leaks into the immediate vicinity of the detonator 24, then detonation will occur in the ordinary fashion. That is, the electric current will be applied to the foil 48 which will be vaporized almost in an instant. This is particularly concentrated at the neck 49. The disc 50 is sheared to form a flyer that impacts against the secondary explosive plug. The flyer impact is sufficient to ordinarily obtain detonation.
If well fluids leak into the sealed housing, they provide an equivalent resistor 47 which reduces the current flow. It may very well sufficiently reduce current flow to completely avoid detonation of the secondary explosive 53. Moreover, while fluid is admitted to the area around the pins and provides electrical shorting, such fluid is also admitted between the secondary explosive 53 and the detonating cord 60. It fills, at least in some measure, the chamber 58 and prevents the detonating signal from properly triggering operation of the cord 60. This provides two methods of defeating operation of the detonator in the circumstances described with respect to the closed housing assembly shown in FIG. 2. A third method also is possible since fluid may fill the hole 51 and thus disrupt the flyer's pathway.
FIG. 6 shows the detonator 20. The numeral 64 identifies an insulated electrical conductor which is received through a boot 65 at the left hand end of the detonator assembly. This connects with the exposed wire tip 66 from the conductor 64 which is connected with a feedthrough fitting 67. In turn, that connects with a pin 68 serving as an electrical conductor. It is received on the interior of an insulative sleeve 69 which surrounds the pin 68. The insulative sleeve extends the full length of the pin 68. The insulating sleeve is shaped into a surrounding head portion 70. The head portion 70 is constructed integrally within a body portion 71, the body portion abutting the boot 65. The body portion is constructed with a surrounding bead 72 which assists in engaging the boot 65. The body portion 71 is made of conductive material and has an exposed area 72 which serves as a ground return for completion of the electrical circuit necessary for operation. The body 71 thus provides a ground return path and to this end, has s hole 73 formed therein for a ground connection. In similar fashion, the pin 68 is drilled at the end to define a mating hole at 74.
The body portion 71 is joined to a surrounding housing 75. It is joined to the body by suitable pins 76 inserted at spaced locations around the exterior. Fluid leakage is prevented through this connection by incorporation of an O-ring seal 77.
The surrounding external housing 75 is fairly long and extends up into a similar boot 80. The boot 80 is fitted around a detonating cord 81. It grips the detonating cord and protects the various components on the interior. The boot 80 surrounds an internal retaining ring 82 which slips over the detonating cord, and which has an upstanding tubular sleeve portion 83. The sleeve 83 is on the interior of the housing 75 and extends over a portion of an internal alignment sleeve 84. The sleeve 84 is on the centerline of the apparatus. The sleeve 84 is preferably roll crimped at 85. This fastens around the end of the detonating cord 81. This assures a fastened and fixed end supporting shoulder abutting the detonating cord. The sleeve is axially hollow and encloses a charge of explosive material identified at 86. It is locked in position by means of an internally directed shoulder immediately adjacent to an air gap 88.
The gap 88 is immediately adjacent to an explosive charge 89 which is received within a surrounding supportive sleeve 90, the sleeve 90 being positioned adjacent to a pin guide 91. The pin guide 91 supports a pair of pins 92 and 93 which are connected in the sockets at 73 and 74. The pins extend through the guide 91. The pins contact against a wire foil of the same type shown in FIG. 4 adjacent to a disc of the same sort shown in FIG. 5. In other words, the exploding wire foil is again implemented in the detonator 20 in the same fashion as in the embodiment 24 previously described.
This apparatus 20 is hermetically sealed. The boots 65 and 80 seal around the ends to prevent fluid intrusion. The outer housing 75 encompasses the various components on the interior which are received within sealed chambers for operation. The exploding wire foil operates in the same fashion to trigger or detonate the explosive material 89, a shock wave then traverses the air gap 88 to detonate the explosive 86 and thereby provide transfer thru through the barrier 94 to the cord 81. The barrier 94 prevents the detonating cord from moving into the housing 75 due to hydraulic pressure acting on the cord. In this fashion, detonation of the device 20 is accomplished in the same manner as in device 24. An important and primary difference is that the structure is a sealed structure. Both detonators however are provided with shoulders which abut the end of the detonating cord. Moreover, rolled crimps are included to fasten the ends of the detonating cords. The electrical connections are made through pins which are supported in rigid housings, and suitable complete electrical circuits are constructed for exploding the wire foil as shown in FIG. 4.
While the foregoing sets out preferred embodiments of the present apparatus and methods of operation, the scope is determined by the claims which follow: | For use in a perforating gun assembly, a perforating gun detonator is disclosed. One embodiment is hermetically sealed while the other has openings therein to admit well fluids. In both embodiments, a narrow conductive metal foil is provided with a current to vaporize the narrow foil, explode the foil and propel a flyer driven by a shock wave for detonation of a spaced secondary explosive. The explosive then couples explosion into a detonating cord against a shoulder in a housing adjacent to the secondary explosive. The current is formed by means of an AC voltage multiplier circuit providing a charge on a capacitor which is discharged through a spark gap. Charging circuitry includes a blocking capacitor to prevent DC and a resistor for bleeding a small current from the capacitor to ground which prevents static or stray current accumulation. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to medical methods, systems, and kits. More particularly, the present invention relates to methods and apparatus for the treatment of lung diseases, such as COPD, by creating and controlling atelectasis and hypoxia in segments of lung tissue.
[0003] Chronic obstructive pulmonary disease (COPD) is a significant medical problem affecting sixteen million people or about 6% of the U.S. population. Specific diseases in this group include chronic bronchitis, asthmatic bronchitis, and emphysema. While a number of therapeutic interventions are used and have been proposed, none are completely effective, and COPD remains the fourth most common cause of death in the United States. Thus, improved and alternative treatments and therapies would be of significant benefit.
[0004] Management of COPD is largely medical and infrequently surgical. Initially, exercise and smoking cessation are encouraged. Medications including bronchodilators and anti-inflammatories are routinely prescribed. Pulmonary rehabilitation has been shown to improve quality of life and sense of well being. Long term oxygen is generally reserved for the more severely affected patients.
[0005] Emphysema is a condition of the lung characterized by the abnormal permanent enlargement of the airspaces distal to the terminal bronchiole, accompanied by the destruction of their walls. It is known that emphysema and other pulmonary diseases reduce the ability of part of the lungs to fully expel air during the exhalation phase of the breathing cycle. During breathing, the diseased portion of the lung does not fully recoil due to the diseased lung tissue being less elastic than healthy tissue. Consequently, as the airways normally held open by the elastic pull of the lungs become floppy and the diseased lung tissue exerts a diminished driving force during exhalation, the airways close prematurely resulting in air trapping and hyperinflation.
[0006] In addition, hyper-expanded lung tissue occupies more of the pleural space than healthy lung tissue. In most cases, only a part of the lung is diseased while the remaining portion is relatively healthy and therefore still able to efficiently carry out oxygen exchange. By taking up more of the pleural space, the hyper-expanded lung tissue reduces the space available to accommodate the healthy, functioning lung tissue. As a result, the hyper-expanded lung tissue causes inefficient breathing by compressing the adjacent functional airways, alveolar units, and capillaries in relatively healthier lung tissue.
[0007] Lung function in patients suffering from some forms of COPD can be improved by reducing the effective lung volume, typically by resecting diseased portions of the lung. Resection of diseased portions of the lungs both promotes expansion of the non-diseased regions of the lung and decreases the portion of inhaled air which goes into the lungs but is unable to transfer oxygen to the blood. Accordingly, recruitment of previously compressed functional airways, alveolar units, and capillaries in relatively healthier lung is possible resulting in more gas exchange in addition to better matching of lung and chest wall dimensions. Lung reduction is conventionally performed in open chest or thoracoscopic procedures where the lung is resected, typically using stapling devices having integral cutting blades.
[0008] While effective in many cases, conventional lung volume reduction surgery (LVRS) is significantly traumatic to the patient, even when thoracoscopic procedures are employed. Such procedures often result in the unintentional removal of healthy lung tissue, and frequently leave perforations or other discontinuities in the lung which result in air leakage from the remaining lung. Even technically successful procedures can cause respiratory failure, pneumonia, and death. In addition, many older or compromised patients are not able to be candidates for these procedures.
[0009] As an alternative to LVRS, endobronchial volume reduction (EVR) uses endobronchially introduced devices which plug or otherwise isolate a diseased compartment from healthier regions of the lung in order to achieve volume reduction of the diseased compartment. Isolation devices may be implanted in the main airways feeding the diseased region of the lung, and volume reduction takes place via absorption atelectasis after implantation or via collapse by actively suctioning of the target compartment prior to implantation. These implanted isolation devices can be, for example, one-way valves that allow flow in the exhalation direction only or occlusive devices that prevent flow in both directions.
[0010] While a significant improvement over LVRS, EVR suffers from a significant risk of pneumothorax. Pneumothorax is a condition which results from air entering the pleural space surrounding the lung. For reasons that are not fully understood, it has been found by the inventors herein that a sudden blockage of a feeding bronchus can create conditions in the isolated lung region which can in some cases cause a pneumothorax. A spontaneous pneumothorax can result from the tearing of pleural adhesions and blebs lying under the visceral pleura of the non-treated lung areas during the rapid development of absorption atelectasis in the treated lung area.
[0011] For these reasons, it would be desirable to provide alternative and improved methods and devices for performing endobronchial volume reduction and other lung therapies where the risk of inducing a pneumothorax is reduced or eliminated.
[0012] 2. Description of the Background Art
[0013] U.S. Pat. No. 6,679,264 describes an exemplary flow control element that limits, but does not block, fluid flow in at least one direction. The flow control element comprises a valve member supported by a ring. The valve member is preferably a duckbill-type valve having a similar construction to that of the valve member, except that the flaps are formed, secured, oriented or otherwise configured to maintain a flow opening when in their flow-controlling (as opposed to flow-allowing) orientation. The opening is sized and configured to achieve desired flow characteristics through the flow control element.
[0014] U.S. Pat. No. 6,722,360 describes devices and methods for improving breathing in patients with COPD. A mouthpiece is provided, or a device is implanted in the trachea or bronchial passage, to selectively increase flow resistance to expiration while minimally increasing flow resistance to inspiration. The methods and apparatus rely on increasing proximal flow resistance in a manner which mimics “pursed lip” breathing during exhalation which has been found to benefit patients suffering from this disease by keeping the distal airways open for a longer period of time and allowing more of the inspired air volume to be evacuated during the longer exhalation time.
[0015] U.S. Pat. No. 7,011,094 describes devices and methods for implanting sealing components within bronchial lumens. The sealing components may include a septum which can be penetrated with a dilation device which can provide a valve or open flow path through the septum.
[0016] U.S. 2007/0005083 describes the treatment of diseased lung segments by placing a blocking element in an airway of the lung which leads to the diseased segment.
BRIEF SUMMARY OF THE INVENTION
[0017] In accordance with the present invention, the inventors herein have discovered that diseased regions of the lung may be treated by restricting the exchange of air through an airway or bronchus which feeds the diseased region. In contrast to the endobronchial volume reduction (EVR) protocols where air flow from the diseased region into the feeding airway or bronchus is blocked (typically by a one-way valve or a fully occlusive element), the present invention relies on reducing the rate of air exchange between the diseased region and the feeding airway or bronchus while allowing a reduced rate of air flow in both the inhalation or inspiratory direction and the exhalation or expiratory direction.
[0018] Typically, the restriction will be provided by a restrictor which is implanted in the feeding airway or bronchus. The restrictor may be an orifice, a small diameter tube, a perforated membrane, a densely braided structure, perimeter channels, or other fixed-resistance element that impedes the flow of air equally in both directions. Alternatively, the resistor could provide a differential resistance in the two flow directions, for example including two or more parallel flow paths where some of the flow paths are blocked in the inhalation or exhalation direction (but at least some flow paths remain available to permit bi-directional flow at all times). Still further alternatively, the flow resistor could have a variable resistance, e.g., being an iris or other variable resistance valve element. In all cases, however, the flow resistor will permit air flow, usually being about equal, in both the inhalation and exhalation directions to provide for a controlled atelectasis, an induced hypoxia, or in some cases elements of both atelectasis and hypoxia.
[0019] In a first aspect of the present invention, the reduced exchange of air between the feeding airway or bronchus and the diseased or other targeted region of the lung to be treated will induce a controlled atelectasis. “Atelectasis” is the collapse of part or all of the lung region as a result of the reduction of air flow into the region and absorption of the remaining air volume. The air which is in the targeted region will be absorbed by the pulmonary blood circulation over time. Typically, the rate of absorption is small compared to the rate at which the targeted region is filled with new air and large amounts of air come and go with a residual portion of it always remaining in the targeted lung region. By fully blocking the flow of air into the targeted lung region, as is the case with prior EVR protocols, the entrance of new air into the targeted lung region stops abruptly, and absorption of the residual air volume takes place more rapidly. Consequently, the collapse of the treated region can be uncontrolled and occur too rapidly, presenting a significant risk of pneumothorax, which is the collection of air or gas in the space surrounding the lung. By providing the controlled (but restricted) exchange of air between the treated lung region and the feeding airway or bronchus, the collapse of the treated lung region will occur more gradually and reduce the risk of pneumothorax. Gas exchange between the treated lung region and the feeding airway will decrease gradually over time until the pressure difference across the restrictor element reaches zero. At that time, atelectasis has fully developed and absorption ceases. That is, the treated region will eventually collapse as with the EVR protocols, but at a slower rate with the reduced risk of pneumothorax. Typically, the collapse of the treated lung region via atelectasis when treated by the flow restriction methods of the present invention will occur when there is little or no collateral ventilation of the treated lung region.
[0020] In a second aspect of the present invention, the reduced exchange of air between the treated lung region and the feeding airway or bronchus will result in hypoxic pulmonary vasoconstriction (HPV), referred to hereinbelow as “hypoxia.” Hypoxic pulmonary vasoconstriction as a result of asphyxia has been observed since the beginning of the twentieth century, with the first convincing evidence of its existence reported by von Euler and Liljestrand in 1946 (Von Euler and Liljestrand (1946) Observations on the Pulmonary Arterial Blood Pressure in the Cat, Acta Physiol. Scand. 12: 301-320). Hypoxic pulmonary vasoconstriction shifts blood flow from the hypoxic lung regions to adjacent lung regions which are not hypoxic or are less hypoxic. Thus an induced hypoxic condition in a diseased lung segment can shift blood flow to other healthier lung regions to improve gas exchange and arterial oxygenation.
[0021] According to the present invention, there is a potentially significant benefit for a patient who undergoes a simple procedure that creates localized hypoxia in the lung, even with lessened or no lung volume reduction which can occur if, for example, the treated region is collaterally ventilated. By implanting a flow restrictor in the main airway feeding a region of the lung targeted for treatment, a reduction in ventilation to the restricted region takes place. Consequently, a localized hypoxic pulmonary vasoconstriction is induced which diverts blood flow away from the induced hypoxic region to other areas in the lung which are more adequately ventilated and better perfused. As a result, ventilation and perfusion are better matched and the potential for gas exchange is increased.
[0022] According to the methods of the present invention, a lung condition may be treated by implanting an air flow restrictor in an airway of a patient's lung. The restrictor reduces air flow exchange between upstream of the restrictor and downstream of the restrictor. Such air flow restriction induces at least one of controlled atelectasis and localized hypoxia in the treated region beyond the restriction. Controlled atelectasis will cause collapse of the treated region downstream of the air flow restrictor, occurring typically in treated lung regions having minimal or no collateral ventilation with adjacent lung regions. The rate of air exchange between the treated lung region and the feeding airway or bronchus will be controlled to permit collapse of the treated lung region over a preselected time period, usually in the range from 12 hours to 30 days, preferably in the range from 3 days to 15 days. Particular restrictors having dimensions and characteristics to provide for such a controlled collapse are described in more detail below.
[0023] Localized hypoxia will typically occur without significant collapse of the treated lung region, wherein the hypoxia shifts blood flow away from the treated region and to other, typically more healthy, regions of the lung where improved blood oxygenation may occur. Such localized hypoxia will typically occur in treated lung regions which have significant collateral flow with adjacent lung regions, where the collateral flow will typically inhibit or prevent atelectasis and collapse.
[0024] The air flow restrictors of the present invention will typically reduce the volumetric rate of the air flow exchange by an amount in the range from 10% to 99.99% of the unrestricted volumetric rate of air flow exchange, typically in the range from 99% to 99.9% of such unrestricted volumetric air flow.
[0025] The restrictors useful in the methods of the present invention will comprise at least one open passage or flow path which permits restricted air flow exchange. In some instances, the restrictors may consist of a single orifice, while in other instances the restrictors may include a plurality of passages, such as a plurality of openings or perforations formed in a membrane or other blocking element. Usually, the open passage area in the flow restrictor will be in the range from 0.01% to 90% of the total cross-sectional area of the restrictor when implanted in the airway, more typically being in the range from 0.1% to 1% of said area. The total passage area will typically be in the range from 0.01 mm 2 to 5 mm 2 , more typically from 0.1 mm 2 to 1 mm 2 .
[0026] In a further aspect of the present invention, a bronchial flow restrictor comprises a body having at least one open passage or flow path to permit bidirectional air flow therethrough. The body will be adapted to be expanded and anchored within the lung airway for the control of air exchange with a downstream region of the lung. The passage may consist of a single passage, e.g., in the case of an orifice plate, or the restrictor may include a plurality of passages, e.g., in the case of a perforate plate, membrane, or the like. Typically, the open passage area of the restrictor will be in the range from 0.01% to 90% of the cross-sectional area of the body when expanded. Usually, the total area of the open passages will be in the range from 0.01 mm 2 to 50 mm 2 , typically from 0.1 mm 2 to 1 mm 2 . In alternative embodiments, the passages may be formed on the outside of the body. Typically, the body will be elastic so that it may be constrained to a smaller width for introduction to the lung airway and then released to self-expand and anchor at a target location within the airway. Alternatively, the flow restrictor may be malleable (capable of non-elastic expansion) and be expandable by the application of an internal expansion force, e.g., using a deployment balloon.
[0027] In a specific embodiment, the flow restrictor comprises a collapsible medical device made of a plurality of strands or ribbons that are braided, woven, or otherwise enmeshed into a cylindrical shape having a proximal end and a distal end. The strands are connected by a clamping member or otherwise to permit radial expansion and contraction as the axial length is shortened or extended. The braided structure may be very populated with the wire strands or ribbons so that a generally contiguous surface is formed, where the surface has numerous openings or apertures formed between the intersections of adjacent strands or ribbons. The openings provide an equal restriction to air flows going in and out of the target lung segments. The strands may be bare-metal wires, polymer wires or metal wires laminated with a polymer. Optionally, the braided structure may be coated with an eluting drug such as an antibiotic or one for the purpose of reducing or eliminating granulation tissue growth to facilitate elective removal of the restrictor if desired. In another embodiment, the braided structure is coated with a polymer material, but at certain locations it has one or more holes which create a restriction to air flows going in and out of the target lung segments. A variety of design options are presented by the accompanying drawings. This invention also relates to mucus transporting means to be provided with a flow restrictor. Such device would possess at its perimeters transport channels or ports for the physiological media.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIGS. 1A and 1B illustrate a first embodiment of a flow restrictor constructed in accordance with the principles of the present invention having flow apertures in a reduced diameter portion thereof.
[0029] FIGS. 2A-2D illustrate a second embodiment of a flow restrictor constructed in accordance with the principles of the present invention, wherein flow apertures are located in a different location than illustrated in FIGS. 1A and 1B .
[0030] FIG. 3 illustrates a third embodiment of a flow restrictor comprising a silicone body having an orifice tube therein.
[0031] FIG. 4 illustrates a fourth embodiment of a flow restrictor constructed in accordance with the principles of the present invention, which comprises a continuous body structure having windows formed in one end thereof.
[0032] FIGS. 5A and 5B illustrate a fifth embodiment of a flow restrictor constructed in accordance with the principles of the present invention having flow channels formed in an outer surface thereof.
[0033] FIG. 6 illustrates a sixth embodiment of a flow restrictor constructed in accordance with the principles of the present invention having an internal tapered flow restrictive orifice.
[0034] FIG. 7 illustrates a seventh embodiment of a flow restrictor constructed in accordance with the principles of the present invention having an internal tube which provides flow resistance.
[0035] FIGS. 8A and 8B illustrate an eighth embodiment of a flow restrictor constructed in accordance with the principles of the present invention, wherein the flow restrictor has a bell shape and is constructed of a gas penetrable braid.
[0036] FIG. 9 illustrates a ninth embodiment of a flow restrictor constructed in accordance with the principles of the present invention, wherein the flow restrictor comprises a cylindrical body formed of a gas penetrable braid.
[0037] FIG. 10 is an anatomical diagram illustrating the lobar structure of the lungs of a patient.
[0038] FIG. 11 illustrates the trans-esophageal endobronchial placement of a flow restrictor delivery catheter in an airway leading to a diseased lung region.
[0039] FIG. 12 illustrates placement of a flow restrictor by the catheter placement device of FIG. 11 .
[0040] FIGS. 13A and 13B illustrate the physiologic effect of placement of the flow restrictor at an airway leading to a diseased lung region with little or no collateral ventilation.
[0041] FIGS. 14A and 14B illustrate the physiologic response induced by placement of a flow restrictor at an airway feeding a diseased lung region which has significant collateral ventilation.
DETAILED DESCRIPTION OF THE INVENTION
[0042] In the descriptions below, specific designs for bronchial flow restrictors are described. The restrictors can be placed in any bronchial airway, but generally the airways between and including the lobar bronchus and sub-sub-segmental bronchi are the desired airways to restrict. The restrictor is intended to impede air flow in both the inspiratory and expiratory direction usually about equally, and either permanently or temporarily. Flow limitation can be from 10% to 99.99% reduction of flow, usually being from 99% to 99.9% of the unrestricted flow, depending on the clinical need.
[0043] The flow limitation will have at least one of two physiologic effects. In instances where the lung region distal to the restrictor is generally free from collateral ventilation, the restrictor will induce a controlled atelectasis. The distal lung region will collapse, although at a significantly slower rate of collapse than would be the case with complete occlusion of air flow into the region, and the risk of pneumothorax will be significantly reduced. In other instances where the lung region downstream from the flow restrictor is exposed to significant levels of collateral ventilation, the restricted air flow into and from the region will induce hypoxia. The resulting reduced oxygen concentrations distal to the restrictor will catalyze the von Euler reflex to shunt pulmonary perfusion to other, usually more healthy and functional, bronchopulmonary regions of the lung that have not been treated with a restrictor, and thus improve the ventilation-perfusion efficiency of the lung.
[0044] FIGS. 1A and 1B illustrate a bronchial flow restrictor (BFR) 10 constructed of an elastic wire frame 12 which is laminated with an elastomeric membrane 14 . On the proximal end 16 of the BFR, the membrane 14 is incomplete or perforated, creating at least one vent hole 18 . On the distal section 20 of the BFR, apertures 22 are formed in the membrane 14 to create a path for the gas flow. The size and shape of the vent hole 18 and apertures 22 can vary in order to provide a desired flow resistance within the range defined elsewhere herein. This general design permits collapsibility of the BFR for insertion into a small catheter for delivery into the lung, allowing self-expansion of the BFR when released from the catheter. The stepped configuration of this particular design allows the BFR to be placed at or near an airway bifurcation or airway narrowing. For example, the larger proximal end may be placed in a proximal airway so that the distal smaller section 20 extends into the next generation airway which is smaller because it is distal to the proximal airway. The flow restrictions can be fabricated by the techniques described for fabrication of fully occlusive elements and one-way valves set forth in U.S. Pat. No. 6,527,761 and commonly assigned, copending application Ser. No. 11/280,592, the full disclosures of which are incorporated herein by reference.
[0045] FIGS. 2A-2D describe a modified configuration 10 ′ of the previously described BFR in which distal gas flow apertures 24 are positioned to be within the lumen of the distal airway DA after the BFR has been expanded from a radially constrained diameter in the airway to an unconstrained diameter which creates a dilated pocket DP ( FIG. 2D ) in the airway. Thus, the gas flow through apertures 24 is not obstructed by the bronchial wall.
[0046] FIG. 3 is a cross-sectional view of BFR 30 in which a housing 32 includes a gas flow orifice tube 34 on its distal end 36 . The housing can have a “uni-body” construction, typically being molded or cast from silicone or another biocompatible elastomer. In some instances, the housing 32 can have composite construction of wire frame with silicone membrane coating, or be formed from a variety of materials and construction methods. It can be collapsible and self expanding for a catheter based delivery. In other designs, the BFR can be malleable to allow plastic deformation and expansion by a balloon or other expandable deployment on the delivery catheter.
[0047] FIG. 4 illustrates a BFR 40 in which a housing 42 comprises a plurality of windows 44 in a wall of a distal section 46 in order to permit gas flow in and out of the housing. An orifice 48 at the opposite proximal end completes the gas flow path such that the device restricts but does not obstruct gas flow. As with previously described embodiments, the housing 42 can have a uni-body construction or comprise a wire frame with silicone or other membrane covering. It can be either collapsible and self expanding or balloon expandable.
[0048] FIGS. 5A and 5B illustrate BFR 50 which has gas or fluid transport channels 52 shaped or formed into an outer surface or periphery of the housing body 54 . The channels 52 will leave a space or gap between the airway wall in which the BFR is implanted and the surface of the BFR, thus providing a path for fluid flow in both directions. As mentioned previously, the housing 54 can have a uni-body or composite construction. The housing 54 can be collapsible and self expanding or balloon expandable.
[0049] FIG. 6 illustrates a BFR 60 in which a housing 62 houses a funnel-shaped (or hourglass-shaped) diaphragm 64 which provides a gas flow orifice 66 in the center of the diaphragm. Distal and proximal apertures 68 and 70 , respectively, allow air flow into and out of the housing 62 , and the tapered orifice 66 defined by the diaphragm 64 restricts the flow. The diameter of the orifice 66 can be selected to provide a desired flow resistance. The housing 62 can have a uni-body construction or be a wire braided structure encapsulated with silicone or other elastomere. The diaphragm can be a flexible silicone material or other elastomere in order to facilitate compressibility of the BFR 60 for insertion into the lung via a delivery catheter lumen.
[0050] FIG. 7 illustrates BFR 70 in which a gas flow tube 72 is axially aligned in a housing 74 . Construction of the housing 74 can be similar to any of the concepts previously described. The gas flow tube 72 can be constructed of any tubular material, preferably being a flexible polymer. Flexibility is advantageous since a flexible tube will facilitate insertion into the lung. The housing 74 can have any of the constructions described previously.
[0051] FIGS. 8A and B and 9 A and B illustrate non-covered, tightly packed wire braid flow restrictors 80 and 90 . The tight backing of the wire braid can eliminate the need for a membrane cover to achieve occlusion while providing a perforate or foraminous surface 82 and 92 , respectively, to permit a controlled flow of air therethrough.
[0052] Referring now to FIG. 10 , the respiratory system of a patient starts at the mouth and extends through the vocal cords and into the trachea where it then joins the main stem bronchi B which leads into the right lung RL and the left lung LL. The bronchi going into the right lung divide into the three lobar bronchi which lead into the upper lobe RUL, the middle lobe RML and the lower lobe RLL. The lobes of the right lung include a total of ten segments (three in the RUL, two in the RML, and five in the RLL) which are discrete units of the lung separated from each other by a fibrous septum generally referred to as a lung wall. The left lung LL includes only an upper lobe LUL and a lower lobe LLL, where the individual lobes include four to five segments each
[0053] Each lung segment, also referred to as a bronchopulmonary segment, is an anatomically distinct unit or compartment of the lung which is fed air by a tertiary bronchus and which oxygenates blood through a tertiary artery. Normally, the lung segment and its surrounding fibrous septum are intact units which can be surgically removed or separated from the remainder of the lung without interrupting the function of the surrounding lung segments. In some patients, however, the fibrous septum separating the lobes or segments may be perforate or broken, thus allowing air flow between the segments, referred to as “collateral ventilation.”
[0054] Use of a delivery catheter 100 for placement of a BFR in accordance with the principles of the present invention is shown generally in FIGS. 11 and 12 . The catheter 100 is advanced through the mouth, down through the trachea T, and through the main bronchus into the left lung LL. A distal end 102 of catheter 100 is advanced into the left lung LL, and further advanced to an airway which feed a diseased lung region DR. The catheter 100 may be introduced through the main bronchus B and into the left lung LL without the use of a bronchoscope or other primary introducing catheter, as illustrated in FIG. 11 . Alternatively, the catheter 100 may be introduced through a conventional bronchoscope (not shown) which is positioned in the main bronchus above the branch between the right and left lungs. Alternatively, the catheter 100 may be introduced into the lung through a scope, such as a visualizing endotracheal tube (not shown) which is capable of advancing into the branching airways of the lung is advantageous in that it facilitates positioning of the delivery catheter 100 at the desired airway leading to a target lung segment. Construction and use of a visualizing endotracheal tube is taught, for example, in U.S. Pat. No. 5,285,778, the full disclosure of which is incorporated herein by reference. It would be possible, of course, to utilize both the bronchoscope B and the endotracheal tube ET in combination for positioning the delivery catheter 100 in the desired lung segment airway.
[0055] After the distal end 102 of the delivery catheter 100 has been positioned in the main airway or bronchus feeding the diseased region DR, the catheter can optionally be immobilized, for example by inflating a balloon or cuff 104 . After immobilizing the distal end of the catheter, a pusher or other element 106 can be advanced in order to eject the bronchial flow restrictor BFR in the bronchus, where it optionally self-expands to anchor in place. Although not illustrated, it would also be possible to use an inflatable balloon or other deployment device on the catheter 100 in order to position a plastically deformable restrictor at a desired location.
[0056] Referring now to FIGS. 13A and 13B , after the bronchial flow restrictor BFR has been placed in the airway leading to a diseased region DR, illustrated as a first lung segment LS 1 , air flow into and out of the segment as the patient inhales and exhales will be restricted by placement of the BFR, as generally described above. As shown in FIGS. 13A and 13B , the first lung segment LS 1 is surrounded by a fibrous septum FS which is generally intact so that little or no collateral ventilation with adjacent lung segments LS 2 and LS 3 will occur. Thus, as shown in FIG. 13B , the reduced air flow into and out of the treated lung segment LS 1 will induce atelectasis and cause the treated segment to deflate. Deflation of the treated segment LS 1 , in turn, allows the adjacent, healthier lung segments LS 2 and LS 3 to expand and provide improved patient blood oxygenation. Moreover, the slower rate of atelectasis reduces the risk to the patient of pneumothorax, as discussed above.
[0057] Referring now to FIGS. 14A and 14B , in other instances, the diseased lung region DR may have a perforated or otherwise damaged region of the fibrous septum DFS which permits collateral ventilation between the diseased region (LS 1 ) and an adjacent lung region LS 2 . In those instances, air entering via the collateral channels is already low in oxygen and placement of the bronchial flow restrictor BFR will significantly reduce the amount of oxygenated air entering the diseased region LS 1 /DR via the feeding bronchus. As shown in FIG. 14B , over time, the reduced and non-oxygenated air exchange with the diseased region DR will induce hypoxia in the region (shown with the cross-hatching) which will catalyze the von Euler reflex to shunt pulmonary perfusion to other healthier regions of the lung, such as adjacent healthy segments LS 2 and LS 3 .
[0058] It will be appreciated, however, that the induced lung collapse and induced hypoxia may occur to differing degrees in even the same treated region. In particular, the shift between lung collapse and hypoxia may depend, at least in part, on the degree to which collateral ventilation exists between the diseased region and adjacent healthier lung regions. Thus, although it may be desirable to perform a diagnostic on the patient to determine whether or not a particular diseased region is subject to collateral ventilation (as taught, for example, in commonly owned, copending application Ser. No. 11/296,951 (Attorney Docket No. 017534-002820US), filed on Dec. 7, 2005, the full disclosure of which is incorporated herein by reference), it would not be necessary. Treatment of diseased lung regions using the bronchial flow restrictors of the present invention may be advantageous regardless of the collateral ventilation status of a particular region.
[0059] While the above is a complete description of the preferred embodiments of the invention, various alternatives, modifications, and equivalents may be used. Therefore, the above description should not be taken as limiting the scope of the invention which is defined by the appended claims. | Lung conditions are treated by implanting a flow restrictor in a passageway upstream from a diseased lung segment. The restrictor will create an orifice at the implantation site which inhibits air exchange with the segment to induce controlled atelectasis and/or hypoxia. Controlled atelectasis can induce collapse of the diseased segment with a reduced risk of pneumothorax. Hypoxia can promote gas exchange with non-isolated, healthy regions of the lung even in the absence of lung collapse. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of international application PCT/DE02/03247, filed Mar. 9, 2002 and further claims priority to German patent application DE10145295.0, filed Sep. 14, 2001, the both of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
Sorting items of mail in a distribution order is understood to mean the procedure of bringing the items of mail to be distributed into an order which corresponds to the order of the distribution stopping points, for example in accordance with house numbers/mailboxes. These distribution stopping points are walked to or driven to by the distributor systematically in his delivery area. The distribution stopping point is in this case not an absolute sorting destination but a relative position in the distribution order.
Manually, this sorting is very complicated. By means of a sorting machine, this sorting can be carried out with considerably less expenditure on time, the sorting being based on a sorting plan. The sorting plan is a list which performs the allocation of addresses to the defined delivery stopping points, that is to say describes the order. In the machine, it is the relation between the machine-readable address code and the sequence number. Since the number of distribution stopping points is normally larger than the number of sorting compartments of the sorting machines, the distribution order sorting of the items of mail to be sorted is carried out in a plurality of sorting passes. In the process, the items of mail are in each case fed to the sorting machine again in the order sorted in the preceding pass.
The following example illustrates how sorting is carried out in two passes. Assuming that a specific number of items of mail are to be distributed to 20 distribution points. In this case, it is sufficient to have 4 sorting compartments in the first sorting pass and 5 sorting compartments in the second sorting run, since 4×5=20.
Original
Modified
Sorting
Sorting
Delivery
distribution
distribution
compartment
compartment
code
order
order
sorting
sorting
(ZIP code)
number
number
pass 1
pass 2
78453:332/025
1
1A
1 (A)
1
78453:332/027
2
1B
2 (B)
1
78453:332/029
3
1C
3 (C)
1
78453:335/102
4
1D
4 (D)
1
78453:335/104
5
2A
1 (A)
2
.
.
.
.
.
.
.
.
.
.
.
.
78453:347/045
19
5C
3 (C)
5
78453:347/047
20
5D
4 (D)
5
In the first sorting pass, the items of mail are distributed in accordance with the capital letters into four sorting compartments, that is to say the first sorting compartment received all the items of mail which contain an “A”, the second sorting compartment receives all items of mail which contain a “B” and so on. The sorting compartments are emptied and the items of mail are put into the physical input again, specifically beginning with the items of mail from the first sorting compartment (“A”), then with those from the second sorting compartment (“B”) and so on. During the second sorting pass, the items of mail are distributed in accordance with the number into 5 sorting compartments, that is to say the first sorting compartment receives all the items of mail which contain a “1” and so on. Since, after the first sorting pass, the items of mail which contain an “A” are already located in front of the items of mail which contain a “B”, sorting compartment 1 then firstly receives the items of mail which contain “1A”, then “1B” and so on. The same applies in an analogous way to all the other compartments, so that the distribution order sorting is completed after the second sorting pass. According to the prior art, it is necessary to draw up an allocation table, what is known as the sorting plan, which determines an unambiguous relationship between the delivery code, that is to say the ZIP code, and the sorting compartments within one pass. A variant of this method merely produces a relationship between the delivery code and the distribution order number. The sorting compartment allocation is performed during the sorting. Assuming that the distribution order number of a recognized delivery code is known, it is provided by the sorting plan and then has to be translated into a compartment number. The distribution order number in itself can be viewed as a combination of compartment allocation rules which here, for example, exhibits the following features. The machine has 10 compartments (consequently, the distribution order number is a decimal number), the compartments are designated 0 . . . 9 , the number of passes is equal to the number of decimal places in the distribution order partial order number. Example: the distribution order number 528 is sorted in three passes, into compartment 8 in the first sorting pass, into compartment 2 in the second sorting pass, into compartment 5 in the third sorting pass. In another machine with 64 available compartments in the first sorting pass and 30 in the second sorting pass, this same distribution order number ( 528 ) will be distributed as follows: into compartment 16 in the first sorting pass, into compartment 8 in the second sorting pass. In general, it is true that the number of digits corresponds to the number of passes needed, the numeric base of each digit corresponds to the number of compartments available in the respective sorting pass.
This consideration initially disregards the number of items of mail which are to be sorted per distribution order number. Under the assumption that there is a largely equal distribution of the quantities of items of mail, for example on average 3 items of mail for distribution order number, by considering the total quantity of items of mail, the number of sorting compartments and their size, a sorting machine can be utilized in an optimum way without a compartment-full situation occurring. Sorting compartment overflows which occur sporadically can be intercepted by the use of overflow compartments.
During this sorting according to the prior art, sorting compartments can overflow or can also be filled with only a very small number of items of mail. Because of the possible overflow, overflow compartments are provided. However, this reservation of overflow compartments means a reduction in the sorting capacity of the sorting machine with regard to the possible distribution stopping points.
Successive optimization of the sorting plan can reduce the number of necessary overflow compartments, but not replace them, since the composition and the extent of the items of mail remain unknown. When the sorting machine is emptied and the contents of sorting and overflow compartments are brought together, operating errors can occur which, under certain circumstances, change the order to such a great extent that repetition of the sorting becomes necessary.
The use of overflow compartments secondly does not guarantee that no further compartment-full situations can occur. In a method for avoiding compartment overflows according to U.S. Pat. No. 5,363,971, the ZIP codes are read and assigned to distribution stopping points. Then, by means of a microprocessor, the assignment of the ZIP codes to the distribution stopping points is modified in order to optimize the distribution of the items of mail in the compartments. This is done by not all the possible distribution stopping points being used but reserve stopping points being provided. By means of a specific allocation of the ZIP codes to the distribution stopping points and by placing the reserve stopping points between the associated distribution stopping points, it is possible to distribute the items of mail in an improved manner, in order to minimize the probability of compartment overflow. As a result, in the original compartment combination, only the remaining residual quantity is still sorted, which results in undesired nonuniform compartment filling. Given only low levels in the sorting compartments, time losses arise, since the time expended for emptying a little-filled compartment does not differ or differs only insignificantly from emptying a full compartment.
In DE 196 25 007 A1 a method for distribution order sorting is described in which, in order to avoid compartment-full situations, by means of iterative search steps in a simulation of the sorting operation before the sorting operation carried out by the sorting machine, the items of mail of each original distribution starting point are distributed to modified distribution starting points in such a way that the sorting compartments can accommodate the items of mail without any overflow. This iterative simulation is very time-consuming, so that, in a specific time interval, only a limited difference in quantity between the distribution stopping points can be compensated for.
In DE 196 47 973 C1, a description is given of using quantity statistics of the daily occurrence of items of mail from the past in the generation of sorting plans and, in DE 43 02 231 A1, there is an exposition of basing the sorting plan on statistical averages for the occurrence of postal items for specific destinations. However, how the sorting plans are configured in an optimum way with this information is not specified.
SUMMARY OF THE INVENTION
The present invention is therefore based on an object of substantially enlarging the range of the permissible differences in the occurrence of items of mail for various distribution stopping points given identical time periods for the assignment of the sorting compartments to the distribution stopping points, without sorting compartments overflowing.
According to the invention, the quantities of items of mail determined statistically for the individual real distribution order points of a specific distribution order are distributed to the largest possible number of virtual distribution order points, which is formed by the product of the number of the sorting compartments in the sorting passes, for the sorting passes before the last sorting pass, in such a way that the expected items of mail are distributed as uniformly as possible to the virtual distribution order points. The performance of the sorting passes before the last sorting pass is then carried out, in which the actual items of mail are distributed as uniformly as possible to the determined virtual distribution order points. The last sorting pass is then carried out in such a way that the items of mail of a distribution order are sorted into sorting compartments located beside one another.
In the process, it is assumed that, because of the number of sorting compartments which are ready, a sorting machine for the distribution order can process substantially more distribution order points within a sorting process than is necessary for the sorting of one or more real distribution orders. Thus, real distribution order points with large quantities of items of mail can be divided up into many virtual distribution order points with the smallest possible quantities of items of mail. Before the sorting, time-consuming iterative simulation is therefore no longer necessary, instead the subdivision of the items of mail is carried out on the basis of statistically determined frequency distributions.
Thus, the division of the items of mail to the virtual distribution order points before the first sorting pass is advantageously carried out by means of the following steps:
determining the minimum number of sorting compartments in the last/pth sorting pass NSTnmin for a specific distribution order, starting from the number of items of mail and the distribution order points, determining the number of possible virtual distribution order points Vdpn which can be provided for the distribution order, by means of the relationship
Vdpn=NSTp×ΠNST
Π NST=NST 1× NST 2 × . . . NST ( p− 1),
NSTi=number of sorting compartments in the machine in the ith sorting pass, NSTp=number of sorting compartments in the machine in the last sorting pass, determining the number of items of mail Erg to be expected statistically which each virtual distribution order point can accommodate given a uniform distribution, by means of the relationship
Erg=NITEM/Vdpn
where NITEM=number of items of mail from the distribution order to be expected statistically, determining the number of virtual distribution order points Vdpn (Erg) for each real distribution order point on the basis of statistically determined numbers of items of mail for the respective distribution order point, by the statistically determined number of items of mail for this distribution order point being divided by the number of items of mail Erg which each distribution order point can accommodate given uniform distribution, in the case of fractional values of Vdpn (Erg) with larger and smaller integer values, the subdivision to virtual distribution order points being carried out in such a way that the sum of the virtual distribution order points of all the physical distribution order points Σ Vdpn (Erg) corresponds to the number of possible virtual distribution order points Vdpn.
It is advantageous in this connection if, to determine the minimum number of sorting compartments in the last/pth sorting pass, the number of sorting compartments NSTitem to accommodate all the items of mail in the last/pth sorting pass is determined by means of the relationship: NSTitem=NITEM/NSTCAP; where NSTCAP=holding capacity of a sorting compartment and the number of sorting compartments NSTdpn for processing the distribution order points in the last/pth sorting pass is determined by means of the relationship: NSTdpn=NDPN/ΠNST; where NDPN=number of distribution order points and the next largest integer value of the larger value of NSTitem and NSTdpn gives the minimum number of sorting compartments in the last/pth sorting pass.
It is expedient if the sorting compartments for the virtual distribution order points of a real distribution order point are arranged beside one another.
For the economical use of the sorting capacities, it is beneficial, on the basis of a sufficiently large number of sorting compartments and their size, to sort a plurality of distribution orders simultaneously on one mail sorting machine, no more items of mail from further distribution orders being sorted in when a defined filling limit of the sorting compartments is reached.
Sorting in the items of mail for the sorting passes before the last sorting pass is in this case preferably carried out in distribution order layers over all the sorting compartments. In the last sorting pass, the items of mail for the various distribution orders are then separated, by being sorted distribution order by distribution order into compartments located beside one another.
If, following the first subdivision of the real distribution order points into virtual distribution order points, sorting compartments are still unoccupied, then it is advantageous, for the most uniform possible distribution of the items of mail, to assign the virtual distribution order points to the sorting compartments by means of a random algorithm in a further step, while preserving the integrity of the sequence.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will be explained in more detail below in an exemplary embodiment, using the drawings, in which:
FIG. 1 shows the planning of the distribution order sorting;
FIG. 2 shows data flows and modules of a system and marks the points at which the invention is used (distribution algorithm);
FIG. 3 shows a possible distribution of quantities of items of mail to distribution order points within a specific distribution order, as can occur in reality;
FIG. 4 shows a possible arrangement of the items of mail from two different distribution orders in the first sorting pass without the application of the method according to the invention;
FIG. 5 shows the arrangement of two distribution orders in the first sorting pass given subdivision to virtual distribution order points; and
FIG. 6 shows the insertion of sorting compartments in the second sorting pass in the case of unexpectedly high quantities of items of mail in the second sorting pass.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts the starting situation of a complex sorting system. The distribution order definitions 1 , called the distribution order below, are derived from a database-supported system, and contain the assignment of the destination code information to distribution order points and the quantities of items of mail to be expected per distribution order point. In the distribution order sorting planning 2 , the predefined distribution orders are distributed to the available sorting machines. This planning is carried out, firstly, in accordance with logical criteria set by the operator, secondly in accordance with loading criteria of the machines. In practice, this means that the planner attempts to match the logistical criteria of the operator to the existing machine park and, for this purpose, needs a tool which, during the planning, can continuously check whether the capacity limit of one or more machines has already been reached or not. The result of this planning are the distribution order sorting plans 4 for the machines (note: the sorting device for separating the items of mail to be sorted into assignments for each machine, the separating sorting planner 3 , will not be considered in this connection).
FIG. 2 depicts the arrangement of the elements reduced to a single machine. The distribution order definitions 1 are subjected, in the distribution order sorting planning with sorting plan management 5 , to an examination which, as a result, determines the capacity loading of the sorting machine 6 by each of the distribution orders chosen for this machine. To this end, use is made of the distribution algorithm, which will be described in more detail, which subsequently controls the actual sorting in the real sorting machine 6 . By means of this method, during the planning it can already be ensured that delivering the distribution orders to one sorting machine 6 will not exceed its sorting capacity. The sorting plan 4 generated for a machine contains the distribution orders with the assignments of the destination code information to the distribution order points. This sorting plan 4 is loaded into the machine 6 and the same distribution algorithm which has already permitted determination of the distribution in the planning phase controls the real sorting in the machine.
FIG. 3 depicts an example of the distribution of 1800 items of mail to 180 distribution order points within an individual distribution order. An object of the method according to the invention is to arrange this nonuniform distribution on the machine in such a way that the lowest possible capacity loading of the machine occurs.
The characteristic values of a machine in the case of 2 sorting passes are:
NST=number of sorting compartments (210); NSTCAP=number of items of mail which a sorting compartment can accommodate (600); P=number of sorting passes (2).
The characteristic values of the distribution order are:
NITEM=expected total quantity of items of mail (1800); NDPN=number of distribution order points (180).
Under the assumption that the items of mail of the distribution order are to be assembled in the smallest possible number of sorting compartments in the second sorting pass, the minimum requirements for sorting this distribution order can be derived from these characteristic values:
NSTitem = NITEM/
1800/600 = 3
Number of sorting compartments
NSTCAP
to hold all the items of mail
in the second sorting pass
NSTdpn = NDPN/
180/210 = 1
Number of sorting compartments
NST
for processing the
distribution order numbers in
the second sorting pass
The larger of the values NSTitem and NSTdpn is defined as the number of sorting compartments in the second sorting pass.
The minimum number of sorting compartments needed for the first sorting pass can then be determined.
NST1 = NDPN/NST2
180/3 =
Number of sorting compartments for
60
processing the distribution order
numbers in the second sorting pass
Since, because of its size, the machine can process more than one distribution order, and the distribution order separation is carried out automatically at the change from the first to the second sorting pass (each distribution order has its own sorting compartment group in the second sorting pass), a dedicated virtual machine can be described for each distribution order.
The following Table 1 shows some calculation examples of the distribution orders and calculated virtual machines:
TABLE 1
Sorting
Distribution
compartments
order
needed in the
characteristic
second sorting pass
Virtual
values
(calculation)
machine
No.
NITEM
NDPN
NSTitem
NSTdpn
NST2
NST1
1
1800
30
2.99
0.14
3
10
2
1800
180
2.99
0.86
3
60
3
600
180
1.00
0.86
1
180
4
1200
180
1.99
0.86
2
90
5
1500
700
2.49
3.33
4
175
6
600
600
1.00
2.86
3
200
7
1800
630
2.99
3.00
3
210
8
2400
600
3.99
3.00
4
150
9
2400
850
3.99
4.05
5
170
FIG. 4 and Table 1 show that the distribution order examples occupy the machine very differently in the first sorting pass if only the minimum conditions are satisfied in actual fact. It can likewise be seen that that this type of distribution reacts very sensitively to changes in the quantities of items of mail, as based on the loading of the sorting compartments, in particular if the actual quantities of items of mail differ greatly from the expected quantities of items of mail.
FIG. 5 illustrates the distribution of the quantities of items of mail if the actual distribution order points of the distribution order 1 are mapped to the virtual distribution order points. The order is not disrupted by this procedure, but the result is a more uniform distribution of the items of mail to the machine. For the distribution order 1 it is true that 30 real distribution order points 1 each having 60 items of mail are spread to 180 virtual distribution order points each having 10 items of mail. This means that each real distribution order point now contains 6 virtual distribution order points. During the sorting operation, during the distribution to the virtual distribution order points, the distributed items of mail are counted in, since the virtual distribution order points are not a distribution feature on the items of mail but exist only during the distribution process. Items of mail which go beyond the expected quantity of items of mail for a distribution order point are distributed uniformly to the associated virtual distribution order points.
While, in the preceding example, the relationships can be comprehended easily, the method must be refined for a real distribution order, as illustrated in FIG. 3 . The calculation of the sizes of virtual distribution order points and the determination of the resulting distribution to the machine is the central part of the method according to the invention and will be performed separately for each distribution order. The respective result is mapped in a virtual machine (a software machine), which adds up the expected levels in the sorting compartments. The sorting plan management system accepts further distribution orders for a specific machine during the planning only as long as the defined maximum numbers for the quantity of items of mail per sorting compartment are not exceeded.
The calculation of the distribution of a single distribution order is carried out in 4 steps.
Step 1: calculation of the characteristic values and minimum requirements of a distribution order
NSTitem = NITEM/NSTCAP
Number of sorting
compartments to hold all the
expected items of mail in
the pth (p = 2) sorting pass
(last sorting pass)
NSTdpn = NDPN/NST1
Number of sorting
compartments for processing
the distribution order
number in the pth sorting pass
NSTp = (ceil)max(NSTitem,NSTdpn)
Number of sorting
compartments in the pth
(p = 2) sorting pass (greater
value of NSTitem and NSTdpn)
Vdpn = NSTp * NST
Number of possible virtual
distribution order points
which can be provided for
the distribution order
Erg = (float) NITEM/Vdpn
Number of items of mail
which each virtual
distribution order point of
a distribution order is
intended to accommodate on
the basis of the total
number of items of mail
Erg_h = (ceil) Erg
Size of the virtual distribution
order point (high value)
Erg_l = Erg_h − 1
Size of the virtual distribution
order point (low value)
where:
NST1—number of sorting compartments in the machine (in the first sorting pass);
NSTCAP—holding capacity of a sorting compartment;
NITEM—expected number of items of mail from the distribution order;
NDPN—number of the distribution order numbers of a distribution order;
(ceil): next higher integer value;
and (float): floating-point value.
The number of items of mail per virtual distribution order point must be increased from the exact value Erg to the integer value Erg_h. Since, as a result, the sum of all the items of mail (Vdpn*Erg_h) appears to be larger than the actual quantity of items of mail, the integer value Erg_l lower by 1 is additionally introduced.
Step 2: the number of virtual distribution order points for each real distribution order point is calculated, the subdivision of this fractional value to the integer values Erg_h and Erg_l being performed in the ratio Erg.
Step 3: the excess of (actually not present) items of mail which has arisen during the distribution of the quantities of items of mail to the virtual distribution order points of the sizes Erg_h and Erg_l is corrected by replacing elements which have arisen from Erg_h by elements from Erg_l.
Step 4: during the distribution of the quantities of items of mail to virtual distribution order points of the sizes Erg_h and Erg_l, it is possible for the effect to occur that more virtual distribution order points than are available are needed (NST 2 *NST 1 ). This is corrected by introducing a third variable for virtual distribution order points Erg_spec, which can accommodate either a multiple of Erg_h or a multiple of Erg_l of items of mail.
If, during the calculation, cases occur in which, inspite of the smallest possible size 1 of virtual distribution order points, not all the available virtual distribution order points are occupied, the occupied virtual distribution order points can be distributed over the available sorting compartments in accordance with the random principle. This avoids a situation where an accumulation of such virtual distribution order points can occur in one and the same sorting compartment.
During the sorting, statistics about the occurrence of the expected distribution order points are collected. After the end of the first sorting pass, the actual composition or distribution of the quantities of items of mail to the respective distribution order points is known. While, in the first sorting pass, the occurrence of sorting-compartment-full situations can be avoided by means of the uniform distribution of the virtual distribution order points over all the available sorting compartments, in the second sorting pass, as a result of the concentration of the distribution orders to the minimum number of sorting compartments in each case, overflow situations can occur when the actual quantities of items of mail substantially exceed the expected quantities of items of mail. In the preliminary part of the actual sorting, the planning can take account of this circumstance and reserve sorting compartments preventively and notify the machine about this in a suitable manner, as a rule as a constituent part of the sorting plan. These reserve sorting compartments are initially not assigned any distribution order. Since the machine is not also notified, as a sorting plan, of a destination code in accordance with the sorting compartment assignment, but determines this assignment itself with the aid of the method according to the invention, it is also capable of making changes to the sorting compartment assignment independently if required.
FIG. 6 shows the basic sequence. The planning has reserved a sorting compartment at the “end” of the machine or, the with the aid of the calculation carried out by the method according to the invention, takes into account one sorting compartment less than is actually available in the machine. After the end of the first sorting pass, the machine checks, using the statistics, the sorting compartment fillings to be expected for the second sorting pass and, in the process, determines that the second sorting compartment of the distribution order 1 is to accommodate more items of mail than has been specified for the sorting compartment. The machine therefore displaces all the sorting compartment assignments above the sorting compartment no. 2 under consideration by one position and then assigns the excess numbers of items of mail from the sorting compartment 2 to the sorting compartment 3 which has now become free. The sorting can therefore be continued without the sequence being delayed by a sorting-compartment-full situation occurring.
The following is a list of symbols used and their intended definition.
NST
Number of sorting compartments in a machine
NSTi
Number of sorting compartments in the machine in
the ith sorting pass
P
Number of sorting passes of a sorting device
NDPN
Number of actual distribution order points of a
given distribution order
VDPN
Number of possible virtual distribution order points
which can be provided for a distribution order
NITEM
Expected number of items of mail of a distribution
order
NSTCAP
Holding capacity of a sorting compartment
NSTitem
Number of sorting compartments to accommodate all
the expected items of mail in the pth (last)
sorting pass
NSTdpn
Number of sorting compartments for processing the
distribution order numbers in the pth (last)
sorting pass.
NSTp
Number of sorting points (compartments) for
sorting in the pth (last) sorting pass = larger
value of NSTitem and NSTdpn.
ΠNST
Product of the numbers of sorting compartments in
the sorting passes without the last sorting pass.
Erg
Number of items of mail which each virtual
distribution order point of a distribution order
is intended to accommodate on the basis of the
total number of items of mail.
Erg_h
Size of a virtual distribution stopping point
(high value)
Erg_l
Size of a virtual distribution stopping point (low value)
Erg_spec
Size of a virtual distribution stopping point,
SPECIAL value, multiple of Erg_h or Erg_l. | In the present invention a sorting machine in a distribution order is made to process a substantially higher number of distribution order points, within a sorting process, than necessary for sorting in one or several real distribution orders based on the available pigeon holes. Real distribution order points with large quantities of mailing pieces are distributed between several virtual distribution order points with a minimum quantity of mailing pieces. The quantity of mailing pieces statistically determined for each real distribution order point of a defined distribution order are distributed between the virtual distribution order points, as regularly as possible, for the sorting passes preceding the final sorting pass. Then, the sorting passes preceding the final sorting pass are executed. The final sorting pass is thus executed, such that the mailing pieces of a distribution order are sorted into adjacent pigeon holes. | 8 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to an improved identification card. More specifically, this invention relates to an identification card containing an internal antenna and integrated circuit chip laminated between two protective, non-rigid layers onto which artwork may be printed, which are then laminated between to rigid outer layers.
[0002] “Smart cards” which contain an IC chip are well known in the art and typically have been used for credit card and ATM transactions. Smart cards may either have contacts on their surface to interface with a card reader or they may be contactless cards and incorporate an antenna within the body of the card to transfer data without physical contact with a reading device.
[0003] Typically smart cards have been made with a rigid core onto which an IC chip and antenna are positioned by means of glue or a mechanical device. The rigid core is then covered with a plastic, encasing the structure in a polymer. For example, U.S. Pat. No. 5,809,633 issued to Mundigl, et al. discloses a method whereby an antenna is inserted into a recess in a carrier body. U.S. Pat. No. 5,955,021 issued to Tiffany, III teaches the use of low shrinkage glue to secure the electronic components to a rigid plastic core layer, which is then placed into a bottom mold assembly. A top mold assembly is then attached to the bottom mold creating a void. Thermoplastic is then injected into the void space to secure the electronic components. Similarly, U.S. Pat. No. 6,049,463 issued to O'Malley, et al. discloses a microelectric assembly including an antenna embedded within a polymeric card by means of a mold assembly. The antenna and chip are placed into a mold and polymeric material is injected into the mold thus encasing the components.
[0004] U.S. Pat. No. 6,036,099 issued to Leighton discloses a process for manufacturing a combination contact/contactless smart card via a lamination process utilizing core sheets made from polyvinyl chloride (PVC), polyester, or acrylonitrile-butadiene-styrene (ABS). In the Leighton method, a region of the card is milled to expose the contacts of the card.
[0005] Due to the rigidity of the components used in the prior art cards, the electronic components cards can be subject to damage from bending stresses. Also, securing the antenna and chip with glue or a mechanical means is complicated and can needlessly increase the costs of production. Understandably, processes utilizing molds involve increased costs of tooling and production not seen in a lamination process. Both the highly plasticized poly(vinyl chloride) type and the polyester/poly(vinyl chloride) composite type can become brittle over time because of migration of the plasticizers, thus reducing the resistance of the document to cracking; such cracking renders the card unusable and vulnerable to tampering. Data that are crucial to the identification of the bearer are often covertly repeated on the document in encrypted form for data verification in a magnetic stripe, bar code, radio frequency module or integrated circuit chip. The inability to retrieve such data due to cracking renders the document invalid. In addition, many of the polyester/poly(vinyl chloride) composite documents have exhibited extreme sensitivity to combinations of heat and humidity, as evidenced by delaminating and curling of the document structure.
[0006] Therefore, a need exists for a low-cost, easily constructed identification card having an antenna and chip incorporated into the body of the card, which protects these electronic components from damage. Applicants' invention relates to a unique structure capable of protecting the IC chip and antenna. Applicants' invention contains two relatively shock-absorbing layers, which may contain indicia. In an embodiment, two rigid outer laminate layers encase the relatively shock-absorbing layers, adding structural support and protection. Applicants' card differs from the prior art in that normally rigid materials are used throughout the card, thus permitting external stresses and bending to damage the delicate IC chip and antenna. In applicants' improved design, rigid outer layers disseminate external forces over a broad area of compliant layers, thus protecting the electronic components.
SUMMARY OF THE INVENTION
[0007] Accordingly, this invention provides an identification card comprising:
[0008] a core layer comprising a silica-filled polyolefin, said core layer having a first side and a second side,
[0009] at least one antenna fixed to said to said first side of said core layer,
[0010] at least one computer chip electrically connected to said antenna,
[0011] a bottom sheet comprising a silica-filled polyolefin attached to said first side of said core by a first adhesive layer such that said antenna and said chip are enveloped between said core and said bottom sheet.
[0012] an akyld resin spid containing an anti-binding agent printed on said first side of said core layer,
[0013] a first laminate layer attached to said second side of said core layer by a second adhesive layer,
[0014] a second laminate layer attached to said bottom sheet by a third adhesive layer such that said core and said bottom sheet are encased between said first laminate layer and said second laminate layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 of the attached drawings shows a cross-section of an identification card of the present invention.
[0016] FIG. 2 of the attached drawings shows a cross-section of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] To prepare an identification card of the present invention the first step is pre-shrinking a core layer. In order to provide an identification document having a bright white background and good color rendition, it is generally preferred that the core layer be formed from an opaque sheet of printable silica-filled polyolefin, such as the materials sold commercially by PPG Industries, Inc., Pittsburgh, Pa. under the Registered Trade Mark “TESLIN” sheet.
[0018] The first indicium or indicia, which are typically the invariant information common to a large number of identification documents, for example the name and logo of the organization issuing the documents, may be formed by any known process capable of forming the indicium on the specific core material used.
[0019] However, since it is usually desired to provide numerous copies of the first indicium on a large area of core layer material (in the form of a large sheet or web) in order to allow the preparation of a large number of “blank” documents at one time, a printing process such as color laser printing, is normally used to apply the first indicium. A modified laser printer useful for forming the first indicium in the present process is described in U.S. Pat. No. 5,579,694.
[0020] In order to minimize the risk of damage to the fragile electronic components, preferably alkyd resin spids containing an anti-binding agent are printed onto one side of the shrunken core sheet on the side opposite from the indicia. These spids may be printed in any pattern, however, in an embodiment they are printed onto the core in a “racetrack” or oval pattern. Antennae, typically silver-epoxy antennae, are then printed onto the spids in a matching pattern. Integrated circuit chips are attached to solder bumps on the antennae in the conventional manner.
[0021] The core layer with attached antennae and IC chips is then bonded to a bottom sheet of printable, silica-filled polyolefin with an adhesive layer. The adhesive layer may be composed of a number of commercially available adhesives, however, very desirably it is composed of a co-polyester based adhesive such as the adhesive sold commercially by Transilwrap, Inc., Richmond, Ind. under the name Transilwrap® TXP(3). Because IC chips are typically much thicker than the antennae, preferably recesses are cut in the TXP(3) adhesive layer to accommodate the IC chips. By removing a section of the adhesive, the identification card will be of uniform thickness. Because recesses were cut in this TXP(3) adhesive layer, in order to bond the IC chip to the bottom layer, an additional layer of adhesive is required. Although this adhesive may comprise any suitable adhesive, in the preferred embodiment it is a carboxylated polyethylene hot melt adhesive such as that manufactured by Transilwrap, Inc. and sold under the name Transilwrap® KRTY. This adhesive is applied to the bottom layer prior to assembly of the card and serves to bind the IC chip to the bottom layer. During lamination of the identification card, the TXP(3) adhesive layer will flow freely thus adhering the core sheet with the bottom sheet, sandwiching the electronic components in a bonded, flexible laminate of silica-filled polyolefin.
[0022] Two layers of substantially transparent polymer are affixed to the bonded core layer/bottom layer structure. Depending upon the material used for the core layer and bottom layer, the process used to produce the first indicium and the type of substantially transparent polymer employed, fixation of the polymer layers to the core layer may be effected by heat and pressure alone. However, it is generally preferred to provide an adhesive layer on each polymer layer to improve its adhesion to the core layer. This adhesive layer may be a polyester, polyester urethane, polyether urethane or polyolefin hot melt or ultraviolet or thermally cured adhesive, and the adhesive may be coated, cast or extruded on to one surface of the polymer sheet. The polymer layers themselves may be formed from any polymer having sufficient transparency, for example polyester, polycarbonate; polystyrene, cellulose ester, polyolefin, polysulfone, or polyimide. Either an amorphous or biaxially oriented polymer may be used. Two specific preferred polyesters for use in the process of the present invention is poly(ethylene terephthalate) (PET), which is readily available commercially, for example from ICI Americas Inc., Wilmington, Del. 19850 under the Registered Trade Mark “MELINEX”, and poly(ethylene terephthalate glycol) (PETG), which is readily available commercially from Eastman Kodak Chemical, Kingsport, Tenn. The polymer layers provide mechanical strength to the image-receiving layer or layers and hence to the image(s) in the finished document. The thickness of the polymer layers is not critical, although it is generally preferred that the thickness of each polymer layer (including the thickness of its associated adhesive layer, if any) be at least about 0.1 mm, and desirably is in the range of from about 0.125 to about 0.225 mm. Any conventional lamination process may effect lamination of the polymer layers to the core layer, and such processes are well known to those skilled in the production of identification documents.
[0023] The image-receiving layer of the present identification document may be formed of any material capable of receiving an image by dye diffusion thermal transfer. However, very desirably the dye diffusion thermal transfer printing step of the present process is effected by the process of U.S. Pat. No. 5,334,573. This patent describes a receiving sheet or layer which is comprised of a polymer system of which at least one polymer is capable of receiving image-forming materials from a donor sheet with the application of heat, the polymer system of the receiving sheet or layer being incompatible with the polymer of the donor sheet at the receiving sheet/donor sheet interface so that there is no adhesion between the donor sheet and the receiving sheet or layer during printing. In addition, the polymer system of the receiving sheet or layer can be substantially free from release agents, such as silicone-based oils, poly(organosiloxanes), fluorinated polymers, fluorine or phosphate-containing surfactants, fatty acid surfactants and waxes. The present process may employ any of the donor sheet/image-receiving layer combinations described in this patent. Suitable binder materials for the dyes, which are immiscible with the polymer system of the image-receiving layer, include cellulose resins, cellulose acetate butyrate, vinyl resins such as poly(vinyl alcohol), poly(vinylpyrrolidone) poly(vinyl acetate), vinyl alcohol/vinyl butyrate copolymers and polyesters. Polymers which can be used in the image-receiving layer and which are immiscible with the aforementioned donor binders include polyester, polyacrylate, polycarbonate, poly(4-vinylpyridine), poly(vinyl acetate), polystyrene and its copolymers, polyurethane, polyamide, poly(vinyl chloride), polyacrylonitrile, or a polymeric liquid crystal resin. The most common image-receiving layer polymers are polyester, polycaprolactone and poly(vinyl chloride). Processes for forming such image-receiving layers are also described in detail in this patent; in most cases, the polymer(s) used to form the image-receiving layer are dissolved in an organic solvent, such as methyl ethyl ketone, dichloromethane or chloroform, and the resultant solution coated onto the polymer layer using conventional coating apparatus, and the solvent evaporated to form the image-receiving layer. However, if desired the image-receiving layer can be applied to the polymer layer by extrusion casting, or by slot, gravure or other known coating methods.
[0024] The identification cards of the present invention may have only a single image-receiving layer, but is generally preferred that they have two image-receiving layers, one such layer being provided on each layer of polyester on the side thereof remote from the core layer. Typically, one or more second indicia intended for human reading may be printed on the image-receiving layer on the front side of the identification document, and one or more additional second indicia intended for machine reading (for example, bar codes) may be printed on the image-receiving layer on the back side.
[0025] Following the printing of the second indicia on the image-receiving layer, a protective layer is affixed over at least the portion of the or each image-receiving layer carrying the second indicia; this protective layer serves to protect the relatively fragile image-receiving layer from damage, and also prevents bleeding of the thermal transfer dye from the image-receiving layer. Materials suitable for forming such protective layers are known to those skilled in the art of dye diffusion thermal transfer printing and any of the conventional materials may be used provided they have sufficient transparency and sufficient adhesion to the specific image-receiving layer with which they are in contact and block bleeding of dye from this layer. Typically, the protective layer will be a biaxially oriented polyester or other optically clear durable plastic film.
[0026] The protective layer desirably provides additional security features for the identification card. For example, the protective layer may include a low cohesivity polymeric layer, an optically variable ink, an image printed in an ink which is readable in the infra-red or ultraviolet but is invisible in normal white light, an image printed in a fluorescent or phosphorescent ink, or any other available security feature which protects the document against tampering or counterfeiting, and which does not compromise the ability of the protective layer to protect the identification document against wear and the elements.
[0027] In an alternate embodiment, the image-receiving layer may be formed from any material capable of receiving ink-jet printing. Many commercially available inkjet receiver coatings will suffice, however it is important that the inkjet receiver coating is only applied in the area where printing will occur, to ensure that the polyester layer will properly adhere to the core layer. The identification card may then be personalized with a common inkjet printer prior to addition of the polyester layers. In this embodiment the personalized information is printed between the core layer and the polyester layers, thus eliminating the need for an additional protective layer.
[0028] FIG. 1 of the accompanying drawings shows a schematic cross-section through an embodiment of an identification card of the present invention. The document comprises a core layer 12 and a bottom layer 14 , both formed of an opaque white reflective polyolefin (preferably the aforementioned TESLIN® sheet). One side of the core layer and one side of the bottom sheet are printed with fixed indicia 16 . Sandwiched between the core layer 12 and the bottom layer 14 are an antenna 18 connected to an integrated circuit chip 20 . An alkyd resin spid 22 lies beneath the core layer 12 and the antenna 18 . An adhesive layer 24 (preferably KRTY) is applied to the bottom layer 14 on the side facing the core layer 12 . The bottom layer 14 and the core layer 12 are joined with an adhesive layer 26 (preferably TXP(3)). Recesses 28 are cut into the adhesive layer 26 to accommodate the integrated circuit chip 20 .
[0029] The core layer 12 and bottom layer 14 are sandwiched between two polymer layers 30 formed from an amorphous or biaxially oriented polyester or other optically clear plastic such as polycarbonate. Each of these polymer layers 30 is fixedly secured to the core layer 12 and bottom layer 14 by an adhesive layer 32 . On the opposed side of each polymer layer 30 from the laminated core layer 12 and bottom layer 14 is provided an image-receiving layer 34 suited to accept a printed image or portrait or other variable indicia by dye diffusion thermal transfer methods.
[0030] After the variable indicia have been printed on the image-receiving layers 34 , a biaxially oriented polyester or other optically clear durable plastic protective layer 36 is applied to protect the variable indicia and prevent bleeding of dye from the image-receiving layers 34 . The protective layer 36 may be provided with a low cohesivity layer, security ink or other security feature.
[0031] FIG. 2 of the accompanying drawings shows a schematic cross-section through an alternate embodiment of an identification card of the present invention. The document, generally designated 10 , comprises a core layer 12 and a bottom layer 14 , both formed of an opaque white reflective polyolefin (preferably the aforementioned TESLIN® sheet). Opposed sides of the core layer and the bottom sheet are printed with fixed indicia 16 . Sandwiched between the core layer 12 and the bottom layer 14 is an antenna 18 connected to an integrated circuit chip 20 . An alkyd resin spid 22 lies beneath the core layer 12 and the antenna 18 . An adhesive layer 24 (preferably KRTY) is applied to the bottom layer 14 on the side facing the core layer 12 . The bottom layer 14 and the core layer 12 are joined with an adhesive layer 26 (preferably TXP(3)). Recesses 28 are cut into the adhesive layer 26 to accommodate the integrated circuit chip 20 .
[0032] The laminated core layer 12 and bottom layer 14 is sandwiched between two polymer layers 30 formed from an amorphous or biaxially oriented polyester or other optically clear plastic such as polycarbonate. An inkjet receiver coating 38 is supplied between the core layer 12 and a polymer layer 30 . The inkjet receiver coating 38 may contain personalized data 40 Each of the polymer layers 30 is fixedly secured to the core layer 12 and bottom layer 14 by a layer 32 of adhesive.
[0033] The following Examples are now given, though by way of illustration only, to show details of specific preferred reagents, conditions and techniques used to prepare identification cards of the present invention.
EXAMPLE 1
[0034] Core layers of silica-filled polyolefin were prepared, preferably of the aforementioned TESLIN®, of 0.01″ thickness in the size of four A4 sheets (210 mm×297 mm×4 mm). The core layers were heated at 105° C. for approximately 30 minutes to pre-shrink the material. Alkyd resin spids, in a racetrack design, were then printed on the bottom side of the shrunken core layers, and background artwork was printed on a side of the core layers. Silver-epoxy antennae were then screen-printed onto the spidded areas of the sheets, and IC chips were then attached to the antennae. Because the core layers were heated repeatedly during this process, it is important that the polyloefin be pre-shrunk to avoid any shrinking problems during printing of the artwork or attachment of the electronic components.
[0035] Bottom layers were prepared by pre-shrinking 10 mm thick silica-filled polyolefin sheet in the manner described above. Artwork was printed onto a side of the bottom layer. 1.5 mm of an adhesive, preferably KRTY, was applied to an opposed side of the bottom layers to adhere the IC chip to the bottom layer.
[0036] The core layers and the bottom layers were joined by a free film of adhesive (7 mm of TXP (3)) cut into A 4 sized sheets. Holes were precut in the TXP(3) adhesive sheets to accommodate the IC chips. The core layers and bottom layers were then joined by the TXP(3) adhesive layer such that the antennae and chips were sandwiched between them, thus encasing and protecting the electronic components. The core layers and bottom layers were joined (up to 10 at a time) using a Tetrahedron press. Initially, the pressure used was very low (of less than approximately 400 psi) and the temperature was relatively high (approximately 290° F.) so that the TXP(3) adhesive layer was allowed to flow and so that the electronic components are not damaged. Pressure and temperature were then increased to approximately 3 ksi and 300° F. to bond the three layers together. The temperature was then lowered to approximately 170° F. while the pressure remained relatively high (approximately 2 ksi) so that the TXP(3) adhesive layer would solidify without altering the form of the pressed core layer. Pressure was then reduced and the press was opened, yielding a core layer/bottom layer laminate encasing the electronic components.
[0037] This core layer/bottom layer was then laminated using a nip-roll lamination process. The top laminate material used was a 7/3 TXP (5)/KRTY onto which a dye diffusion thermal transfer receiver coating had been applied to the adhesive side. The bottom laminate was a 7/3 TXP (5)/KRTY layer. The resulting card was then imprinted with personal information on both the front and back using an Atlantek printer. Security features, such as UV sensitive inks or Polasecure®, can be added to the top surface of the card. After this, a 0.001″ thick bi-axial polyester laminate was applied to both sides of the identification card.
EXAMPLE 2
[0038] The core layer/bottom layer was prepared as described in Example 1. For personalization, however, an inkjet receiver coating, preferably a Grace-Davision formulation, was patch-coated onto selective areas of the core layer opposite the bottom layer. It is important that the entire core layer was not coated with the receiver coating or the core would not properly adhere to the polyester laminate. Image and text were printed onto the receiving layer using a Canon® 8200 printer and pigment-based inks. The printed cores were then belt laminated on both sides using 7/3 TXP (0)/KRTY as both the top and bottom laminate.
[0039] From the foregoing, it will be seen that the present invention provides an identification card which affords significant improvements in durability (by protecting the integrated circuit chip and antenna) and ease of manufacture as compared with the prior art identification cards and smart cards described above. It is to be understood that the above-described embodiments are merely illustrative of the present invention and represent a limited number of the possible specific embodiments that can provide applications of the principles of the invention. Numerous and varied other arrangements may be readily devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention as claimed. | An identification card is prepared by attaching an antenna and integrated circuit chip onto a core layer of polyolefin, attaching a bottom sheet to the core layer thus encasing the antenna and integrated circuit chip, providing an image-receiving layer on one or both outer surfaces of the resulting sandwich, and laminating a protective layer or layers over the image-receiving layer(s). The identification document displays improved durability, ease of manufacture and protection of the electronic components. | 6 |
BACKGROUND
[0001] Rain gutters are widely installed along the rooftop eaves of millions of homes and sloped-roof buildings in North America, Europe, and other parts of the world. These rain gutters serve an important role in properly channeling water runoff to appropriate destinations such as storm water mains or drainage ponds. By diverting roof runoff away from the walls of a building, rain gutters also reduce structural damage that would otherwise be caused by the flow of rainwater onto the walls. In addition to rainwater, substantial amounts of debris (such as leaves, tree branches, silt runoff from roof shingles, and the like) tend to accumulate in rain gutters over time, which can eventually constrict or prevent any rainwater from flowing properly.
[0002] Various tools have been described for facilitating rain gutter cleaning. For example, U.S. Pre-grant Appln. Pub. 2006/0289036 (incorporated herein by reference) relates to an elongated pole that emits compressed gas to blow leaves out of a gutter. Similarly, U.S. Pat. No. 6,471,271 (incorporated herein by reference) relates to a mechanical device, also including an elongated pole, in which a pair of tongs mounted at the end of the pole are opened and closed by pulling a rope to thrash debris out of a gutter.
[0003] However, the manual tools set forth in those documents can cause the user to fatigue his or her arms from holding heavy poles up as high as twenty feet overhead when attempting to remove debris from a gutter. For example, the user must raise the manual gutter cleaning tool up to the rain gutter and keep it raised for the duration of the cleaning. Furthermore, it may not be possible for the user to ascertain whether any residual matted debris remains in the gutter after attempting a removal, because the rain gutter is typically too high above the user for any visual inspection to be feasible.
SUMMARY
[0004] In view of the above, as well as other considerations, presently disclosed is a mobile robot for cleaning debris from rain gutters (herein referred to as a “gutter cleaning robot”). The gutter cleaning robot includes a debris auger at a front end of the main body of the gutter cleaning robot, and moves forward along the gutter while motivating the debris auger to clear debris from the gutter being traversed. Accordingly, rain gutters may be effectively cleaned without requiring a user to manipulate strenuous overhead equipment and minimize climbing a ladder.
[0005] In accordance with a first example, a gutter cleaning robot may have a drive system for propelling the gutter cleaning robot along a rain gutter, and a debris auger detachably connected to the gutter cleaning robot for agitating debris out of the rain gutter.
[0006] The gutter cleaning robot may also have a chassis (also referred to herein as a main body) including a robot connector for mechanically driving the debris auger, and a debris auger connector disposed on the debris auger for interfacing with the robot connector.
[0007] The debris auger connector may include one or more connector concavities extending into the debris auger connector, each connector concavity being aligned substantially parallel to a longitudinal axis of the debris auger connector, in which the robot connector includes one or more tines each arranged to extend into a respective connector concavity of the debris auger connector. Also, the robot connector may further include a locking collar concavity, in which the debris auger further includes a shroud disposed around the debris auger connector, the shroud provided for enveloping the robot connector when the debris auger is attached to the main body of the gutter cleaning robot, in which the shroud includes a locking protrusion extending from an inner surface of the shroud for engaging the locking collar concavity of the robot connector.
[0008] In the gutter cleaning robot, the debris auger connector may include a hexagonal concavity extending into the debris auger connector, the hexagonal concavity aligned substantially parallel to a longitudinal axis of the debris auger connector, in which the robot connector includes a hexagonal protrusion for extending into the hexagonal concavity of the debris auger connector. The debris auger may be interchangeable with one or more alternative debris augers; and/or may include a spiral screw for drilling into debris. The alternative debris augers may include a flail-type auger, a bristle-type auger, a flap-type auger, a twisting flap-type auger, an irregular protrusion-type auger, a revolving horizontal tines-type auger, a screw-and-flap-type auger, and/or a plow-type auger; and further, the debris auger may include a pneumatic tube for blowing air onto the debris.
[0009] The drive system of the gutter cleaning robot may include a caterpillar tread for contacting an interior surface of the rain gutter; and may also include a drive motor, at least two front wheels disposed on opposite lateral sides of the main body of the gutter cleaning robot for guiding the gutter cleaning robot along the rain gutter, and two rear wheels disposed on opposite lateral sides of the main body of the gutter cleaning robot and operably connected to the drive motor.
[0010] The gutter cleaning robot may also be usable with a remote control for operating the gutter cleaning robot via a wireless signal transmitted to the gutter cleaning robot.
[0011] The gutter cleaning robot may include a light emitting diode on the remote control that blinks when the remote control transmits a signal; and/or another emitting diode on the gutter cleaning robot that blinks when the gutter cleaning robot receives a signal. The gutter cleaning robot may also have a detachable handle or a tote loop disposed on the main body of the gutter cleaning robot for hanging onto a positioning hook that can hoist the gutter cleaning robot into the rain gutter; and/or an ammeter for monitoring an auger current supplied to the debris auger motor, and a controller for receiving input from the ammeter and controlling the drive motor and the debris auger motor, in which the controller can modulate the drive motor when the auger current exceeds a threshold value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is a perspective view of a house having a rain gutter and drainpipe.
[0013] FIG. 1B is a detail view of a corner of the rain gutter shown in FIG. 1A .
[0014] FIG. 1C is an oblique partial cutaway view of a rain gutter having four kinds of gutter hanging braces.
[0015] FIG. 1D is a partial cutaway view of a gutter cleaning robot traversing a rain gutter, in which the height of the gutter cleaning robot affords clearance to pass underneath a gutter hanging brace.
[0016] FIG. 2 is a partial cutaway view of a gutter cleaning robot.
[0017] FIGS. 3A and 3B are front and rear aspect views, respectively, of the gutter cleaning robot shown in FIG. 2 .
[0018] FIG. 4 is a schematic view of a gutter cleaning robot having caterpillar treads and a removable handle.
[0019] FIG. 5 is an exploded view of a gutter cleaning robot having a flattened profile, showing the placement of batteries and drive components within the chassis.
[0020] FIG. 6 is a diagram of a gutter cleaning robot operated by a wireless remote control.
[0021] FIGS. 7A and 7B are isometric views of a debris auger 350 having flails.
[0022] FIGS. 8A and 8B are isometric views of a debris auger 350 having bristles.
[0023] FIGS. 9A and 9B are isometric views of a debris auger 350 having longitudinal flaps.
[0024] FIGS. 10A and 10B are isometric views of a debris auger 350 having oblique flaps.
[0025] FIGS. 11A and 11B are isometric views of a debris auger 350 having a screw.
[0026] FIGS. 12A and 12B are isometric views of a concave debris auger 350 having rigid protrusions.
[0027] FIGS. 13A and 13B are isometric views of a debris auger 350 having rigid protrusions.
[0028] FIGS. 14A and 14B are isometric views of a debris auger 350 having flaps connected to a screw;
[0029] FIG. 14C is an oblique view of a debris auger 350 having flaps and a bristle, which is rotatable to eject debris;
[0030] FIG. 14D is an oblique view of a robot 10 traversing a gutter 51 using the auger 350 of FIG. 14C ;
[0031] FIG. 15 is a front aspect view of a debris auger connector.
[0032] FIG. 16 is a perspective view of a debris auger 350 and a robot connector.
[0033] FIG. 17 is a perspective view of a debris auger 350 having flails and a debris auger connector.
[0034] FIG. 18 is a perspective view of a debris auger 350 having longitudinal flaps and a debris auger connector.
[0035] FIG. 19A is a partial cutaway view of an alternative debris auger connector having a locking shroud with a locking protrusion.
[0036] FIG. 19B is a perspective view of a robot connector having a concave locking collar corresponding to the locking protrusion of the locking shroud shown in FIG. 19A .
[0037] FIG. 20 is a partial cutaway profile view of a pneumatic debris auger 350 .
[0038] FIG. 21 is a photograph illustrating a variety of alternative debris augers.
[0039] FIG. 22 is a photograph illustrating debris being ejected from a gutter by a gutter cleaning robot.
[0040] FIG. 23 is a partially transparent perspective view of a gutter cleaning robot having obliquely aligned rear drive wheels and a suspension.
[0041] FIG. 24 is an oblique perspective view of a gutter cleaning robot having a removable handle.
[0042] FIG. 25 is a partial cutaway view of a gutter cleaning robot having a debris auger disposed on two longitudinal ends thereof.
[0043] FIGS. 26A and 26B are isometric views of a plow-type debris auger.
[0044] FIG. 27 is a front aspect view of a debris auger connector having a hexagonal concavity.
[0045] FIG. 28 is a perspective view of a debris auger connector having a hexagonal concavity and a robot connector having a hexagonal protrusion.
[0046] FIG. 29 is a flowchart illustrating a method for controlling the drive motor and debris auger.
[0047] FIGS. 30A through 30D are schematic diagrams illustrating possible alignments of battery cells in a gutter cleaning robot chassis.
DETAILED DESCRIPTION
[0048] FIG. 1A shows a house 40 having a roof 45 supported by walls 43 . The roof 45 is sloped and includes tar shingles, cedar shakes, or another roof-building material. A rain gutter 51 is disposed along the eaves of the roof 45 . Also, a drain spout 52 drains water from the gutter 51 via a hole in the bottom of the gutter 51 . As rain or other water falls on the roof 45 , the rainwater slides down to the eaves where it collects in the gutter 51 and flows down through the drain spout 52 .
[0049] Another example of a roof having a rain gutter is shown in FIG. 1B , in which the rain gutter 51 includes a corner 53 where two straight sections are joined. Debris 91 also collects in the gutter 51 , and includes material such as silt, leaves, branches, and other detritus.
[0050] FIG. 22 illustrates a gutter cleaning robot 10 traversing the gutter 51 . As the gutter cleaning robot 10 moves forward through the gutter 51 , the gutter cleaning robot 10 ejects debris 91 out from the gutter 51 .
[0051] In accordance with a first embodiment, FIG. 2 shows a gutter cleaning robot 10 for traversing the gutter 51 and clearing debris 91 . The gutter cleaning robot 10 includes a main body 101 onto which rear drive wheels 175 are disposed, as well as two front wheels 176 . A drive motor 170 , such as a DC brushed or brushless motor with encoders, provides motivating force to rotate the rear wheels 175 , which may preferably be aligned in an oblique orientation so as to contact the interior side walls of the gutter 51 rather than only the bottom interior surface thereof. The power output of the drive motor 170 may be transmitted directly to the treads 179 or wheels 175 ; or, alternatively, a reducing mechanical transmission may be interposed between the drive motor 170 and the treads 179 or wheels 175 . The gutter cleaning robot 10 also includes a detachable debris auger 350 for agitating or moving the debris 91 .
[0052] The debris auger 350 is connected to a debris auger motor 160 within the main body 101 via a debris auger shaft 163 . The drive motor 170 and debris auger motor 160 are preferably controlled by an electronic controller having a memory store for storing computer instructions for controlling the drive motor 170 and/or the auger motor 160 . In a preferred embodiment, a microcontroller serves as the electronic controller; or, in a possible alternative embodiment, the microcontroller may be a microprocessor. As a further alternative, the electronic controller may include a PLA or FPGA device.
[0053] The gutter shown in FIG. 1C illustrates four common kinds of rain gutter hanging arrangements in which straps or braces are used. The inside hanger method employs straps 1101 spanning the width of the rain gutter 51 , in which screws or nails go through the strap from inside the gutter into a fascia board at the edge of the roof. The outside hanger method uses outside hangers 1101 A, 1101 B mounted to the fascia board behind the rain gutter 51 , and the rain gutter 51 is disposed on the outside hangers 1101 A, 1101 B. In the strap hanger method, straps 1103 are nailed under shingles into the roof sheathing. The spike and ferrule method uses spikes 1104 driven through the rain gutter 51 into the fascia board, in which ferrules are used to maintain the appropriate width of the gutter trough and to prevent the spikes 1104 from pulling against or distorting the rain gutter 51 .
[0054] In each of the above-noted gutter hanging arrangements, a strap or spike crosses the trough of the gutter transversely, and presents a possible obstacle to any gutter cleaning robot 10 moving along the through of the rain gutter 51 . Accordingly, in a preferred embodiment, the gutter cleaning robot 10 has an overall height profile that is low enough to afford sufficient clearance between the topmost part of the gutter cleaning robot 10 and the straps or spikes that cross over the trough of the rain gutter 51 .
[0055] As illustrated in FIG. 1D , for example, a gutter cleaning robot 10 includes a detachable handle 180 and caterpillar treads 179 that are disposed so as to permit the gutter cleaning robot 10 to pass underneath spikes 1104 that support the rain gutter 51 . Another example of a gutter cleaning robot 10 including a detachable handle 180 is illustrated in FIG. 24 . The detachable handle 180 facilitates handling and transportation of the gutter cleaning robot 10 by a user, and may be removed when the gutter cleaning robot 10 is operated in a rain gutter 51 having low overhead clearance. The detachable handle 180 may be fastened to the chassis 101 using a latch, wingnuts, magnets, velcro, or any other fastening arrangement suitable to permit attachment and removal of the detachable handle 180 to the gutter cleaning robot 10 .
[0056] Many rain gutters 51 have either a round trough bottom or a substantially flat trough bottom. Rain gutters for residential housing typically have a width of between four to six inches, with the typical k-style gutter being five inches wide and the typical half-round gutter being six inches wide; thus, typical widths for rain gutters 51 may range between three to seven inches. The depth of many installed rain gutters 51 is approximately 75% the width of the rain gutter, and rain gutter depths typically range between about 60% to 90% of the width of the rain gutter. drain spouts commonly installed to rain gutters typically have 2×3″, 3×4″ or 4×5″ rectangular cross-sections, and the rain gutters generally have rectangular holes of similar shape where they interface with the drain spouts.
[0057] The gutter cleaning robot 10 preferably has a width and caterpillar tread arrangement (or wheel, or other drive system) suitable to traverse rectangular hole of at least about three inches by four inches. The gutter cleaning robot 10 may alternatively have a width and drive system placement suitable to traverse holes having a width in the range of about two to five inches, and/or a length in the range of about two to six inches.
[0058] Many installed rain gutters 51 can support up to about 50 pounds per lineal foot. Accordingly, the gutter cleaning robot 10 preferably has a weight sufficiently low so as to be supported by the weight load capacity of common rain gutters, taking into account the weight of a typical load of debris 91 .
[0059] FIG. 3A shows a rear aspect view of the gutter cleaning robot 10 . In this example, the debris auger 350 has flaps, the end portions of which extend beyond the outer perimeter of the main body 101 and are thus visible. Also, FIG. 3B shows a front aspect view of the gutter cleaning robot 10 . Because the gutter cleaning robot 10 may be required to traverse both flat-bottom rain gutters and round-bottom rain gutters, in a preferred embodiment the gutter cleaning robot 10 has a longitudinal cross-section having a substantially rounded bottom and a substantially flattened top, as illustrated in FIG. 5 or FIG. 23 (as non-limiting examples), in order to facilitate movement along either round-bottom or flat-bottom rain gutters while affording sufficient overhead clearance to permit the gutter cleaning robot 10 to pass underneath obstacles such as support braces. Alternatively, the gutter cleaning robot 10 may have other types of longitudinal cross-section outline such as a cylinder, rectangle, or other polygonal shape.
[0060] FIG. 4 illustrates an embodiment of a gutter cleaning robot 10 having caterpillar treads 179 as a traction drive and a removable handle 180 disposed on top of the chassis 101 of the gutter cleaning robot 51 . In addition, batteries 177 are disposed within the chassis 101 . The batteries 177 may include a single rechargeable cell, or include one or more commercially available cells, such as “D”-size alkaline cells, NiCd cells, nickel metal hydride cells, lithium cells, or any other kind of battery suitable for providing sufficient current and power the drive system 170 and auger 350 of the gutter cleaning robot 10 .
[0061] In a preferred embodiment, the treads 179 or wheels 175 are disposed toward the edges of the gutter cleaning robot 10 so that they are separated horizontally by a distance of at least about 2 inches. Because drain spouts 52 often have a width in the range of about two to six inches, the wheels 175 or treads 179 are preferably disposed apart by a distance sufficient to enable the gutter cleaning robot 10 to straddle a hole while moving forward through a rain gutter 51 . As an example, the horizontal distance between the wheels 175 or treads 179 may be chosen from a range extending from substantially two inches to substantially six inches.
[0062] The wheels 175 or treads 179 may be spring mounted to the chassis 101 of the gutter cleaning robot 10 , to increase the traction pressure applied by the wheels 175 or treads against the side walls of the rain gutter 51 . This increased traction pressure minimizes torsion caused by the action of the auger 350 , and/or may further ensure that the gutter cleaning robot 10 remains within the rain gutter 51 during operation, such as when the gutter cleaning robot 10 is performing an escape behavior in response to becoming stuck.
[0063] In FIG. 5 , a preferred embodiment is illustrated in which the gutter cleaning robot 10 includes caterpillar treads 179 , and has a top chassis section 101 B and a bottom chassis section 101 A that house the drive system 170 , batteries 177 and the auger motor 160 . The batteries 177 are disposed substantially laterally in an in-line arrangement, so as to minimize the necessary height of the chassis sections 101 A, 101 B. The top and bottom chassis sections 101 A, 101 B are contoured so as to closely conform to the shape of the components housed therewithin, providing a compact, substantially flat profile of the assembled gutter cleaning robot 10 . Accordingly, the height of the gutter cleaning robot 10 may be minimized, and overhead clearance optimized.
[0064] A typical clearance between the bottom-most point of a common rain gutter 51 and a fastening strap is 2.75 inches. Preferably, the gutter cleaning robot 10 has a maximum height and diameter of about 2.5 inches; or, alternatively, the gutter cleaning robot 10 may have a height and/or diameter up to substantially 2.75 inches, or to another distance representing the clearance from a rain gutter bottom to a fastening strap or brace.
[0065] A typical “D” size battery has a diameter of approximately 1.3465 inches. Thus where “D” size batteries are used, the gutter cleaning robot 10 preferably has a diameter equal to or slightly larger than the diameter of a standard D cell battery. For example, the gutter cleaning robot 10 may have a height of at least 1.4 inches. Alternatively, the gutter cleaning robot 10 may have a height and/or diameter within the range of between about 1.4 inches to about 2.5 inches; or a height and/or diameter of at least 1.4 inches, inter alia.
[0066] In one example, as shown in FIG. 4 , a gutter cleaning robot 10 has a chassis 2.5 inches in diameter, and uses “D” size batteries 177 disposed within the chassis 101 . Because the “D” size batteries 177 have a width of 1.3465 inches, no more than two “D” size batteries can be placed on top of the other, or else they will not fit within the chassis 101 . Several example battery arrangements are illustrated in FIGS. 30A through 30D : FIG. 30A shows four batteries 177 arranged one battery high in a square pattern; FIG. 30B shows four batteries arranged squarely two batteries high, with two sets of two batteries next to each other and stacked on top of one another; FIG. 30C shows three batteries, in which first and second batteries are arranged horizontally aligned, one atop the other, and the third battery is disposed perpendicular to the other two batteries; and FIG. 30D shows three batteries arranged in a triangular pattern such that a first battery is disposed on top of second and third batteries placed side by side, all in horizontal alignment. In embodiments in which other types of batteries are used, the gutter cleaning robot 10 may have a height or diameter equal to or greater than at least the exterior diameter of that type of battery, for example.
[0067] The wheel 175 or tread 1779 assembly may include a mechanical switch to determine whether the gutter cleaning robot 10 has fallen out of the rain gutter 51 , or whether one of the wheels 175 is stuck in a hole. The switch is activated by a decrease in spring tension between the wheels 175 or treads 179 and the walls of the rain gutter 51 . When the spring's tension is low enough to activate the mechanical switch, the gutter cleaning robot may alert the user and promptly cease powering the drive motor 170 and auger motor 160 . This switch's state is preferably reset each time the gutter cleaning robot 10 is powered up, and may be ignored until after initialization. Furthermore, the switch is preferably only active when the gutter cleaning robot 10 is powered on; also, in at least one embodiment, a dip switch can be included on the gutter cleaning robot 10 to cause the gutter cleaning robot 10 to either monitor or ignore the switch.
[0068] The gutter cleaning robot 10 may be directed using a remote control 6 , as shown in FIG. 6 . The remote control 6 includes a joystick and/or buttons for entering commands to be sent to the gutter cleaning robot 10 (such as, for example, start/stop commands). The remote control 6 may transmit user-entered commands to the gutter cleaning robot 10 via radio frequency communication, which the gutter cleaning robot 10 receives via antennae 116 . The remote control 6 and the gutter cleaning robot 10 may each include a respective light emitting diode (LED) or other visual or audible indicator, such as a light bulb or buzzer, for indicating when the remote control 6 is transmitting and/or when the gutter cleaning robot 10 is receiving a signal from the remote control 6 . For example, when the remote control 6 is transmitting a signal, the LED on the remote control may blink; and/or when the gutter cleaning robot 10 receives a signal from the remote control 6 , the LED on the gutter cleaning robot 10 may blink.
[0069] FIGS. 7A through 14B illustrate isometric views of various augers that may be interchangeably attached to the gutter cleaning robot 10 . These debris augers may be replaced with another debris auger 350 when appropriate; for example, when matted debris is clogging a gutter, the user may affix a screw-type debris auger 350 to the gutter cleaning robot 10 for effectively penetrating the matted debris. Later, if the user desires not to drop debris 91 onto a walkway below the gutter 51 but instead to move the debris 91 to another portion of the gutter 51 , the user can detach the screw-type debris auger 350 and then affix a plow-type debris auger 350 that can push the debris 91 rather than move it out of the gutter 51 .
[0070] The auger 350 preferably has a diameter at least equal to the diameter of the chassis 101 of the gutter cleaning robot 10 , as measured tip-to-tip. In one embodiment, the auger 350 has a diameter no greater than substantially 3 inches. Alternatively, the diameter of the auger 350 may be within the range of between about 2.5 inches to about 3.5 inches. The auger 350 preferably operates at a speed in the range of between about 1000 RPM (rotations per minute) to about 1500 RPM. The auger 350 may be made of a substantially flexible material, such as a polymer or plastic, that can deform when it comes into contact with rigid objects. Because the diameter of the auger 350 may exceed the clearance between the gutter's floor and a support strap or brace, the auger 350 may come into contact with straps or braces as the gutter cleaning robot 350 travels under the straps or braces. In order to ensure mobility, the auger 350 is preferably made of a material that deforms when it comes into contact with the type of strap or brace used to support the rain gutter 51 .
[0071] In FIGS. 7A and 7B , a flail-type debris auger 350 includes several flexible protruding flails. When the flail-type debris auger 350 is rotated under the power of the debris auger motor 160 , the flails contact debris 91 and fling the debris 91 out of the gutter 51 .
[0072] FIGS. 8A and 8B illustrate a brush-type debris auger 350 having several rows of bristles affixed to a central wire, similar to a pipe cleaner. The bristles rotate, thereby agitating debris 91 and moving it out of the gutter 51 .
[0073] FIGS. 9A and 9B illustrate a flap-type debris auger 350 including flexible flaps centrally connected to a spool. The flaps may include a rubber or elastomeric material that adheres to debris 91 , to effectively grab the debris 91 and facilitate removal of the debris 91 from the gutter 51 .
[0074] A twisting flap-type debris auger 350 is shown in FIGS. 10A and 10B . The twisting flap-type debris auger 350 may be similar to the flap-type debris auger 350 shown in FIGS. 9A and 9B , differing in that the flaps are connected along a twisting path to the central spool rather than in a straight (parallel to the longitudinal axis) arrangement.
[0075] FIGS. 11A and 11B illustrate a screw-type debris auger 350 . The screw-type debris auger 350 includes a conical spiral screw, similar to a drill bit, having screwed threading for effectively penetrating matted debris 91 and motivating loosened debris material out of the gutter 51 .
[0076] An irregular protrusion-type debris auger 350 is shown in FIGS. 12A and 12B , having a hemispherical portion from which irregular finger-like protrusions extend to effectively seize chunks of debris 91 . The irregular protrusion-type debris auger 350 may have a form similar to a spaghetti mixer, as a non-limiting example.
[0077] FIGS. 13A and 13B illustrate a horizontal tines-type debris auger 350 that has straight tines extending forward from a circular outer track. The tines, when revolving, can agitate large masses of debris 91 .
[0078] FIGS. 14A and 14B illustrate an screw-and-flaps-type debris auger 350 combining the features of the screw-type debris auger 350 with the flaps of the flap-type debris auger 350 . Accordingly, the screw-and-flaps-type debris auger 350 can both penetrate matted debris 91 and also seize granular debris 91 that may be agitated loose from the matted debris 91 during a cleaning operation of the gutter cleaning robot 10 .
[0079] Although the debris augers shown in FIGS. 7A through 14B are illustrated as non-limiting examples, the varieties and types of debris augers are not limited thereto. As further non-limiting examples, FIG. 20 illustrates a pneumatic debris auger 350 and FIGS. 26A and 26B illustrate a plow-type debris auger 350 .
[0080] The pneumatic-type debris auger 350 shown in FIG. 20 includes a conical portion that may include screwed threading like the screw-type debris auger 350 shown in FIGS. 11A and 11B , for example. In addition, the pneumatic-type debris auger 350 includes a hollow central passage 333 and openings 335 through which a fluid, such as pressurized gas (which may include air, nitrogen, helium, or any other suitable gas or combination of gases) or liquid may be passed. The pressurized air preferably emerges from the openings 335 at a velocity and rate of flow sufficient to agitate the debris 91 . Accordingly, the breaking up of matted or chunky debris 91 is further enhanced by the action of the pressurized gas. Alternatively, pressurized liquid—such as water—may instead be passed through the central passage 333 and openings 335 , and likewise applied to the debris 91 . The pressurized liquid may include any suitable liquid, such as water or an aqueous cleaning solution (for example, detergents or surfactants dissolved in water); furthermore, the liquid may be heated above the ambient temperature, in order to aid in the break-up of leaf resin or tar and to promote agitation of the debris 91 , for example.
[0081] FIGS. 26A and 26B illustrate a plow-type debris auger 350 having a form similar to a cow-catcher. When the plow-type debris auger 350 is affixed to the gutter cleaning robot 10 , the gutter cleaning robot 10 pushes the debris 91 forward through the gutter 51 instead of ejecting the debris 91 out of the gutter 51 . This can be useful when the user prefers to avoid debris 91 from spilling onto a clean area of ground below the gutter 51 , for example. After the debris 91 is pushed to a more appropriate section of the gutter 51 , the user can exchange the plow-type debris auger 350 with another debris auger 350 for ejecting the debris 91 .
[0082] Also, FIG. 21 illustrates various additional non-limiting examples of debris augers.
[0083] The debris auger 350 may be non-interchangeably connected to the gutter cleaning robot 10 , by forming the debris auger 350 integrally with the gutter cleaning robot 10 or by permanently affixing the debris auger 350 to the gutter cleaning robot 10 by welding or using adhesives, for example. Preferably, however, the debris auger 350 is detachably and interchangeably connectable to the gutter cleaning robot 10 . As shown in FIG. 15 , the debris auger 350 may include a debris auger connector 310 disposed on a gutter cleaning robot 10 —facing end of the debris auger 350 . The debris auger connector 310 includes one or more concavities, such as first, second and third concavities 321 , 322 , 333 , for example.
[0084] FIG. 16 illustrates a conical screw-with-sweeping-flaps-type debris auger 351 having a debris auger connector 310 for interfacing with a corresponding robot connector 130 disposed on the gutter cleaning robot 10 (for example, the robot connector 130 may be provided as part of, and/or at the distal end of, the debris auger shaft 163 ). The robot connector 130 includes one or more protrusions, such as first, second and third protrusions 131 , 132 , 133 that each extend into a respective concavity 321 , 322 or 323 in the debris auger connector 310 .
[0085] When the debris auger 351 is affixed to the gutter cleaning robot 10 , the protrusions of the robot connector 130 impart rotating force against the inner surfaces of the concavities of the debris auger connector 321 , thus motivating the debris auger 361 . FIG. 17 shows another example, in which a flail-type debris auger 352 includes a debris auger connector 310 ; and FIG. 18 illustrates an example of a flap-type debris auger 353 having a debris auger connector 310 .
[0086] In accordance with another embodiment, a shroud 315 may be provided surrounding the debris auger connector 310 . As shown in FIG. 19 , the shroud 315 may extend outward from the surface onto which the debris auger connector 310 is disposed, so as to envelope or extend over the robot connector 130 when the debris auger 350 is connected to the gutter cleaning robot 10 .
[0087] The shroud 315 may further include an annular locking protrusion 316 extending partially inward toward the central longitudinal axis of the shroud 315 , with the robot connector 130 correspondingly including a locking collar concavity 138 disposed therealong. When the debris auger 350 having the shroud 315 is attached to the gutter cleaning robot 10 , the annular locking protrusion 316 flexibly extends into the locking collar concavity of the robot connector 130 , thus tending to retain the debris auger 350 in connection with the gutter cleaning robot 10 until force sufficient to dislodge the annular locking protrusion 316 out of the locking collar concavity 136 is applied to separate the debris auger 350 from the gutter cleaning robot 10 .
[0088] FIG. 23 illustrates a suspension of the gutter cleaning robot 10 . The rear wheels 175 are obliquely angled with regard to the vertical axis, in order to wedge the rear wheels 175 against the side and/or bottom surfaces of the gutter and improve tractional contact therebetween. Also, a spring suspension may further be provided to permit the rear wheels 175 (driven by the drive motor 170 ) to remain in frictional contact with the gutter 51 even when the main body 101 is jolted during a cleaning operation. Accordingly, even when the gutter cleaning robot 10 encounters a section of gutter 51 having a hole at the bottom where the drain spout 52 connects to the gutter 51 , the gutter cleaning robot 10 can nonetheless safely traverse the hole.
[0089] In accordance with another embodiment, the gutter cleaning robot 10 may include a debris auger shaft 163 that extends both to the front and rear end portions of the main body 101 . Accordingly, as illustrated in FIG. 25 , a debris auger 350 may be affixed to either end (or even both ends simultaneously) of the gutter cleaning robot 10 . Accordingly, in this embodiment, the user can detach the debris auger 350 from one end of the gutter cleaning robot 10 and attach it to the opposite end, without having to remove the gutter cleaning robot 10 from the rain gutter 51 , for example.
[0090] As shown in FIG. 27 , the debris auger connector 310 may include a single concavity 324 that preferably has an outline suitable for imparting rotational force to the debris auger connector 310 . The debris auger connector 310 in the example of FIG. 27 has a hexagonal concavity 324 . FIG. 28 illustrates a robot connector 130 that has a single hexagonal protrusion for inserting into the hexagonal concavity 324 of the debris auger connector 310 .
[0091] The gutter cleaning robot 10 may operate entirely under the control of the user using a remote control 6 ; alternatively, the gutter cleaning robot 10 may operate autonomously or semi-autonomously. For example, the gutter cleaning robot 10 may include an on-board controller that executes a control routine for modulating the forward motion of the gutter cleaning robot 10 through the gutter 51 . The gutter cleaning robot 10 may include sensors and monitors, such as an ammeter for monitoring the drive current provided to the drive motor 160 and/or the debris auger 350 current provided to the debris auger motor 170 .
[0092] FIG. 29 illustrates a method for controlling the drive motor 160 and the debris auger motor 170 in response to a mechanical drive resistance as ascertained by an ammeter monitoring the drive current supplied to the drive motor 160 . At step 2901 , the routine ascertains the drive current from the ammeter (for example, by reading a memory-mapped register that is updated by the ammeter). If step 2902 determines that the drive current exceeds a deadlock threshold current value (which corresponds to a drive current high enough to indicate that the gutter cleaning robot 10 is futilely attempting to proceed against an obstacle that prevents any forward motion by the gutter cleaning robot 10 ), then step 2903 halts both the drive motor 160 and the debris auger motor 170 in order to prevent burnout or damage to the gutter cleaning robot 10 or debris auger 350 .
[0093] Otherwise, step 2904 determines whether the drive current exceeds a bogged threshold (that is, a threshold current value corresponding to a state in which the gutter cleaning robot 10 can proceed, but only slowly because of copious debris 91 in the gutter 51 , referred to as being “bogged”). If not, the routine returns to step 2901 ; otherwise, step 2905 reduces the commanded drive speed of the drive motor 160 .
[0094] Accordingly, the example method illustrated in FIG. 29 monitors the drive current and appropriately responds to obstacles or resistance encountered when traversing the gutter 51 —if the gutter cleaning robot 10 is entirely prevented from moving forward, then the gutter cleaning robot 10 is halted so that the user can remedy the situation; if instead the gutter cleaning robot 10 is moving forward, albeit slowly, then the gutter cleaning robot 10 reduces the commanded velocity of traversal.
[0095] The gutter cleaning robot 10 may perform an escape behavior when triggered by appropriate sensor conditions. For example, the operating speed and/or direction of the drive motor 170 and/or the auger motor 160 may be repeatedly or cyclically shifted, in order to agitate or break free of an obstacle. Tables 1 illustrates various current sensor conditions and example escape behavior responses:
[0000]
TABLE 1
Drive Motor
Auger Motor
Circumstances
Current
Current
Action/Response
Auger and
current > TH
current > TH
Spin both the wheels
Wheels stuck
and the auger quickly
in a direction opposite
to the direction of
movement
Auger is stuck
current <= TH
current > TH
Spin the auger quickly
in a direction opposite
to the direction of
movement
Wheels are
current > TH
current <= TH
Spin the wheels
stuck
quickly in a direction
opposite to the
direction of movement
[0096] When the gutter cleaning robot 10 has already performed an escape behavior but the triggering sensor conditions have not been resolved after an appropriate length of time, the gutter cleaning robot 10 may then perform a panic behavior as a second level response. Table 1 illustrates example panic behaviors that may be performed in response to various conditions:
[0000]
TABLE 2
Drive Motor
Auger Motor
Circumstances
Current
Current
Previous Behaviors Used
Present Action/Response
Auger/Wheels stuck
current > TH
current > TH
Behavior: Spinning both the
Power down the device and
wheels and the auger quickly in a
alert the user.
opposite direction.
Duration: Executed six times—
three times forward and three
times backward.
Auger is stuck
current <= TH
current > TH
Behavior: Spinning the auger
Spin the drive motor in an
quickly in an opposite direction.
opposite direction. Then spin
Duration: Executed six times—
the auger motor in 10 quick
three times forward and three
bursts of forward and backward
times backward.
movement.
Wheels are stuck
current > TH
current <= TH
Behavior: Spinning the wheels
Per down the device and
quickly in an opposite direction.
alert the user.
Duration: Executed six times—
three times forward and three
times backward. | A gutter cleaning robot can traverse rain gutters to agitate and remove debris. The gutter cleaning robot is equipped with a debris auger at a front end that contacts and ejects the debris, and has a drive system for propelling the gutter cleaning robot along the rain gutter. The debris auger can include a spiral screw or various other forms of auger, and may be interchangeable by the user so as to enhance the effectiveness of the gutter cleaning robot in various environments or modes of operation. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to electronic transactions generally, and more particularly to a method and apparatus for initiating a transaction from an electronic mail message.
[0003] 2. Discussion of the Background
[0004] Electronic commerce has become big business. It is well known among Internet merchants that the amount of time, clicks and web pages required for a consumer to complete an Internet purchase has a direct and dramatic effect on sales. Therefore, much effort has been expended in minimizing the amount of time and number of actions required to make an Internet purchase. An example of a U.S. patent directed toward this problem is U.S. Pat. No. No. 5,960,411 (“the '411 patent”), which is directed to a method and system that allows an Internet purchase to be made with a single click of a user's mouse. While the '411 patent does streamline the purchasing process somewhat, it still suffers from the drawback that a user must first locate the desired item in order to place an order for it and thus does not streamline the purchase process to the fullest extent possible. It is also known to send emails to customers that include links to merchant websites. While such emails provide a shortcut to a merchant's website, the user must still click on the link to go to the merchant's website and then perform further actions in order to initiate the transaction.
[0005] What is needed is a streamlined process that will further minimize the amount of time and effort required to initiate and complete an electronic commerce transaction.
SUMMARY OF THE INVENTION
[0006] The present invention meets the aforementioned need to a great extent by providing a system and method in which an electronic mail message (an “email”) which includes a description of a proposed transaction (e.g., a description of goods for sale along with a price for the goods) is sent to an end user and the end user is provided with the ability to initiate and complete the transaction by activating a button in the email without the need for the end user to visit the website. The transaction is preferably conducted using a secure channel technology such as Secure Socket Layer (SSL) or Transport Layer Security (TLS). In one embodiment, the secure channel is established by spawning a browser window and utilizing support for secure channels that is built into the browser.
[0007] In one embodiment of the invention, the user completes an order form in the email including data such as name, address, credit card number, etc., prior to initiating the transaction. The entered data is automatically transferred to a transaction server upon initiation of the transaction.
[0008] In another embodiment of the transaction, a customer number, or other identifying data (e.g., name and address) is included in the email received by the end user and automatically sent to the transaction server, thereby further simplifying the purchasing process. The identifying data may be linked to a credit card that is known to the merchant in advance such that transmitting the credit card number for each purchase is not necessary. Alternatively, all customer identification other than the credit card number may be included in the email and the customer is only required to enter the credit card number prior to initiating the transaction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A more complete appreciation of the invention and many of the attendant features and advantages thereof will be readily obtained as the same become better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0010] [0010]FIG. 1 is a sequence diagram showing the transfer of an email according to one embodiment of the present invention.
[0011] [0011]FIG. 2 is a screen shot showing the email of FIG. 1.
[0012] [0012]FIG. 3 is a sequence diagram showing the initiation of a transaction from the email of FIG. 2.
[0013] [0013]FIG. 4 is a screen shot of a website showing a confirmation of the transaction initiated from the email of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present invention will be discussed with reference to preferred embodiments of methods and system for initiating electronic commerce transactions from email. For ease of understanding, certain method steps are delineated as separate steps; however, these steps should not be construed as necessarily distinct nor order dependent in their performance. Specific details, such as types of transactions, types of data required for transactions, etc., are provided in order to provide a thorough understanding of the invention. The preferred embodiments discussed herein should not be understood to limit the invention.
[0015] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts, a sequence 100 of steps 150 - 158 for creating and transferring an email according to an embodiment of the invention is illustrated in FIG. 1. At step 150 , an email object is composed at a processor 110 . An exemplary form of email object, or simply email, 200 , in which flowers are offered for sale, is illustrated in FIG. 2.
[0016] The email 200 includes a field 210 in which is displayed the name of the merchant selling the flowers. Fields 220 show various flower arrangements being offered for sale. In email 200 , four different flower arrangements are offered. In preferred embodiments of the invention, the number of different goods/services is kept small, preferably 1-5 goods/services, although larger numbers of goods/services are within the purview of the invention. The email 200 also includes a billing information field 230 into which a customer receiving the email may enter billing information such as name, address, and credit card information. The email 200 further includes a recipient information field 240 , which may be used to enter shipping information in the event that it is different from the billing information. Finally, the email 200 includes a Purchase “button” 250 , which the customer may press to initiate the transaction offered in the email. (As used herein, the term button is used in a generic sense and should be understood to refer to any mechanism, now known or later developed, by which a customer can indicate a desire to accept a proposed transaction.) The email 200 is preferably composed using HTML (Hyper Text Mark-up Language) in a manner that is well known in the art. Base 64 encoding may be used to hide underlying email text and code from the user.
[0017] Referring now back to FIG. 1, after the email 200 has been composed, the processor 110 transmits the email 200 to a mail transfer agent (i.e., an email server) 120 along with a destination(s) for the email 200 at step 152 . The mail transfer agent 120 then sends the email 200 to the required destinations including a customer mail transfer agent 130 at step 154 , preferably using Simple Mail Transfer Protocol (SMTP). The email 200 is stored at the end user mail transfer agent 130 until the customer's mail user agent 140 (e.g., Microsoft Outlook Express) checks for new messages at step 156 . Then, the email 200 is sent from the end user mail transfer agent 130 to the end user mail user agent 140 , where it is viewed by the customer using the mail user agent 140 .
[0018] Referring now to FIG. 3, if the customer viewing the email 200 decides to purchase any of the goods or services shown in the email 200 , the customer enters the required information (e.g., name, address and credit card number) in the billing information field 230 and any other required/desired information (e.g., quantity of items ordered, shipping information, etc.) at step 350 . When the customer activates the Purchase button 250 , the mail user agent 140 spawns a new browser window 310 (which preferably can be seen by the customer) with a request that includes an https URL (uniform resource locator) for a transaction server 320 and the information entered by the customer as step 352 . This causes the browser window 310 to initiate SSL handshaking and certificate exchange with the transaction server 320 at steps 354 and 356 , thereby causing a secure communications channel to be established. Once the secure channel between the transaction server 320 and the browser window 310 has been established, the customer information is sent from the new browser window 310 to the transaction server 320 at step 360 .
[0019] The transaction server 320 then stores the transaction in a database and downloads a confirmation 400 (as shown in FIG. 4) of the transaction to the new browser window 310 at step 362 . Finally, at step 364 , the merchant server 330 is notified of the transaction and takes the appropriate action based on the information provided by the customer.
[0020] It should be noted that, with the exception of the customer filling in the information discussed in connection with step 350 , which is done “in the email” (that is, the customer enters the information in the same window in which the email is displayed by the mail user agent 140 ), the entire transaction is completed with a single click of the Purchase button 250 from the point of view of the customer. There is no need for the customer to go to a website, or even open a browser window, prior to viewing the email 200 and activating the Purchase button 250 . This makes it much easier for a customer to order a desired product as compared to known methods.
[0021] In the embodiment illustrated in FIGS. 1 - 4 , the customer is required to enter identification information such as name and address. In some embodiments, in which individualized emails are directed toward targeted customers, the information in these fields may be inserted into the email in advance. In still other embodiments, emails to existing customers may include a customer identification code which is transmitted to the transaction server 320 when a “Purchase Using Default Options” button is activated. In these embodiments, the customer code sent to the merchant is all that is needed as the merchant may have pre-stored all of the information needed to complete the transaction. In these embodiments, if the default information is correct, the entire transaction may be completed with one simple click. Of course, emails in such an embodiment may also provide the customer with the opportunity to modify the default information.
[0022] As discussed above, the new browser window 310 is visible to the customer when it is opened. One of the reasons the new browser window 310 is opened is to take advantage of the built-in support for SSL/TLS secure channels provided by most current browsers such as Microsoft Internet Explorer and Netscape Navigator. This is done because most current mail user agents (e.g., Microsoft Outlook, Eudora, etc.) do not support such secure channels although they support the display of HTML documents. One possible alternative to the embodiment discussed above it to “hide” the new browser window 310 from the end user. In such an embodiment, confirmation of the transaction could be provided by way of a separate email from the transaction server 320 or the merchant server 330 to the mail user agent 140 rather than through the download of a confirmation web page to the new browser window 310 . Of course, the need for a new browser window 310 may be eliminated entirely if the mail user agent 120 is equipped to support secure channel communications.
[0023] In the embodiment discussed above, the transaction server 320 and the merchant server 330 are illustrated as separate entities. Such an arrangement allows for a service provider to act as a “middle man” between the customer and the merchant selling the goods, thereby eliminating the need for any modification to the merchant's web site to be performed. This provides the opportunity for a fee to be collected by the service provider for all transactions forwarded to the merchant server 330 . Such a fee might be collected as a result of the service provider having prepared and/or sent the email 200 . In other embodiments, the browser window 310 communicates directly with the merchant server 330 , thereby “cutting out the middle man.”
[0024] In alternate embodiments, the functions of other entities shown as separate may be performed by the same physical device. For example, the functions performed by the mail transfer agent 120 and the transaction server 320 may be performed by a single server. Those of skill in the art will recognize that other combinations of functions are similarly possible.
[0025] Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | In a method and apparatus for conducting electronic commerce, an email is sent to a prospective customer. The email includes an offer for sale, a field in which customer information may be entered by the customer, and a button which may be activated by the customer to accept the offer. Upon activation of the button, a secure communications channel is established between the customer's computer and a transaction server. The secure channel is preferably established by spawning a browser window and using support for secure channels built into the browser. The acceptance of the offer is sent via the secure channel and a confirmation of the offer is then sent to the customer, preferably to the browser window. The order may be forwarded to a merchant for processing. | 6 |
This is a divisional of Application Ser. No. 07/689,671 pending filed Apr. 23, 1991, which is a continuation of Application Ser. No. 07/264,604 filed Oct. 31, 1988, now abandoned.
FIELD OF THE INVENTION
The present invention is directed to magnetic data storage devices and more particularly to a magnetic data storage device within a substantially sealed enclosure that has the transducer separated from the media by a thin film of recirculated, low viscosity liquid lubricant.
BACKGROUND OF THE INVENTION
State of the art magnetic disk drives presently, and for some time have used a transducer carrying slider which flies over the media surface and is separated therefrom by a film of air. As recording densities become greater, the head is required to fly lower and the magnetic layer of the media becomes thinner. When the spacing between head and media is reduced from 25 or more microinches to fewer than ten microinches and the media magnetic layer thickness is reduced from as much as 50 to fewer than 5 microinches, the physical contact that occasionally occurs between head and media is of major concern.
To provide an acceptable rigid disk drive lifetime, the current technology employs a thin layer of a fluorocarbon lubricant applied to the magnetic medium during manufacture of the disk. This lubricant film is critically needed by the. head/disk interface (HDI) to minimize wear to these components and significantly extend the lifetime of the disk drive to an acceptable level. A problem with this technology arises from depletion of the lubricant film with use. The loss of lubricant can be attributed to hydrodynamic ejection from the HDI due to air shear phenomena, thermal volatilization, thermal decomposition followed by bonding to the medium and lubricant spinoff.
These, and other wear processes at the HDI increase as the lubricant is lost and ultimately result in failure. The total wear to the HDI can be categorized into two distinct modes; first, a rapid wear rate that occurs during start/stop operations and second, a slower wear rate due to repeated high speed contacts at the HDI during normal file operations (disk at or near maximum speed). Wear associated with the start/stop process is only slightly dependent on head fly height, whereas for the latter case, a lowering of the fly height will dramatically increase the wear rate at disk drive operating speed (flyability). The increase for this latter case-has been attributed to an increase in the collision frequency with disk asperities and debris (both foreign and from generated wear products). In this case, the presence of a lubricant film plays a critical role in protecting the HDI, but with the reduction in head fly height the lubricant film is also depleted more rapidly. Thus, for these reasons a reduction in flying height greatly increases the likelihood of early disk drive failure. The reason for reducing head flying height is to obtain an increase in the magnetic storage density. An additional problem encountered here is to also reduce the wear rate to the head gap. For these reasons, and because of their relationship to disk drive reliability, the current technology is limited by the achievable lowest flying height as a barrier to further increases in data storage density.
A proposed technique for providing a continuous lubricant supply for a magnetic media surface is shown in U.S. Pat. Nos. 2,969,435 and 3,005,675. In both patents a supply of lubricant is sprayed onto the disk or drum surface ahead of the area of contact between transducer head and media surface. This mode of placing a layer of lubricant on the media surface would not be compatible with the system of the present invention wherein a transducer is made to adjoin the media during relative motion therebetween with a separation of but 1 or 2 microinches. A later patent, U.S. Pat. No. 4,633,351 attempts to overcome some of the problems associated with the earlier patented techniques by spraying water or a volatile liquid solvent ahead of the transducer to create a thin liquid film between the head and the recording media surface.
SUMMARY OF THE INVENTION
The present invention resolves the reliability problem associated with near contact recording by supplying a recirculating film of liquid lubricant with the transducer head supported on a lubricant film rather than on a layer of air. The higher viscosity and lack of compressibility of the fluid film separating the transducer and storage medium allows the transducer to be reliably maintained at a significantly lower fly height. A separation of one to two microinches between the transducer carrying slider and the disk surface can be maintained.
The system includes a wick structure that carries liquid lubricant from the reservoir at the lowest point in the head disk enclosure to the disk at the inner diameter of the disk storage surface by capillary action. The liquid is gradually spun by the centrifugal force of the spinning disk to the periphery from which it leaves as minute droplets to return by gravity to the reservoir. The wick structure may be formed of any absorbant material that does not shed particulate matter within the enclosure. It may take the form of a porous plastic or even be made of a material such as a type of "clean room" paper that is highly absorbant while having the property of not releasing fibers or other constituents of which it is composed as particulate debris.
The liquid lubricant also differs in character from that used in conventional systems that use air bearings and storage disks with permanently applied lubricants. The lubricant may be similar to such formulations, but has a much lower viscosity to provide the desired thin lubricant film at the disk rotational speeds and the environmental temperature range in which the drive is required to function.
Although the transducer head suspensions used in the practice of the invention can be the same as used in air bearing type system, typically of the Winchester or Whitney designs, the slider or transducer head structure must be modified to adapt to the use of a liquid film rather than an air film. Instead of the multiple rails that present air bearing surfaces, the modified slider can use a single rail with a very narrow bearing surface or an even more effective design that present three minute triangular feet. In the latter design one foot adjoins the leading edge and two are at the trailing edge and terminate rearwardly at the thin film transducers. Thus a much smaller bearing surface is used with the more viscous bearing fluid.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic plan view with the cover removed showing a disk drive incorporating the present invention.
FIG. 2 is a vertical section of the disk drive of FIG. 1.
FIG. 3 is a side -elevation of a transducer head structure used in the practice of the present invention.
FIG. 4 is a bottom view of the head shown in FIG. 3.
FIG. 5 shows the structure of one of the feet that present the bearing surface upon which the slider is supported.
FIG. 6 is a schematic showing of an alternative embodiment of a disk drive lubricant recirculating system using a pumping action integral with the hub-disk assembly.
FIG. 7 is a schematic showing of a further alternative embodiment of a lubricant recirculating system using a distillation technique.
DETAILED DESCRIPTION
FIGS. 1 and 2 respectively show a schematic plan view of a drive with the cover removed and a sectional elevation. Illustrated is a typical rigid disk drive with a linear voice coil motor (VCM) driven actuator 10. The actuator 10 drives a head-arm assembly which may include typical head suspension devices 11 such as the common Winchester or Whitney suspension designs. The head assembly is contained within an enclosure including a cast base member 12 which also serves as a liquid lubricant reservoir and a cover 13 which has a flange 14 that compresses a gasket 15 against the upper planar surface of the base 12 casting to effect a seal. The rigid disk media 17 are carried by the hub 18 that is mounted to rotate in unison with the rotor of a spindle motor positioned within an upwardly extending depression 20 in base 12. The motor shaft extends through a bearing tower to connect to the hub 18.
The liquid lubricant used in the system of the present invention is required to be thermally stable, have a correct viscosity which is very low and be non-reactive. A simple, straight chain hydrocarbon with the desired low viscosity and a simple molecule that will not degrade is recommended. In operation, hexadecane has been used. Lubricants commonly used on disk surfaces, but having much reduced viscosity are satisfactory. However, with the greater quantity of lubricant used in the present technique as compared with the quantity required for the normal single application to the disk surface, the cost of the material becomes a factor in lubricant selection. A wick structure 22 is formed of porous material, such as plastic, ceramic or paper. The wick structure 22 must possess porosity to permit liquid lubricant to travel by capillary action from the reservoir 23 formed in base 12 to the media surface in minute quantities to replenish and maintain a film of lubricant on the media surfaces. The material of the wick 22, in addition to providing a capillary path, must also not shed particles and thereby become a source of particulate material within the enclosure. The film thickness should preferably be one micron and should not exceed 5 microns, since as the film thickness increases, the power required to drive the heads through the lubricant film increases. As the lubricant is spun off the disk and replaced, the wick 22 also functions as a lubricant filter to prevent the recirculation of particles captured in the liquid lubricant back to the media surfaces.
To minimize wear between the wick and the location of contact at the ID of the disk, the wick should generate lift and fly' like the slider. The loading pressure of the wick on the disk can be much lighter than for the slider, because the sliding height can be much higher and less tightly controlled.
Recirculation need not be accomplished using a wick structure. Two alternative methods are illustrated in FIGS. 6 and 7. Lubricant can be transported with no contacting parts using the left handed spiral passage of the embodiment of FIG. 6 or the distillation technique of FIG. 7.
FIGS. 6 and 7 show a base casting 50 that defines a liquid reservoir and is enclosed by a base cover 51. Disks 53 are mounted for rotation on a hub 55 and separated by a spacer 56. The disks 53 are compressively retained between a hub flange surface 57 and a confining surface 59 on the clamping member 60. An actuator 62 mounts the transducer heads 63 for movement between concentric tracks on the disk surfaces. Lubricant is supplied to the annular space 65 between the hub 55 and the assembly of disks 53 and spacer 56. Radial scratches or recesses in the hub surface 57, clamp surface 59 and the upper and lower spacer surfaces 66 provide a passage for the lubricant from the annular space 65 to the disk surfaces, with the size of such passages affording the limitation on the rate of fluid distribution to the respective disk surfaces.
In FIG. 6, a thin plate member 70 isolates the fluid in the reservoir volume from the windage effect of the confronting rotating disk surfaces and permits the lubricant to flow radially inward toward hub 55 through an annular filter 71. The hub has a left handed spiral recess 72 formed in the inner surface that draws lubricant upward as the hub assembly rotates for delivery through the radial passages 74 to the annular space 65.
The method of recirculation by distillation (FIG. 7) is most effective in the case of a hermetically sealed file with the lubricant under its own vapor pressure (no air present). The lubricant evaporates from the warmer parts of the file and condenses on the relatively cool cover 51. The cover is contoured with a conical depression 80 such that the condensate will drain to a point directly above the spinning hub assembly and drip into a hub clamp member opening 81. The passage through the clamp member opening has a conical side wall surface 82 that increases in diameter in the downward direction so that centrifugal force will not fling the liquid out of the passageway. In operation, the distillation should proceed slightly faster than the lubricant flow rate required for the disks so that the intermediate reservoir at the top of the hub will remain full. Excess lubricant overflows from the top of the hub and is flung harmlessly to the file walls.
In the device of FIG. 7, the heat generated by an electronic circuit card (not shown) below the head-disk enclosure and the heat generated by the motor will be sufficient to drive this distillation process. The top cover 51 is the coolest area of the drive enclosure and localized cooling is provided at the contoured, conical surface 80 overlying the hub by the provision of cooling fins 83 at the outer surface. In this mode of lubricant recirculation a filter is not required since particulate material is retained in the reservoir and is not recirculated with the lubricant vapor.
Although many of the drive system assemblies, such as the actuator 10, transducer suspensions 11 and disk assemblies, are of conventional design, the head structure is a total departure from the normal slider designs used with the more common transducers that are separated from the media surface by a film of air.
Initially a three rail head was used with the rails reduced in width to reduce the fluid bearing surface to meet the needs of a system using a liquid film rather than a film of air to support a slider above the recording surface. This emulated the air bearing sliders which have been the most successful in current practice while using a reduced bearing area in response to the recognized greater supporting capability of a liquid film.
A further development resulted in the slider 25 shown in FIG. 3 which is of normal length, about 4 millimeters and has a mounting groove 26 to permit attachment to the gimbal spring structure of a standard Winchester suspension; however, the bearing surfaces are wholly different. As more clearly seen in the bottom view of FIG. 4, instead of the rails or other air bearing surfaces or even very narrow rails with greatly reduced air bearing surface areas, the bearing surfaces are more optimally provided by the three very small feet 28, 29.
The modified slider structure is shown in FIGS. 3 through 5. The slider as illustrated has substantially the same overall dimensions as the air bearing sliders used in current product lines, a length of 4.025 millimeters, a width of 3.207 millimeters and a height of less than one millimeter. The feet 28, 29; however, are short, narrow and present very minute fluid bearing surfaces 30. The feet can be 0.0057 inches in length with a triangular form. The surface includes a 10 degree included angle at the leading end and is only 0.001 inch wide at the trailing edge. Each foot depends downwardly from the lower surface of the slider body a distance of 25 to 50 microns with the foot side walls 31 that extend to join the lower slider surface curved to blend into the slider body. This provides greater strength for the physically small foot. Because the bearing surface is so small, the slider body could be made much smaller than that shown which was based on dimensions used for air bearing type sliders.
In addition to two rail and three rails sliders with reduced area rail bearing surfaces, that are suggested by the prior art air bearing sliders and the three triangular foot configuration that is shown and described, numerous other bearing surface configuration are operable. The number of triangular feet may be varied and the positioning of the feet can be changed. Also, other bearing surface shapes can be used such as rectangular feet.
As seen in FIG. 5, the 10 degree included angle at the leading edge of the foot is between one side 33 that extends parallel to the axis of the slider and the other side 34 is inclined thereto. The side of the foot parallel to the slider axis is disposed toward the disk inner diameter and the inclined surface is positioned facing the outer diameter. This angled relationship of the triangular sides of the feet 28, 29 extending from the foot leading portion enable the lubricant film and any minute debris that might be included therein to be deflected toward the disk outer diameter and ultimately, off the disk. The transducer 37 or transducers carried by the slider 25 are of the thin film type mounted on the rear surface 36 and presenting the transducing gap at the edge 35 of the foot 28.
Ferrite core heads have also been made and the magnetic performance demonstrated. With such heads, the glassed gap is incorporated into one (or more) of the feet at the point where the foot width is equal to the desired magnetic track width.
The depth of the lubricant film does not exceed 5 microns and preferably has a thickness of about 1 micron. The feet 28, 29 which are 25 to 50 microns in height, hold the body of the slider above the lubricant as the bearing surfaces are supported only 1 to 2 microinches above the media surface. The slider has been operated using a 3.5 gram load which causes a pressure at the bearing surface of less than 1000 pounds per square inch. In practice, the pressure is about 800 pounds per square inch across the fluid film at the bearing surface. If a higher gram load is desired, the area of the bearing surfaces can be increased by designing the linear dimensions to be longer, and maintaining the same angles.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the spirit and scope of the invention. | A rotating magnetic storage device is shown wherein the transducer and media are separated during operation by a thin film of low viscosity liquid lubricant that is recirculated from a reservoir within the head-media enclosure. Lubricant recirculation can be effected by capillary action using a wick, mechanical pumping and metering or distillation techniques. As compared to devices using air bearing separation, the transducer carrying slider has very small bearing surfaces which may be in the form of narrow rails or small depending foot elements. This enables fly heights. of 2 microinches using a film of one micron thickness. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to centrifugal casting equipment having a vacuum assist.
2. Description of the Prior Art
Centrifugal casting techniques rotate the molds containing the casting cavities. The cavities are displaced from the axis of rotation so as to rotate about the axis. The centrifugal forces generated by this rotation drives the casting material into the cavities.
A typical casting system of this type employs molds comprised of two discs of silicone or organic rubber. Models of the items to be molded are placed between the mold discs. The mold discs are then placed in a vulcanizing machine. Pressure and heat are applied to the molds to vulcanize the rubber and form it around the patterns.
After curing, the molds are separated and the patterns removed. Runners are cut from a central sprue of the molds to the edge of each cavity.
The molds are then reassembled and placed in a centrifugal casting machine. After the casting machine has begun spinning, the casting material, such as precatalyzed resin or low temperature metal alloy, is poured in the central sprue. The casting material is thrown into the mold cavities by the centrifugal force where it solidifies. The mold halves are then separated and the castings removed.
While the technique of centrifugal casting has been found to be highly satisfactory, several shortcomings have been noted. It may be difficult to insure that the air displaced by the casting material can escape the cavity. While vents may be provided to the cavity, air can still become trapped in undercuts preventing formation of perfect castings. The turbulence of the casting material and air in the cavity often results in internal voids in the casting.
SUMMARY OF THE PRESENT INVENTION
It is, therefore, the object of the present invention to provide an improvement in centrifugal casting apparatus which enhances the quality of the castings formed by such equipment.
Another object of the present invention is to provide such an improvement which may be fitted to existing centrifugal casting machines without the need for major alteration of the existing equipment.
Briefly, the present invention contemplates applying a vacuum to the cavities of the mold to withdraw the air from the mold prior to filling and thereby insure complete and rapid filling of the cavities. Superior castings are also provided.
The assistance in filling the casting cavity provided by the vacuum permits the use of lower speeds in the centrifugal casting machine and lower temperatures for molten casting materials. The lower temperatures decreases the cycle time of the machine and increases the life of molds such as the silicone rubber molds described above. The lower temperatures and speeds and the vacuum obtained with the present invention improve the quality of the castings by producing denser castings having a minimum of shrinkage and low porosity through a reduction of turbulence within the cavity.
The vacuum also assists in holding the molds together reducing the pressure needed to seal the molds. By reducing the pressure in the mold cavities, the likelihood of distortion of the mold and cavity is significantly reduced.
The vacuum may be applied to the cavity by providing a passage in the shaft which provides rotation to the molds. One end of this passage is connected to a source of vacuum. The other end of the passage opens on the plate which supports the molds on the shaft. A conduit is provided in the molds which connects the mold cavities to the exterior of the molds. Connection means are provided to interconnect the passage and the conduits, thereby to apply the vacuum to the casting cavities.
The end of the shaft passage may open on the surface of the plate which receives the molds. In this event the conduit opens on the abutting surface of the molds and may be connected to the passage by radial channels in the plate. In another embodiment of the invention, the conduit and passage open on the periphery of the molds and plate and a peripheral connection means, typically a peripheral chamber, is employed for purposes of interconnection.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the centrifugal casing machine incorporating the present invention.
FIG. 2 is a perspective view of portions of the centrifugal casting machine shown in FIG. 1 showing one embodiment of the present invention.
FIG. 3 is a partially broken away elevational view showing one embodiment of the present invention.
FIG. 4 is a partially broken away elevational view, with certain elements in cross section, showing another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIG. 1 a centrifugal casting machine 10. The machine includes a frame 12 which supports the machine on the floor. The machine also includes a shaft 14 journalled in frame 12. Shaft 14 is driven by motor 16 for rotation about a vertical axis.
As shown in FIG. 2, plate 18 is mounted on the upper end of shaft 14 to receive on its exposed surface 19, upper mold 20 and lower mold 22. Molds 20 and 22 may be formed of silicone or organic rubber or other suitable material including metal. Molds 20 and 22 contain the mold cavities in which the castings are formed. One such cavity 24 is exemplarily shown in FIG. 2. Upper mold 20 contains central sprue 26 through which the casting material is received in the molds. Lower mold 22 contains depression 28 at the lower end of sprue 26 and runner 30 connecting the sprue with cavity 24. Projections 32 on lower mold 22 mate with corresponding depressions on upper mold 20 for orienting the molds with respect to each other. A clamping means 34 is provided for clamping the molds together with central sprue 26 aligned with the axis of shaft 14. The clamping means may include an upper plate 36 containing funnel 38 for the casting material. Protective shroud 40 surrounds the rotating parts of casting machine 10.
In operation, molds 20 and 22 are clamped between plates 18 and 36 as by actuating air cylinder 42 coupled to the molds. Motor 16 is energized to rotate shaft 14, plates 18 and 36 and molds 20 and 22. The casting material, such as molten metal or catalyzable resin, is poured through funnel 38 into sprue 26 and depression 28. The casting material is flung by the centrifugal forces in the rotating molds down runner 30 and into cavity 24 to fill the cavity and form the casting. When the casting material has hardened, motor 16 is deenergized. Upper plate 36 and molds 20 and 22 are removed from plate 18 and separated along the parting line to remove the casting.
To provide the vacuum to cavity 24, a passage 42 is provided along the axis of shaft 14. The lower end of this passage is connected to rotary valve 44. See FIGS. 3 and 4. Rotary valve 44 connects passage 42 to vacuum tube 46 and vacuum pump 48 mounted on frame 12 as shown in FIG. 1. In the alternative, a central source of vacuum may be used for a plurality of machines. The upper end of passage 42 opens on surface 19 of plate 18 which abuts the lower surface of lower mold 22. In order to connect passage 42 with cavity 24, a plurality of vacuum channels are provided in surface 19 of plate 18. These channels may take the spoked wheel configuration shown in FIG. 2 containing spoke-like channels 50 and rim-like channel 52.
A vacuum channel 54 is cut in the parting surface of lower mold 22. A hole 56 is drilled through lower mold 22 from the end of vacuum channel 54 to open into one of the spoke-like channels 50 or rim-like channel 52 formed in surface 19 of plate 18.
In operation, molds 20 and 22 are assembled on plate 18, making sure that hole 56 opens into a spoke channel 50 or rim channel 52. Vacuum pump 48 is energized to produce a vacuum. The level of vacuum may be generally selected in accordance with the viscosity of the casting material. This vacuum is transmitted through vacuum tube 46, rotating valve 44, vacuum passage 42, the channels 48, 50 in plate 18, hole 56, vacuum channel 54 to cavity 24. Motor 16 is energized to rotate shaft 14, plates 18 and 36, and molds 20 and 22. The vacuum is maintained in cavity 24 by rotating valve 44. The casting material is poured in sprue 26 and supplied by centrifugal force down runner 30 into cavity 24. The evacuation of cavity 24 provided by the vacuum insures attainment of the advantages noted above.
The lessening of the squeezing pressure applied to the molds lessens the likelihood of the compression of molds 20 and 22. blocking channel 54 in the parting surface of one of the molds. The length of channel 54 may be selected so that any casting material drawn into the passage will harden in the channel where it can easily be removed upon opening the molds. Channel 54 may be made labyrithine for this purpose.
When the casting material has hardened, motor 16 and vacuum pump 48 are deenergized. After plates 18 and 36 and upper and lower molds 20 and 22 have stopped spinning, the molds are separated and the casting removed.
FIG. 4 shows an alternative embodiment of the present invention. In this embodiment, the vacuum passage 42 in shaft 14 does not open on surface 19 of plate 18 but rather is connected through plate 18 by vacuum passage 60 to the exterior of the plate.
Cavity 24 is connected to the exterior of one of molds 20 and 22 as by a channel along the parting line of the molds, similar to channel 54, or by the passage 62 through one of the molds shown in FIG. 4.
Upper plate 36 which assists in clamping the molds to plate 18 is formed with a depending skirt 66. Skirt 66 of cap 36 extends along the peripheral exterior of molds 20 and 22 and plate 18. An O-ring 68 mounted in groove 70 forms a seal between the lower edge of skirt 66 and plate 18 and chamber 72.
The operation of the embodiment shown in FIG. 4 resembles that of the embodiment shown in FIGS. 2 and 3. The vacuum applied to line 42 is passed through conduit 60 to chamber 72 formed on the exterior of the molds and plate by skirt 66 of cap 36. Cavity 24 is connected to chamber 72 as by passage 62 so that the cavity is evacuated during casting. | A centrifugal casting machine includes a rotatable shaft having a mounting plate for receiving a pair of molds containing the casting cavities. A passage in the shaft has one end connected to a source of vacuum and the other end opening in the plate. A conduit is provided from the casting cavities to the exterior of the molds. Connection means are provided for applying the vacuum in the passage to the cavity through the conduit. The vacuum so applied improves both the operation of the casting machine and the quality of the castings. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to embroidery machine, and more particularly, to an embroidery machine, in which a presser foot (a cloth pressing member) can be separately driven by its own drive source, independently from the drive source of a needle bar.
2. Description of the Related Art
Generally, an embroidery machine is a biaxial positioning control machine in which an embroidery stitch frame for fixing fabric undergoes horizontal motion in x-axis and y-axis directions while a needle bar thereof moves up and down.
Since this embroidery machine does needlework while the embroidery stitch frame, fixing the fabric, is transferred in x-axis and y-axis directions, the precise and constant-speed movement of the embroidery frame has a close relationship to the quality of an embroidered pattern.
Accordingly, a drive source of the embroidery machine, which transfers the needle bar in vertical directions and the embroidery stitch frame in the x-axis and y-axis directions, is generally implemented with a servo motor, which can be precisely controlled, or a motor, the position of which can be controlled.
FIG. 1 is a perspective view illustrating of the embroidery machine and partially expanded view of sewing head, FIG. 2A is a perspective view illustrating a drive structure for a presser foot and a needle bar of the embroidery machine of the prior art, and FIG. 2B is an expanded view of part “A” of FIG. 2A .
As shown in FIG. 1 , a plurality of sewing heads 2 is fixedly arranged in the front portion of an upper beam of an embroidery machine 1 along the length thereof. In each of the sewing heads 2 , an upper shaft (not shown) is arranged to laterally extend through a sewing arm 3 , and a needle bar support case 4 is assembled to the front portion of the sewing arm 3 in such a fashion that the needle bar support case 4 is laterally movable.
In the lower portion of the needle bar support case 4 , a plurality of presser feet 5 (so-called cloth pressing members), which act to prevent a sheet of cloth to be sewn from coming loose when it is being sewn, is provided. Each of the presser feet 5 is set to be vertically movable in cooperation with a needle bar (see the reference number 18 in FIG. 2A ).
The needle bar 18 is set to be vertically movable using the rotation driving force of an upper shaft motor (not shown), and a needle (not shown), which forms sewing eyes in the sheet of cloth to be sewn, is mounted on the lower end of the needle bar 18 .
Now the drive structure for the presser foot 5 and the needle bar 18 will be described more fully with reference to FIGS. 2A and 2B . A needle bar driving cam 10 is attached to the outer circumference of an upper shaft, which rotates using the rotation driving force of the upper shaft motor.
A needle bar driving rod 11 is mounted on the outer periphery of the needle bar driving cam 10 in such a fashion that the needle bar driving rod 11 is vertically displaceable in response to the amount of eccentricity of the needle bar driving cam 10 .
The needle bar driving rod 11 is connected to an intermediate portion of a needle bar drive lever 12 . Accordingly, the needle bar drive lever 12 can vertically pivot around a predetermined rotation point by a predetermined amount corresponding to the amount of eccentricity of the needle bar driving cam 10 .
The needle bar drive lever 12 is connected, by a needle bar link (not shown), to a needle bar drive block 13 , which is vertically movable on a needle bar guide shaft 15 , so that the needle bar drive block 13 can vertically move to the extent that the needle bar drive lever 12 rotates.
A needle bar controlling block 14 , which is rotatably provided inside the needle bar drive block 13 , can be coupled to or decoupled from a needle bar holder 17 a, which is fastened to the outer circumference of the needle bar 18 . A presser foot holder 6 is mounted on the outer circumference of the needle bar 18 under the needle bar holder 17 a, in such a fashion that it can move vertically.
A spring 19 having a predetermined elastic force is mounted between the needle bar holder 17 a and the presser foot holder 6 , and cooperates with the needle driver 18 in order to drive the presser foot 5 .
The presser foot holder 6 is fixedly fastened with the presser foot 5 , which prevents the sheet of cloth to be sewn from coming loose while it is being sewn. Now the drive structure for the needle bar 18 and the presser foot 5 , as constructed above, will be described in more detail.
The driving force of the upper shaft rotates the motor upper shaft, which in turn rotates the needle bar driving cam 10 fastened to the upper shaft, so that the needle bar driving rod 11 , the needle bar drive lever 12 and the needle bar drive block 13 operate cooperatively.
In a position where the needle bar holder 17 a, which is fixedly fastened to the outer circumference of the needle bar 18 , and the needle bar controlling block 14 , which is inserted into the needle bar drive block 13 , are coupled with each other, the needle bar 18 vertically reciprocates in response to the vertical movement of the needle bar drive block 13 . Here, the presser foot holder 6 , fastened to the presser foot 5 , operates using the elastic force of the spring 19 .
That is, the needle bar holder 17 a, which moves downward, generates a pressing force on the spring 19 , thereby pressing down the presser foot holder 6 . Then, the presser foot 5 , fastened to the presser foot holder 6 , moves downward in cooperation with the needle bar 18 .
Conversely, when the needle bar holder 17 a moves upward, the pressing force on the spring 19 is released, so that the needle bar holder 17 a on the lower end of the needle bar 18 pulls the presser foot 5 upward, thereby moving the presser foot 5 upward.
The conventional drive structure for the presser foot 5 , as described above, does not have a driving source, but operates in cooperation with the movement of the needle bar 18 . Accordingly, there are problems in that an operator or a user cannot freely change some parameters of the presser foot 5 , such as the stroke (i.e., the distance between the top dead point and the bottom dead point), the bottom dead point, and the moving track.
During the downward movement of the presser foot 5 , the presser foot holder 6 contacts the outer surface of the needle bar support case 4 to stop the presser foot 5 . However, the contact between the needle bar support case 4 and the presser foot holder 6 produces noise upon impact. Furthermore, since contact is frequent, the presser foot holder 6 is constantly vulnerable to damage.
SUMMARY OF THE INVENTION
The present invention has been made to solve the foregoing problems with the prior art, and therefore the present invention provides an embroidery machine, which has a separate drive structure for a presser foot, so that the stroke or the lower end point of a presser foot can be freely changed and the moving track of the presser foot can be freely generated.
The present invention also provides an embroidery machine, which has a height adjustment mechanism for a presser foot, so that the height of the presser foot can be adjusted according to the type or thickness of the sheet of cloth to be sewn.
According to an aspect of the present invention, there is provided an embroidery machine, which includes a sewing arm having an upper shaft for providing a driving force, a needle bar support case, which is assembled to a front portion of the sewing arm so as to be laterally movable, a needle bar provided in a needle bar support case, the needle bar having a needle at a lower end thereof and vertically carrying the needle using a rotation driving force of the upper shaft, and a presser foot, which is provided in the needle bar support case so as to be vertically movable, characterized in that each of the needle bar and the presser foot is operated by an individual drive mechanism.
In the embroidery machine of the invention, the presser foot drive mechanism may include a presser foot drive cam, which is fastened to the upper shaft so as to be rotated thereby; a presser foot drive cam transmission member, which is coupled with the outer circumference of the presser foot drive cam so as to be rocked thereby; a presser foot drive lever, which is connected to the presser foot drive transmission member so as to vertically pivot about a pivot point; a presser foot drive link, which vertically reciprocates according to the amount that the presser foot drive lever pivots; and a presser foot drive block, which reciprocates along a needle bar guide shaft in cooperation with vertical movement of the presser foot drive link.
In the embroidery machine of the invention, the presser foot drive cam transmission member may be a cam roller, which is in contact with a cam follower, the cam follower provided on the presser foot drive cam, or a drive rod, which is coupled with the outer circumference of the presser foot drive cam.
In the embroidery machine of the invention, the presser foot drive block may further include a presser foot holder gripper, which is fastened to a presser foot holder, wherein the presser foot holder is coupled with the outer circumference of the needle bar so as to be vertically slidable thereon.
In the embroidery machine of the invention, the presser foot drive block may include a buffer spring, which is coupled with the outer circumference of the needle bar guide shaft so as to be vertically reciprocable thereon together with the presser foot holder gripper.
In the embroidery machine of the invention, the presser foot holder gripper may be installed inside the presser foot drive block so as to be rotatable about the needle bar guide shaft, thereby being capable of coupling with or decoupling from the presser foot.
In the embroidery machine of the invention, the presser foot holder may be connected to a presser foot assembly, which is provided parallel to the needle bar and is vertically movable.
In the embroidery machine of the invention, the presser foot assembly may include a presser foot guide bushing, which is fastened to the presser foot holder; and a presser foot support, which is coupled at an upper end thereof with the presser foot guide bushing and at a lower end thereof with the presser foot.
In the embroidery machine of the invention, the presser foot assembly may further include a coupling bushing, which supports and fixes both the presser foot support and the needle bar.
In the embroidery machine of the invention, the presser foot may be detachably coupled with the lower end of the presser foot support.
In the embroidery machine of the invention, the presser foot drive mechanism may further include a presser foot height adjustment mechanism, which displaces the pivot point of the presser foot drive lever in a predetermined direction, thereby adjusting the height of the upper end point or the lower end point of the presser foot.
In the embroidery machine of the invention, the presser foot height adjustment mechanism may include a drive motor for generating a driving force; a drive pulley, which is operably coupled with a motor shaft of the drive motor; a follower pulley, which is connected to and rotates following the drive pulley; and an eccentric member having a drive shaft at one portion thereof and a fastening protrusion at the opposite central portion thereof, the fastening protrusion eccentrically protruding from the central portion, wherein the drive shaft is connected to the follower pulley and the fastening protrusion is connected to the pivot point of the presser foot drive lever, so that the eccentric member displaces the pivot point of the presser foot drive lever using the driving force from the drive motor.
In the embroidery machine of the invention, the presser foot height adjustment mechanism may further include an eccentric member support having a hollow space in the central portion thereof, through which the drive shaft of the eccentric member extends.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view illustrating of the embroidery machine and partially expanded view of sewing head;
FIG. 2A is a perspective view illustrating a drive structure for a presser foot and a needle bar of the embroidery machine of the prior art;
FIG. 2B is an expanded view of part “A” of FIG. 2A ;
FIG. 3 is a perspective view illustrating a sewing head having a drive structure for a presser foot according to an embodiment of the present invention;
FIG. 4A is a perspective view illustrating the drive structure for a presser foot according to the present invention;
FIG. 4B is an expanded view of part “B” of FIG. 4A , seen from one direction;
FIG. 4C is an expanded view of part “B” of FIG. 4A , seen from the other direction;
FIG. 5 is a side elevation view illustrating the drive structure for a presser foot according to the present invention, in the mounted position;
FIG. 6A is a perspective view illustrating the drive structure for a presser foot having a height adjustment mechanism according to the present invention;
FIG. 6B is an expanded view of part “C” of FIG. 6A ; and
FIG. 6C is an expanded perspective view illustrating the construction of the height adjustment mechanism of an embroidery machine according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embroidery machine according to the present invention will be described more fully with reference to the accompanying drawings.
FIG. 3 is a perspective view illustrating a sewing head having a drive structure for a presser foot according to an embodiment of the present invention, FIG. 4A is a perspective view illustrating the drive structure for a presser foot according to the present invention, FIG. 4B is an expanded view of part “B” of FIG. 4A , seen from one direction, FIG. 4C is an expanded view of part “B” of FIG. 4A , seen from the other direction, and FIG. 5 is a side elevation view illustrating the drive structure for a presser foot according to the present invention, in the mounted position.
Referring to FIGS. 3 to 5 , the embroidery machine of the present invention is constructed in such a fashion that each of the needle bar and the presser foot is actuated by an independent drive mechanism.
In the drive structure for a presser foot, as shown in FIGS. 4A to 5 , a rotation driving force from an upper shaft motor (not shown) rotates a presser foot drive cam 112 , which is fastened to the outer circumference of an upper shaft 104 , which extends through a sewing arm 102 .
Then, a presser foot driving power transmission unit rocks in cooperation with the rotation of the presser foot drive cam 112 , and a presser foot 128 , which is connected to the presser foot driving power transmission unit, vertically rocks in cooperation with the presser foot driving power transmission unit.
Here, in the presser foot driving power transmission unit, a presser foot drive cam transmission member 110 vertically reciprocates in cooperation with the rotation of the presser foot drive cam 112 , a presser foot drive lever 114 , which is connected to the presser foot drive cam transmission member 110 , vertically pivots about the pivot point 114 a of the central portion, and a presser foot drive link 116 vertically reciprocates according to the amount that the presser foot drive lever 114 pivots.
A presser foot drive block 118 also reciprocally moves along a needle bar guide shaft 130 according to the amount of vertical movement of the presser foot drive link 116 .
According to this embodiment of the present invention, the presser foot drive cam transmission member 110 is implemented with a presser foot drive rod, which is coupled to the outer circumference of the presser foot drive cam 112 , thereby rotatably housing the presser foot drive cam 112 therein, and thus vertically reciprocates according to the amount of eccentricity of the presser foot drive cam 112 , which rotates in cooperation with the rotation of the upper shaft 104 .
It should be understood, however, that the presser foot drive cam transmission member 110 of the present invention is not limited to the above-mentioned structure, but may be implemented with a cam roller (not shown), which contacts a cam follow, that is, a grooved track in the presser foot drive cam 112 .
The presser foot drive lever 114 is pivotally connected, at a first end thereof, to the lower end of the presser foot drive cam transmission member 110 , and is connected, at a second end thereof, to the presser foot drive link 116 , so that the two ends of the presser foot drive lever 114 reciprocally pivot around the pivot point 114 a of the central portion according to the amount of vertical movement of the presser foot drive cam transmission member 110 .
The presser foot drive link 116 is rotatably connected, at a first end thereof, to the second end of the presser foot drive lever 114 , and is pivotally connected, at a second end thereof, to the presser foot drive block 118 , so that it can vertically reciprocate according to the amount that the presser foot drive lever 114 pivots.
A presser foot holder 118 a is coupled to the outer circumference of the needle bar 132 to be vertically slidable, and is fastened to a presser foot holder gripper 118 b, which is disposed inside the presser foot drive block 118 . The presser foot drive block 118 is also connected to the second end of the presser foot drive link 116 . Accordingly, the presser foot drive block 118 can vertically reciprocate according to the amount of vertical movement of the presser foot drive link 116 .
A buffer spring 118 c having a predetermined amount of elasticity is housed, together with the presser foot holder gripper 118 b, inside the presser foot drive block 118 in such a fashion that the buffer spring 118 c can vertically reciprocate on the outer circumference of the needle bar guide shaft 130 while constantly pressing the presser foot holder gripper 118 b. This, as a result, makes it possible to prevent both the presser foot holder 118 a and the presser foot holder gripper 118 b from being damaged by an unexpected malfunction of the presser foot 128 .
Here, like the above-mentioned needle control block (see the reference number 14 in FIG. 2A ), the presser foot holder gripper 118 b can be set to pivot about the needle bar guide shaft 130 inside the presser foot drive block 118 so as to couple with or decouple from the presser foot holder 118 a, or, on the contrary, can be fixed so as not to pivot.
The presser foot holder 118 a, coupled with the presser foot holder gripper 118 b, is set to be vertically reciprocable on the outer circumference, and is coupled, at one portion thereof, with a presser foot assembly 120 .
The presser foot assembly 120 has a presser foot guide bushing 122 , which is fastened to the presser foot holder 118 a, and a presser foot support 124 , which is fixedly coupled with the bottom of the presser foot guide bushing 122 . The presser foot support 124 is arranged to be parallel to the needle bar 132 , and is coupled, at the bottom thereof, with the presser foot 128 .
The presser foot assembly 120 also includes an additional coupling bushing 126 , which fixedly holds both the lower end of the presser foot support 124 and the lower end of the needle bar 132 . The presser foot 128 is detachably coupled to the lower end of the presser foot support 124 via suitable fasteners, such as male and female threads, so that it can be freely mounted to and removed from the presser foot support 124 . In FIG. 3 , reference number 134 , which is not described, indicates a needle bar support case.
The drive structure for a presser foot according to this embodiment of the present invention will be described more fully with reference to the accompanying drawings.
When the upper shaft 104 rotates using the rotation driving force of the upper motor (not shown), the presser foot drive cam 112 , coupled to the upper shaft 104 , rotates in cooperation therewith. In response to the rotation of the presser foot drive cam 112 , the presser foot drive cam transmission member 110 vertically reciprocates according to the amount of eccentricity of the presser foot drive cam 112 .
As the presser foot drive cam transmission member 110 moves vertically, the presser foot drive lever 114 , connected to the lower end of the presser foot drive cam transmission member 110 , vertically pivots about the pivot point. In cooperation with this action, the presser foot drive block 118 , connected to the presser foot drive lever 114 via the presser foot drive link 116 , vertically reciprocates on the needle bar guide shaft 130 .
As the presser foot drive block 118 moves vertically, the presser foot holder 118 a, fastened to the presser foot holder gripper 118 b, which is housed inside the presser foot drive block 118 , vertically moves in cooperation with the presser foot drive block 118 . In cooperation with this action, the presser foot assembly 120 , fastened to the presser foot holder 118 a, also moves vertically.
Furthermore, the needle bar 132 , connected to the bottom of the presser foot holder 118 a, which is fastened to the presser foot drive block 118 , vertically moves inside the sewing head 100 , and the presser foot 128 , coupled to the lower end of the presser foot support 124 , also vertically operates.
FIG. 6A is a perspective view illustrating the drive structure for a presser foot having a height adjustment mechanism according to the present invention, FIG. 6B is an expanded view of part “C” of FIG. 6A , and FIG. 6C is an expanded perspective view illustrating the construction of the height adjustment mechanism of a sewing machine according to the present invention.
Referring to FIGS. 6A to 6C , the height adjustment mechanism of the present invention acts to displace the pivot point of the presser foot drive lever 114 in a predetermined direction, thereby adjusting the upper dead point and the lower dead point of the presser foot 128 , and includes a drive motor 140 , a drive pulley 142 , operably coupled with the drive motor 140 , a follower pulley 143 , which is connected to and rotates following the drive pulley 142 , and an eccentric member 145 , which displaces the pivot point of the presser foot drive lever 114 using the driving force of the drive motor 140 .
The drive motor 140 has a motor shaft protruding from one face thereof, and the front face of a case storing the drive motor 140 is bolt-fastened to one face of the sewing arm 102 via a connector bracket 141 , which has a U-shaped cross section when seen from the front.
The drive pulley 142 is attached to the motor shaft of the drive motor 140 , and is connected, via a belt 146 , to the follower pulley 143 , which has a larger diameter. The eccentric member 145 extends through both a hollow space 144 a of a cylindrical eccentric member support 144 and a hole of the follower pulley 143 , and is then connected to the follower pulley 143 .
While the drive pulley 142 and the follower pulley 143 are connected to each other via the belt 146 in this embodiment of the present invention, they may be directly meshed with each other.
The eccentric member 145 has a cylindrical body 145 a, a drive shaft 145 b, which protrudes from one face of the cylindrical body 145 a, and a fastening protrusion 145 c, which is formed in the opposite face of the cylindrical body 145 a and eccentrically protrudes from the center thereof. The eccentric member 145 is connected, at the drive shaft 145 b, to the follower pulley 143 , and at the meshing protrusion 145 c, to the pivot point 114 a of the presser drive lever 114 , so that the pivot point 114 a of the presser foot drive lever 114 can be displaced upward or downward by the eccentric member 145 .
According to the present invention, the position of the upper and lower dead points of the presser foot 128 can be easily and correctly controlled, since the pivot point 114 a of the presser foot drive lever 114 can be displaced upward or downward through the control of the drive motor 140 . Accordingly, this makes it possible to automatically control a sewing operation in response to the thickness of a sheet of cloth to be sewn.
That is, in the case where the presser foot 128 is required to be raised to a predetermined height, the drive pulley 142 rotates in response to the counterclockwise rotation of the drive motor 140 . The rotation of the drive pulley 142 is transmitted to the follower pulley 143 , and then, through the eccentric member support 144 and the eccentric member 145 , to the presser foot drive lever 114 .
Furthermore, the transmission of the rotation, as described above, acts to raise the presser foot drive block 118 through the presser foot drive link 116 . In response to the upward movement of the needle bar 132 , connected to the presser foot holder 118 a, which is fastened to the presser foot drive block 118 , the presser foot 128 also rises to a predetermined height.
In the opposite case, where the presser foot 128 is about to descend to a predetermined height, a rotational force from clockwise operation of the drive motor 140 acts, through the presser foot drive link 116 , on the presser foot 118 , thereby causing the presser foot 118 to descend. Then, the needle bar 132 , connected to the presser foot holder 118 a, moves downward, and, in response to this descent, the presser foot 128 also moves downward.
Accordingly, the presser foot height adjustment mechanism makes it possible to adjust the height of the lower end point of the presser foot 128 according to the thickness of the sheet of cloth to be sewn. That is, it is possible to adjust the height of the presser foot 128 by displacing the pivot point 114 a of the presser foot drive lever 114 .
In a sewing operation, when a sheet of cloth to be sewn is relatively thick, the height adjustment mechanism is operated to raise the height of the lower dead point of the presser foot 128 . When the sheet of cloth to be sewn is relatively thin, the height adjustment mechanism is operated to lower the height of the lower dead point of the presser foot 128 .
A program can be used to automatically control the drive motor 140 according to the thickness of the sheet of cloth to be sewn. For example, in the case where a sewing pattern is inputted, an embroidery stitch frame, to which fabric is fixed, is slightly moved in x-axis and y-axis directions, followed by manually determining the position at which the thickness of the sheet of cloth is changed.
Then, the determined position and the height of the presser foot 128 from a needle plate (not shown) at the determined position (or the number of drive pulses inputted to the drive motor) are inputted as data, or rather than the input data, the number of needles up to the position where the thickness of the sheet of cloth changes is set.
Accordingly, in a sewing operation, when the position where the thickness of the sheet of cloth changes is reached, the number of pulses (or the number of needles) is supplied according to the height inputted to the drive motor 140 , so that the lower end point of the presser foot 128 can be automatically controlled.
According to the invention as set forth above, the presser foot is driven by a separate drive structure, independently from the needle bar, so that the moving track of the presser foot can be freely generated, and thus the stroke or the lower end point of the presser foot can be freely produced.
Furthermore, the height adjustment mechanism can adjust the height of the presser foot according to the type or thickness of a sheet of cloth to be sewn, thereby enhancing the efficiency of an embroidery machine operation.
While the embroidery machine of the present invention has been described with reference to the particular illustrative embodiments and the accompanying drawings, it is not to be limited thereto. It is to be appreciated that those skilled in the art can substitute, change or modify the embodiments in various forms without departing from the scope and spirit of the present invention. | An embroidery machine includes a sewing arm having an upper shaft for providing a driving force, a needle bar support case, which is assembled to a front portion of the sewing arm so as to be laterally movable, a needle bar provided in a needle bar support case, the needle bar having a needle at a lower end thereof and vertically carrying the needle using a rotation driving force of the upper shaft, and a presser foot, which is provided in the needle bar support case so as to be vertically movable, characterized in that each of the needle bar and the presser foot is operated by an individual drive mechanism. The presser foot is separately driven by its own drive source, independent of the drive source of the needle bar. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a device for recording and/or reading binary data on both faces of a flexible magnetic disk, which may be contained in a cardboard or plastics sleeve. The magnetic disk is normally constituted by a thin plastics sheet coated on both sides with a layer of magnetisable material, and can rotate inside its sleeve by virtue of the presence of a lubricating material. The sleeve has a central through hole via which access can be gained to the magnetic disk from both sides in order to rotate it by drive means. The faces of the sleeve are provided with a pair of opposed slots disposed radially relative to the disk, through which access can be gained to the disk by means of the magnetic recording and/or reading heads.
Before bringing the magnetic heads into contact with the disk faces, the sleeve is urged by a presser against a fixed reference surface, in order to flatten the sleeve in a zone close to its radial slots, and thus position the disk in a nominal working plane.
A recording and/or reading device is known in which two arms disposed on opposite sides of the disk are pivoted to a carriage mobile radially along the axis of the sleeve slots, and are both movable between a rest position, in which they are spaced well away from the magnetisable surfaces of the disk, and a working position in which they are in proximity to the disk. A magnetic head is mounted by means of a very yieldable spring at the end of each arm, and can rotate in all directions about a central support. During reading and/or recording operations, the two opposing heads are kept in contact with the disk faces by means of a very small load, of about 8 grams. Because of this and the great yieldability of their springs, the magnetic heads are in theory free to follow every oscillation of the disk during its rotation, and can also move along an axis perpendicular to the plane of the disk, if this latter becomes disposed in a plane other than its nominal plane of rotation.
Beside requiring high precision in tests of its assembly and its setting in the apparatus in which it is mounted, this device has the drawback of causing excessive wear of the disk, in particular during the stage in which the heads "land" on the magnetised surfaces, and of providing very inconstant contact between the magnetic heads and the disk, and as a consequence a signal which is of non-uniform amplitude.
In another known device, the lower magnetic head is fixed on to the carriage, and its surface which makes contact with the disk is perfectly flat in order to define a reference surface against which the disk rests with its lower face.
The lower head is positioned on the carriage in such a manner that its flat surface is always above the nominal plane of rotation of the disk so that, during operation, the head "penetrates" into the disk, deforming it locally. A load of about 18 grams is applied to the upper head, which is of the type in the device described heretofore, and this tends to flatten the disk zone between the heads against the flat surface of the lower head. The lower head is therefore in an absolutely fixed position relative to the direction normal to the plane of the disk. Moreover, the disk can become positioned in planes other than the nominal plane because of the sleeve tolerances, and the tolerances of the entire recording and/or reading apparatus. The consequence is that this latter device has the drawback of very variable local deformation of the disk. Under marginal apparatus and disk conditions, due to variations in their friction coefficient and sleeve thicknesses, this causes inconstant head-disk contact, and a signal of non-uniform amplitude. Moreover, when this local deformation reaches the upper limiting level, there is considerable wear of the disk during its rotation.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a device for recording and/or reading binary data on both faces of a flexible magnetic disk, in which the head-disk contact is always ensured and constant, in order to provide a recorded and/or read signal which is uniform in amplitude, and in which the heads do not subject the disk to wear during its rotation. The device according to the invention comprises means for supporting and rotating the disk, a carriage mobile radially relative to the disk, a first magnetic head resiliently mounted at the end of an arm pivoted to the carriage in order to bear against a first face of the disk, and a second magnetic head mounted in an opposed position to the first head in order to bear against a second face of the disk, wherein the second head is connected to the carriage by resilient means such as to allow it to move along an axis perpendicular to the plane of the disk, substantially without rotating.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be described in more detail, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a partly sectional plan view of a device embodying the invention;
FIG. 2 is a partly sectional side view of the device of FIG. 1;
FIG. 3 is a section on the line 3--3 of FIG. 1;
FIG. 4 is a plan view of a first detail of the device during a manufacturing stage;
FIG. 5 is an enlarged detail of the device; and
FIG. 6 is a diagrammatic plan view of a flexible magnetic disk of the type handled by the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The device embodying the invention can record and/or read binary data on both faces of a flexible magnetic disk 10 (FIG. 6) contained in a sleeve 11 which is substantially square and closed on all sides. The magnetic disk 10, known commercially as a "floppy disk" is constituted by a thin plastics sheet having a thickness of about 0.08 mm coated on both faces with a layer of magnetisable material a few microns thick, and can rotate in the sleeve 11 without damage, due to the presence of a lubricating material. A spindle of known type, not shown on the drawings, can engage with the disk 10 through a central hole 12 in the sleeve 11, and rotate it.
The sleeve 11 is also provided with a pair of opposed slots 14 (FIGS. 3 and 7) disposed radially to the disk 10. In the zone comprising the slots 14, the thickness of the sleeve 11 is about 1 millimeter. The apparatus which handle such flexible magnetic disks are conventionally provided with a fixed horizontal reference surface 16 (FIGS. 1 and 3), on which the sleeve 11 rests. The sleeve is pressed down by a plate 18 with a force P of about 80 grams. The effect of the force P is that the sleeve 11 and disk 10 tend to become flattened and become disposed in a nominal working plane n, (FIG. 5). In particular, as one side of the sleeve has a thickness of about 0.45 mm with a tolerance of ±150 μm, the nominal theoretical plane n in which the lower face of the disk becomes disposed is 0.45 mm±150 μm higher than the plane of the reference surface 16.
The device embodying the invention (FIGS. 1 and 2) comprises a plastics carriage 20 with a rear body 21 (to the left of the figures) and two substantially parallel lateral arms 22 and 23. The carriage 20 is slidable on two cylindrical guides 26 and 27 along an axis x, radial with respect to the disk 10, by means of two bushes 24 integral with and projecting laterally from the arm 22, and a pair of guide lugs 25 integral with and projecting laterally from the arm 23. The carriage 20 is driven along the guides 26 and 27 in known manner, for example by means of an electric motor.
A magnetic head 30, which will be described in detail hereinafter, is cemented on to a plastics block 31 located in the front part of the carriage 20, and connected to the rear body 21 by means of two parallel leaf springs 32 disposed in a substantially horizontal plane when in their rest position. These springs 32 are about 20 mm long, and have a substantially linear elastic characteristic with a very low coefficient of elasticity, for example 0.015 mm/g. Springs 32, a magnetic head 30 and carriage 20 form a virtual articulated parallelogram. The assembly of the spring 32 will also be described in detail hereinafter.
An upper arm 36 is pivoted, by means of two lugs 35 thereof, on a pin 33 in the rear body 21, and its front end carries a further magnetic head 37 opposing the head 30. The pin 33 is of metal, and has its central cylindrical part 28 housed in a bore 29 in the rear body 21. The two ends of the pin 33 are conical, and each is housed in a corresponding bore 34 of the lugs 35, which have a diameter smaller than the central part 28 of the pin 33. The lugs 35 are of metal, and are resiliently urged towards the body 21 of the carriage 20 so as to totally take up the slack between their bores 34 and the conical ends of the pin 33.
A spring 38 of known type resiliently connects the head 37 to two projections 39 and 40 of the arm 36, in such a manner as to enable the head to rotate in any direction about a central support 41.
The arm 36 is also provided with a lateral lug 42, by means of which a control electromagnet, of known type and not shown on the drawings, can selectively move the upper magnetic head 37 away from the disk 10, or allow it to go towards the disk 10. A helical spring 43 compressed between the rear body 21 and a tail end 44 of the arm 36, tends to urge the head 37 downwards with a predetermined force F (FIG. 3) of about 15 grams.
The lower head 30 (FIG. 5) is of the type known as a "button head", with a central surface 50 which is normally in contact with the lower face of the disk, and which is connected to the base by means of an annular connection portion 51 having a radius R 1 of about 50 mm. In order to improve the head-disk contact and limit the wear of this latter, the surface 50 instead of being flat or hemispherical, as in the case of known heads, is cylindrical and has its generating lines parallel to the axis x. The radius of curvature R 2 of the surface 50 exceeds 100 mm and may be about 150 mm.
The leaf springs 32 are assembled on the carriage 20 as follows. Initially, the block 31 (FIG. 4) is connected to the rear body 21 of the carriage 20 by means of four struts 52 parallel to the axis x, formed during the moulding of the carriage 20. In addition, during moulding, the body 21 is so profiled that it comprises a first centering pin 54 (FIG. 2), while the block 31 comprises a second centering pin 55.
The leaf springs 32 are embedded separately at their ends in two plastics blocks 56 and 57 of substantially parallelepiped shape, each comprising a central bore, 58 and 59 respectively. The two blocks 56 and 57 are then cemented one to the body 21 of the carriage 20 and the other to the front block 31. On being inserted into the bores 58, 59 respectively, the pins 54 and 55 position the springs 32 accurately relative to the body 21 and block 31.
After cementing the blocks 56 and 57, the struts 52 are removed, thus providing a resilient connection between the block 31 and body 21 of the carriage 20.
The operation of the device is as follows. When in the first position, and without the disk inserted into the apparatus, the lower magnetic head 30 is normally positioned such that the apex of its surface 50 is at a higher level than the theoretical nominal plane n (FIG. 5). This level is about 1 millimeter, but can vary between 0.3 mm and 2 mm, above the plane n and this is one of the characteristics of the device embodying the invention.
When a sleeve 11 containing a magnetic disk 10 is inserted into the apparatus on which the device is mounted, the lower head 30 comes into contact with the lower face of the disk 10. The weight of the disk 10 and of the sleeve 11 cause the lower head 30 to fall by about 0.1 mm.
The disk 10 (FIG. 1) is then rotated clockwise relative to the sleeve 11, which remains at rest. The carriage 20 is moved along the axis x radially with respect to the disk 10 until the head 30 is positioned on the required section on which binary data is to be recorded and/or read. The presser 18 is lowered, and the case 11 is pressed against the fixed horizontal reference surface 16. The disk 10 becomes flattened, to cause the lower head 30 to fall further by about another 0.1 mm. This value is related only to the pressure of the disk 10 on the head 30, and not to the mechanical dimensions of the sleeve, because of which any type of commercially known sleeve is always accepted by the device, without adversely influencing the head-disk position.
Immediately afterwards, the upper head 37 is brought into contact with the upper face of the disk 10. Under the action of the force F applied by the spring 43, the lower head 30 further falls by about 0.3 mm, and this force is balanced by the reaction R (FIG. 3) applied to the head 30 by the leaf spring 32.
From this, it is apparent that the level at which the heads 30 and 37 become positioned relative to the nominal working plane n of the disk 10 is exclusively a function of the forces F and R, and of the component of the force P in the zone of the heads, and is not strictly related to the mechanical dimensions of the apparatus and sleeve 11 relative to the carriage 20.
The penetration of the lower head 30 into the disk 10 varies according to the position in which the head 30 is located relative to the nominal plane n before inserting the disk 10 into the apparatus. In particular, the penetration varies under certain operating conditions between zero and 1.3 mm.
Moreover, this penetration also varies during operation, in that the unit formed by the two heads 30 and 37 pressed together by a force F of about 15 grams is resiliently connected to the fixed body 21 of the carriage 20, and this unit is therefore able to follow the oscillations of the disk 10 in a vertical direction.
A further characteristic of the device embodying the invention is that because of the parallelogram connection provided by the springs 32, the lower head 30 can move vertically, while always keeping the generating lines of the surface 50 parallel to the axis x. It is apparent that because of the elasticity of the leaf springs 32, small torsional movements of the lower head 30 are possible, but those are of an order of magnitude less than the movements due to the bending of the springs 32.
In this manner, because of the resilient connection of the lower head 30, the shape of the head 30, the variable penetration of the lower head 30 into the disk 10, and the load applied to the upper head, the contact between the magnetic heads 30 and 37 and the disk 10 is always ensured and constant, and the recorded and/or read signal is always uniform in amplitude. Moreover, as the lower head 30 adapts itself to the vertical oscillations of the disk 10, the wear of this latter is also very reduced. | The device comprises a carriage mobile radially relative to the disk, and on which lower and upper opposing magnetic heads are mounted, each for recording and/or reading a corresponding disk face. The upper magnetic head is resiliently mounted at the end of an arm pivoted to the carriage and is urged against the disk with a predetermined load determined by a spring. A flexible joint enables it to rotate in all directions about a central support. The lower magnetic head is connected to the carriage by means of a pair of parallel leaf springs which enable it to move along an axis normal to the plane of the disk without rotation, whereby both heads maintain good contact regardless of the height of the nominal plane of the disk. | 6 |
This application claims priority under 35 U.S.C. §119(e) of provisional patent application Ser. No. 61/329,361, filed on Apr. 29, 2010, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure
The present disclosure relates to the manufacture of reclosable packages or bags, particularly manufacturing processes wherein the ends of the zipper need to line up at the fin seal to insure success of the closure. This may be applied to wide mouth openings wherein a long unisex zipper is placed across the width of a film going through a machine, such as a vertical form fill seal machine, to make a pouch. The pouch could be of many styles, including a pillow, gusseted, or quad seal style.
2. Description of the Prior Art
High speed manufacture of reclosable packages is well-developed and very satisfactory for its intended purposes. However, further increases in manufacturing speed and decreases in manufacturing costs are always sought. In particular, some manufacturing processes for reclosable packages including, but not limited to, form fill and seal processes, could benefit from improvements to bring fine adjustment to the alignment of zipper profiles at the fin seal to further decrease any registration tolerances or errors, and further consistently increase the aesthetic appeal of the resulting package. Typical tolerances or errors are on the order of one eighth to one quarter of an inch, and may be as low as one sixteenth of an inch for ease of closure.
The possible misalignment of the zipper location at the fin seal can be induced by such factors as errors in the printing of the film registration marks; errors in the placement of the zipper on the film; errors created by the increased drag caused by the zipper at the fill tube and from the film distance travelled (drag) from the upstream sensor measuring the film registration marks; and errors created by the product flowing intermittently into the fill tube and hitting the pouch bottom creating a standing wave of varying tension around the fill tube.
SUMMARY AND OBJECTS OF THE DISCLOSURE
It is therefore an object of the present disclosure to improve the fine adjustment in the alignment of zipper profiles at a fin seal in manufacturing processes for reclosable packages. This is particularly adaptable to, but not limited to, form fill seal manufacturing processes.
This and other objects are attained by positioning a trim sensor (such as a vision system or similar apparatus or method) to sense the position of the zipper ends at the fin sealing location (such as the fill tube in a form fill seal apparatus). The output of the trim sensor is used to adjust belt or roller speeds, or similar operational parameters to bring the zipper profiles into alignment at the fin seal.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawing, wherein:
FIG. 1 is a perspective view of a vertical form fill seal machine implementing an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that FIG. 1 is a perspective view of a vertical form fill seal machine 10 implementing an embodiment of the present disclosure.
The vertical form fill seal machine 10 includes a roll 12 , from which a continuous sheet 14 of polymeric web or film is provided in a machine direction. Sheet 14 includes lateral edges 15 , 17 oriented in the machine direction. Sheet 14 is typically guided by roller pairs such as those illustrated at 16 , 18 , 20 , 22 . A zipper strip 24 is provided from zipper strip roll 26 (or other source, such as a cartridge-type supply of successive zipper strips 24 in the form of zipper segments). Zipper strip 24 may be colored, dosed or otherwise treated or marked in order to aid in the accuracy of the sensing thereof. The zipper strip 24 is applied and sealed across the sheet 14 of web or film in transverse direction, typically in the proximity of roller pair 18 . At least one sensor 30 is provided in the proximity of roller pair 22 for determining the presence and speed of sheet 14 of web or film. The output of sensor 30 is provided to control logic system 32 via first digital servo drive 34 . Control logic system 32 includes an operator terminal 38 which typically includes a keyboard and a display screen. Control logic system 32 is in communication with first and second digital servo drives 34 , 36 .
Sheet 14 of web or film is wrapped around fill tube 40 so that lateral edges 15 , 17 are brought together and sealed in a fin seal by a machine direction sealing bar (not shown). Trim sensors (or registration sensors) 42 , 43 are located near the junction of lateral edges 15 , 17 around the fill tube 40 and senses the position of the transversely-oriented zipper strip 24 with respect to the fin seal formed in the sheet 14 of web or film. The trim sensors 42 , 43 are positioned so as to monitor both ends of the zipper strip 24 and thereby provide information regarding the alignment thereof. The trim sensors 42 , 43 may be electric eyes or comprise a vision system. Further alternatives include proximity sensors which may include inductive proximity sensors, capacity proximity sensors, ultrasonic proximity sensors and photoelectric sensors (with capacitive or photoelectric sensors being typically used for a plastic target and inductive proximity sensors typically being used for a metal target). Additionally, as described hereinafter, pressure switch 70 may be substituted for trim sensors 42 , 43 . The output of trim sensors 42 , 43 , similar to the output of sensor 30 , is supplied to control logic system 32 via first digital servo drive 34 . Control logic system 32 uses the information from trim sensors 42 , 43 to adjust the web speed, including the side-to-side web speed, as induced by drive roller assembly 50 which includes first drive belt 51 on a first side of fill tube 40 and second drive belt 53 on a second side of fill tube 40 , opposite from the first side. First and second drive belts 51 , 53 are driven by first and second drive roller servo motors 52 , 55 , respectively, which are, in turn, controlled by control logic system 32 via first digital servo drive 34 thereby controlling the placement and alignment of the ends of zipper strip 24 with respect to the fin seal. In this context, the term “drive roller servo motor” is being used to describe a mechanical device that delivers torque to rollers, belts, gear boxes and similar devices. Additionally, a KAMBEROLLER® steering guide from Fife Corporation may be an acceptable alternative for this purpose.
First digital servo drive 34 is illustrated as controlling both first and second drive belts 51 , 53 , independently. This independent control is typically necessary in order to control the side-to-side web speed, and the alignment of zipper strip 24 . In some applications, first digital servo drive 34 may be replaced with two digital servo drives.
The filled package 300 is formed by contents 200 being fed through fill tube 40 into the tube formed by sheet 14 with transverse sealing bar assembly 54 typically forming the upper seal of a lower completed package 300 and the lower seal of an upwardly adjacent package 300 ′ (or, if the packages are manufactured in an inverted configuration, the lower seal of a lower completed package 300 and the upper seal of an upwardly adjacent package 300 ′). Transverse sealing bar assembly 54 is driven by low inertia brushless servo motor 56 , which is controlled by control logic system 32 via second digital servo drive 36 . The calculated desired speed of transverse sealing bar assembly 54 may likewise be influenced by the reading from the trim sensors 42 , 43 .
In this way, trim sensors 42 , 43 (or registration sensors) are added to the vertical form fill and seal machine 10 to correct the film position in order to maintain the correct position (such as, but not limited to, a print position) relative to the end of the package 300 (such as, but not limited to, a pouch).
Further possible refinements to the disclosed embodiment include providing a sheet 14 of film with registration marks on either linear exterior and detecting these registration marks by registration sensors 42 , 43 (typically electric eyes). The friction belts of drive roller assembly 50 which advance the sheet 14 of film are accelerated or decelerated as needed in order to line up the registration marks on either edge of the web or film as it descends the fill tube 40 . This is turn, aligns the edges of the zipper strip 24 with respect to the fin seal. A further refinement includes adding pressure switches (illustrated on FIG. 1 as element 70 , and typically having the same line of communication as illustrated for trim sensors 42 , 43 ) located on the forming tube 40 which may detect either side of the zipper strip 24 .
Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. | The disclosure relates to relates to the use of trim sensors, registration sensors or pressure sensors to sense the position of a zipper during the manufacture of reclosable packages, particularly manufacturing processes wherein the ends of the zipper need to line up at the fin seal to insure success of the closure. The output of the sensors is used to adjust belt or roller speeds, or similar operational parameters to bring the zipper profiles into alignment at the fin seal. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation of U.S. patent application Ser. No. 11/549,526 filed Oct. 13, 2006, which claims priority from Japanese Patent Application No. 2005-314706 filed Oct. 28, 2005, the entire contents of each of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a print control apparatus, a print control method, a program, and a storage medium that perform printing by correcting a color deviation in a printer engine.
2. Description of the Related Art
A color deviation occurs in a tandem type color printer because a different photoreceptor is used for each color. Conventionally, optical methods such as mirror adjustments have been used for color deviation correction and particularly, for bending/inclination correction in a sub-scanning direction.
Japanese Patent Application Laid-Open No. 10-243248 proposes a method of correcting a color deviation by controlling transmission timing of an image. However, according to this method, an amount of correction cannot be changed with respect to a main scanning position and thus bending/inclination in the sub-scanning direction cannot be corrected.
Also, Japanese Patent Application Laid-Open No. 2001-38964 proposes a method of correcting bending/inclination in the sub-scanning direction by changing a readout position using three or more band buffers. However, according to this method, three or more band buffers are required and complex hardware is necessary that changes the readout position according to the amount of correction which varies in accordance with the main scanning position.
SUMMARY OF THE INVENTION
The present invention is directed to printing with a minimum of band buffers and correcting bending/inclination in a sub-scanning direction without making optical adjustments or using special hardware.
According to an aspect of the present invention, a print control apparatus includes: a band buffer for storing a 1-band image; an image correcting unit for correcting images stored in the band buffer; an intermediate buffer for storing images corrected by the image correcting unit that lie outside a band area; and an image output unit for outputting images including images stored in the intermediate buffer and image of a next band corrected by the image correcting unit that lie inside the band area.
According to another aspect of the present invention, a print control method includes: storing a 1-band image in a band buffer; correcting images stored in the band buffer; storing images that are corrected that lie outside a band area in an intermediate buffer; and outputting images including images stored in the intermediate buffer and images of a next band that are corrected b that lie inside the band area.
Further features of the present invention will become apparent from the following detailed description of exemplary embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a block diagram showing an exemplary functional configuration of a print control apparatus according to an embodiment of the present invention.
FIG. 2 is a block diagram showing details of an exemplary configuration of a printer according to an embodiment of the present invention.
FIG. 3 is a flowchart showing exemplary processing for a printer driver according to an embodiment of the present invention.
FIG. 4 is an illustration showing exemplary mapping of a main scanning position in color deviation correction in an embodiment of the present invention.
FIG. 5 is a flowchart showing exemplary processing for color deviation correction in an embodiment of the present invention.
FIG. 6 is an illustration showing an exemplary flow of data for color deviation correction in an embodiment of the present invention.
FIG. 7 is a block diagram showing exemplary hardware of a computer according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Embodiments of the invention will be described in detail below with reference to the drawings.
First Exemplary Embodiment
FIG. 1 is a block diagram showing a functional configuration of a print control apparatus according to an exemplary embodiment of the present invention. A computer 1 includes hardware such as a central processing unit (CPU), memory, a hard disk, a compact disk read-only memory (CDROM) drive, a keyboard, a mouse, a monitor, and a network interface. FIG. 7 is a block diagram showing exemplary hardware of the computer 1 .
In FIG. 7 , the computer 1 includes an input control unit 700 , a display unit 701 , a network interface unit 702 , a CPU 703 , ROM 704 , random access memory (RAM) 705 , a hard disk drive (HDD) 706 , and an input/output interface 707 .
Each of the above components is connected via the input/output interface 707 . The input control unit 700 controls the keyboard/mouse that receive input from a user. The display unit 701 provides an output screen (monitor) to the user. The network interface unit 702 communicates with an external device via a network 101 . The CPU 703 controls each component of the computer 1 . If the computer 1 is a server computer, processing of the computer 1 is performed based on a control program stored in one of the ROM 704 and the HDD 706 shown in FIGS. 3 and 5 . The ROM 704 stores the control program and data. The RAM 705 is used as a temporary storage area and a work area. The HDD 706 includes a large-capacity storage area and stores the control program and various data.
In FIG. 1 , an operating system 2 manages hardware provided in the computer 1 , and software such as an application 3 , a printer driver 4 , a language monitor 5 , and a network port driver 6 .
The application 3 is application software such as a word processor and carries out creation/printing of a document according to instructions of an operator.
The printer driver 4 receives a print instruction issued by the application 3 via the operating system 2 and converts the print instruction into a printer command that can be interpreted by the language monitor 5 and a printer 7 .
The language monitor 5 receives the printer command issued by the printer driver 4 and transmits the printer command to the printer 7 via the network port driver 6 . The language monitor 5 also notifies the printer driver 4 of density correction information and color deviation correction information received from the printer 7 via the network port driver 6 .
The network port driver 6 transmits the printer command issued by the language monitor 5 to the printer 7 via the network interface. If the density correction information and color deviation correction information are received from the printer 7 , the network port driver 6 outputs the density correction information and color deviation correction information to the language monitor 5 .
The printer 7 performs printing according to the printer command received from the network port driver 6 .
FIG. 2 is a block diagram showing an exemplary configuration of the printer 7 . A network interface 21 receives a printer command from the computer 1 . A FIFO (first in, first out) memory 22 stores image data of each color received from the network interface 21 . A decoding circuit 23 decodes image data of each color stored in the FIFO memory 22 and outputs the image data to a printer engine 24 . The printer engine 24 is, for example, a laser beam printer engine and performs printing according to instructions of a control circuit 25 based on image data output from the decoding circuit 23 . The control circuit 25 includes, for example, a 1-chip CPU, and controls the network interface 21 , the FIFO memory 22 , the decoding circuit 23 , and the printer engine 24 .
An exemplary printing operation is described below.
When an operator gives a print instruction operating the application 3 on the computer 1 , a print directive is delivered from the application 3 to the printer driver 4 via the operating system 2 . The printer driver 4 converts the print directive issued by the application 3 into image data, compresses the image data, and outputs the compressed image data together with a page start command specifying a paper size, a left margin, an upper margin, and a line length and the number of lines of bitmap data and the like, and a page end command indicating an end of a page.
When a printer command is output, the operating system 2 notifies the language monitor 5 of job start and then delivers the output printer command to the language monitor 5 one by one. When a job is started, the language monitor 5 transmits an occupancy request command to the printer 7 .
If the printer 7 is successfully occupied, the language monitor 5 transmits the received printer commands to the printer 7 one by one. Before transmitting an image data command to the printer 7 , the language monitor 5 transmits a status request command to acquire a status of the printer 7 and confirms that the printer 7 is ready to receive image data commands. When the image data command is received, a control circuit 25 stores the image data in the FIFO memory 22 . When transmission of the printer command for one page is completed, the language monitor 5 transmits a print request command. When the print request command is received, the control circuit 25 directs the printer engine 24 to start printing.
When a print start is directed, the printer engine 24 feeds a sheet of paper and, when the sheet reaches a predetermined location, requests output of image data. When the output of image data is requested, the decoding circuit 23 reads a compressed image from the FIFO memory 22 and outputs decoded original image data to the printer engine 24 . At this time, the image data read from the FIFO memory 22 is eliminated from the FIFO memory 22 .
When printer commands for all pages of the job are transferred, the language monitor 5 transmits an occupancy release command without waiting until the sheet is ejected. Even after transmitting the occupancy release command, the language monitor 5 continues to acquire the status of the printer 7 . The language monitor 5 frees up relevant page memory if the acquired printer status indicates that page printing is normally terminated. If an error is detected, the language monitor 5 retransmits an occupancy request command to try to restore an error page.
Next, details of processing of the printer driver 4 operating on a host are described with reference to FIG. 3 . Before the processing is executed, the printer driver 4 acquires correction amount information of each color in the sub-scanning direction stored in non-volatile memory of the printer 7 at the time of starting each printing job. First, in step S 1 , the printer driver 4 outputs, in accordance with instructions of the application 3 , the page start command that specifies the paper size, the left margin, the upper margin, the line length and the number of lines of bitmap data. At this time, as described below, the upper margin and the number of lines of bitmap data are corrected. Next, in step S 11 , the printer driver 4 outputs as a command, a sub-scanning correction amount at each main scanning position, as described below. Though this command is not required for printing, reference is made to the command if a sub-scanning correction is canceled later or a re-correction is made according to a correction amount of another engine.
Next, in step S 2 , the printer driver 4 creates a 1-band image data consisting of eight bits for each color of red, green, and blue in accordance with a drawing instruction of the application 3 . Next, in step S 3 , the printer driver 4 converts each pixel consisting of eight bits for each color of red, green, and blue into image data consisting of eight bits for each color of yellow, magenta, cyan, and black. At this time, density is corrected by referring to density correction information acquired in advance when a job is started. Next, in step S 4 , the printer driver 4 performs dither processing to image data consisting of eight bits for each color of yellow, magenta, cyan, and black to convert the data into image data consisting of two bits for each color of yellow, magenta, cyan, and black. Next, in step S 5 , the printer driver 4 corrects color deviation in the sub-scanning direction in accordance with a color deviation correction procedure described below. At this time, since some images lie outside a band buffer, as described below, the printer driver 4 holds such images in an intermediate buffer. Next, in step S 6 , the printer driver 4 compresses and outputs each color of a 1-band image data. Next, in step S 7 , the printer driver 4 determines whether processing of all bands in the page has been completed. If processing of all bands in the page has not been completed, the printer driver 4 returns to step S 2 to perform processing of the next band.
If, in step S 7 , it is determined that processing of all bands in the page has been completed, the printer driver 4 , in step S 8 , compresses and outputs the data held in the intermediate buffer, that is, the image data that lay outside the band processed last. Next, in step S 9 , the printer driver 4 outputs a page end command. Next, in step S 10 , the printer driver 4 determines whether processing of all pages has been completed. If processing of all pages has not been completed, the printer driver 4 returns to step S 1 to perform processing of the next page. If processing of all pages has been completed, the printer driver 4 terminates the processing.
Next, how to determine a correction amount in the sub-scanning direction is described. Before shipping from a factory, the correction amount of each color in the sub-scanning direction is measured. The measured correction amount of each color at a left end, in the center, and at aright end of maximum paper is stored in advance in non-volatile memory incorporated into the control circuit 25 of the printer 7 . The printer driver 4 acquires this value from the printer 7 before starting a printing job and first approximates it using a quadratic function.
More specifically, assume that the correction amount in the sub-scanning direction at the left end, in the center, and at the right end of maximum paper be L, M, and R respectively. Then, the correction amount Z=AX 2 +BX+C can be calculated as shown below, where X is a position in the main scanning direction with an origin point in the center. X coordinates at the left end, in the center, and at the right end of maximum paper are −W/2, 0, and W/2 respectively, where W is a width of the maximum paper.
R=A ( W/ 2) 2 +B ( W/ 2)+ C
M=C
L=A (− W/ 2) 2 +B (− W/ 2)+ C
From the above equations, the following solutions are yielded:
A =2( R+L− 2 M )/ W 2
B =( R−L )/ W
C=M
Therefore, the correction amount in the sub-scanning direction Z can be calculated according to the following formula:
Z= 2( R+L− 2 M )( X/W ) 2 +( R−L )( X/W )+ M
Next, based on this formula, the correction amount in the sub-scanning direction will be calculated for all pixel positions in the main scanning direction. Since, at this time, correction in the sub-scanning direction is made by a line, the correction amount is rounded off to a nearest integer on a line basis.
Next, it is described how to determine the correction amount in the sub-scanning direction from coordinates on a band buffer with reference to FIG. 4 . If the paper size is smaller than the maximum size, the paper is generally positioned in the center. Thus, paper positioning is considered when correction is made. In FIG. 4 , an upper horizontal line indicates the X axis and the center thereof is the origin point. A rectangle drawn by a broken line indicates a sheet of paper, the width thereof is w, and the center of the paper agrees with the origin of the X coordinate. A rectangle drawn by a solid line indicates an area in which the printer driver 4 creates an image in step S 2 in FIG. 3 , and the origin of the x and y coordinates thereof is in an upper left corner. The origin of the x coordinate is positioned a left margin LM apart from the left end of the paper. Since the origin of the X coordinate is represented by w/2−LM as the x coordinate, as shown in FIG. 4 , the X coordinate will be calculated as shown below.
X=x+LM−w/ 2
The X coordinate value thus determined is used to calculate the correction amount Z in the sub-scanning direction from the x coordinate by the formula as described above.
Since the paper width w changes depending on the paper size and a different X corresponds to the same x, the correction amount for the same x changes depending on the paper size.
Next, details of color deviation correction processing in step S 5 in FIG. 3 are described with reference to FIG. 5 . In the present exemplary embodiment, one pixel includes two bits for each color and one byte contains four pixels of a specific color. Accordingly, processing is performed in a two-bit unit to change a correction amount for each pixel, which increases time required for processing. To avoid this problem, the same correction amount is applied to four pixels contained in one byte so that processing can be performed in a one-byte unit, which shortens time required for processing.
First, in step S 21 , the printer driver 4 sets a current color to a first color, for example, to cyan. Next, in step S 22 , the printer driver 4 sets a current column to a head, that is, the left end of the band buffer of the current color. Here, the column has the width of one byte. Next, in step S 23 , the printer driver 4 calculates the correction amount of a leftmost pixel of the current column as described above. At this time, the printer driver 4 makes reference to the color deviation correction information acquired in advance when starting a job so as to calculate the correction amount. Since, in the present embodiment, one pixel includes two bits for each color, one byte contains four pixels of specific colors. However, the correction amount of the leftmost pixel in one byte is similarly applied to four pixels in one byte so that processing can be performed in a one-byte unit, as described above. Next, in step S 24 , the printer driver 4 adds a maximum correction amount to the correction amount to obtain a positive value or 0. For example, if the correction amount is between −20 lines to 20 lines, the maximum correction amount of 20 lines is added to obtain 0 line and 40 lines. This processing enables avoiding a case in which processing cannot be performed. Otherwise, when the correction amount becomes a negative value as a result of correcting data in the current band, the data moves to the position of a previous band in which processing is completed.
Next, in step S 25 , the printer driver 4 sets the current byte to the end of the current column, that is, to the current column in the last line of the band buffer. Next, in step S 26 , the printer driver 4 calculates a correction position of the current byte to determine whether the correction position is within the band buffer. More specifically, the printer driver 4 determines whether the position of the current byte below the correction number of lines calculated in step S 24 is within the band buffer. If the correction position of the current byte is within the band buffer, in step S 27 , the printer driver 4 copies the current byte to the correction position calculated in step S 26 and then proceeds to step S 28 . If the correction position of the current byte is not within the band buffer, in step S 36 , the printer driver 4 copies the current byte to a position according to the number of lines lying outside the band buffer in a second intermediate buffer, and then proceeds to step S 28 .
In step S 28 , the printer driver 4 moves up the current byte position by one line. Next, in step S 29 , the printer driver 4 determines whether processing of one column is completed, that is, whether the current byte position is outside a head position of the band buffer. If processing of one column is not completed, the printer driver 4 returns to step S 26 to continue processing of the current column. If processing of one column is completed, in step S 30 , the printer driver 4 copies data by the number of correction lines calculated in step S 24 , from the head line of the current column, from a first intermediate buffer to the band buffer. The first intermediate buffer is assumed to be filled in advance with blank pixels. Next, in step S 31 , the printer driver 4 moves the current column rightward by one byte. Next, in step S 32 , the printer driver 4 determines whether processing of all columns is completed. If processing of all columns is not completed, the printer driver 4 returns to step S 23 to start processing of the next column.
If processing of all columns is completed, in step S 33 , the printer driver 4 copies content of the second intermediate buffer to the first intermediate buffer of the current color. Next, in step S 34 , the printer driver 4 sets the current color to the next color. Next, in step S 35 , the printer driver 4 determines whether processing of all colors is completed. If processing of all colors is not completed, the printer driver 4 returns to step S 22 to start processing of the next color. If processing of all colors is completed, the printer driver 4 terminates color deviation correction processing. The number of lines in the upper margin performed in step S 1 shown in FIG. 3 is corrected by subtracting a value to be added to the correction amount (i.e., the maximum correction amount) in step S 24 . By performing this processing, increase of the upper margin caused by addition of a correction amount in step S 24 can be canceled. The number of lines in bitmap data performed in step S 1 shown in FIG. 3 is corrected by adding the number of lines in the intermediate buffer. Since the number of lines in the intermediate buffer is twice the maximum amount, that value is added.
Next, processing in FIG. 5 is described by taking horizontal bands (lateral direction: main scanning direction), as shown in FIG. 6 , as an example. First, image data in a byte unit at a lower left of a band is written in one of the band buffer and the intermediate buffer in accordance with the correction amount. Next, image data in a byte unit immediately above (longitudinal direction: sub-scanning direction) is written in one of the band buffer and the intermediate buffer in accordance with the correction amount. Image data in a byte unit immediately above is processed sequentially until processing of image data for the band in the longitudinal direction is completed. Then, image data in a byte unit immediately to the right of the image data in a byte unit at the lower left is written in one of the band buffer and the intermediate buffer in accordance with the correction amount. Then, image data in a byte unit immediately above is sequentially processed.
In the above example, processing in the longitudinal direction (sub-scanning direction) has been described, however, a system in which processing is performed in the lateral direction (main scanning direction) can also be realized. More specifically, image data in a byte unit at a lower left of a band is written in one of the band buffer and the intermediate buffer in accordance with the correction amount. Next, image data in a byte unit immediately to the right (lateral direction: main scanning direction) is written in one of the band buffer and the intermediate buffer in accordance with the correction amount. Image data in a byte unit immediately to the right is processed sequentially until processing of image data for the band in the lateral direction is completed. Then, image data in a byte unit immediately above the image data in a byte unit at the lower left is written in one of the band buffer and the intermediate buffer in accordance with the correction amount. Then, image data in a byte unit immediately to the right is processed sequentially.
Next, a flow of data caused by color deviation correction processing will be described with reference to FIG. 6 . First, image data 601 in a first band is formed in the band buffer. When color deviation correction processing is invoked, a correction is made in accordance with the correction amount in the sub-scanning direction. The image data 601 is divided into data 602 that remains in the band buffer, and data 603 that lies outside the band buffer and is stored in the second intermediate buffer. The data 603 stored in the second intermediate buffer is copied to the first intermediate buffer as image data 604 when processing of the first band is completed. Next, image band 605 in a second band is formed in the band buffer. When color deviation correction processing is invoked, the image data 605 is divided into data 606 that remains in the band buffer, and data 607 that lies outside the band buffer and is stored in the second intermediate buffer. Further, the data 604 held in the first intermediate buffer that lay outside the first band is stored in the band buffer as image data 609 .
Correction processing is performed sequentially in this manner. After processing of the last band is performed, data 610 that lay outside the last band is held in the first intermediate buffer. The data 610 is output by processing in step S 8 shown in FIG. 3 .
Second Exemplary Embodiment
A second exemplary embodiment of the present invention is described next. In the second exemplary embodiment, color deviation correction processing is performed before dither processing. More specifically, dither processing in step S 4 and color deviation correction processing in step S 5 shown in FIG. 3 are interchanged. Since an image before dither processing includes eight bits for each color, a correction amount for each pixel is calculated in color deviation correction processing without applying the same correction amount to four pixels.
Third Exemplary Embodiment
A third exemplary embodiment of the present invention is described next. In the third exemplary embodiment, the printer engine 24 has a two-sided printing mechanism. In the case of two-sided printing, while printing on a first side is generally center-aligned like single-sided printing, printing on a second side can be left-aligned. In such a case, the correction amount calculated in step S 23 shown in FIG. 5 is calculated using center alignment for the first side of two-sided printing, similar to the first embodiment and using left alignment for the second side of two-sided printing. More specifically, instead of X=x+LM−w/2 described above, the same formula as the maximum paper, that is, X=x+LM−W/2 can be used for calculation regardless of the paper width.
When the two-sided printing is performed, depending on a combination of a paper transfer direction (longitudinal feed and transverse feed) and a binding direction (longer side binding and shorter side binding), an image on the first side must be rotated by 180°, but this processing can be performed by creating a rotated image in advance in step S 2 shown in FIG. 3 .
Other Embodiments
In the above-described exemplary embodiments, image creation and color deviation corrections are performed by a host computer, but instead other methods can also be used. For example, the printer driver 4 can output a page description language without performing image creation and color deviation corrections so that the printer 7 can perform, based on the received page description language, image creation and color deviation corrections.
As described above, by using the band buffer with a set of four colors, the first intermediate buffer with a set of four colors, and the temporary intermediate buffer with a set of one color, color deviation corrections in the sub-scanning direction can be performed, and printing can be executed without preparing special hardware.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all modifications, equivalent structures and functions. | In order to perform printing by using a minimum of band buffer and correcting bending/inclination in a sub-scanning direction without making optical adjustments and using special hardware, 1-band image data are stored in the band buffer, images stored in the band buffer are corrected, images lying outside a band area are stored in an intermediate buffer, and images including images stored in the intermediate buffer and corrected images of a next band that lie inside the band area are output. | 7 |
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 09/554,397, filed May 15, 2000, which is the U.S. national stage application of PCT/IL98/00552, filed Nov. 11, 1998.
FIELD OF INVENTION
[0002] This invention is in the field of dehumidification and in particular is concerned with improved efficiency of desiccant type dehumidifiers.
BACKGROUND OF INVENTION
[0003] Large scale air dehumidifying systems based on a desiccating agent are associated with two main problems. One problem is that the dried air output is warmer than the moist air input. This result is caused by the heating of the air from latent heat of evaporation as the moisture is removed therefrom and also, to a lesser degree by the heating of the air by transfer of heat from the generally warmer desiccant. A second problem is that regeneration of the desiccant requires considerable energy.
[0004] Dehumidifying systems based on liquid desiccants dehumidify air by passing the air through a tank filled with desiccant. The moist air enters the tank via a moist air inlet and dried air exits the tank via a dried air outlet. In one type of desiccant system a shower of desiccant from a reservoir is sprayed into the tank and, as the desiccant droplets descend through the moist air, they absorb water from it. The desiccant is then returned to the reservoir for reuse. This causes an increase in the water content of the desiccant.
[0005] Water saturated desiccant accumulates in the reservoir and is pumped therefrom to a regenerator unit where it is heated to drive off its absorbed water as vapor. Regenerated desiccant, which heats up in this process, is pumped back into the reservoir, for reuse. Since the water absorption process leads to heating of the air and the regeneration process heats the desiccant, substantial heating of the air takes place during the water absorption process.
[0006] An example of a device using a circulating hygroscopic liquid such as a LiCl desiccant is described in U.S. Pat. No. 4,939,906. In this patent a boiler is provided with finned tubes for the flow of the heated desiccant. This patent also discloses pre-heating the saturated desiccant before it enters the boiler for final regeneration by direct transfer of heat thereto from desiccant leaving the tank.
[0007] Other variations of systems using re-circulated desiccant solutions for dehumidifying air are shown in U.S. Pat. Nos. 4,635,446, 4,691,530 and 4,723,417. Many of these systems utilize transfer of heat from one portion of the dehumidifier to another to improve its efficiency.
[0008] In general, regeneration of the liquid desiccant requires its heating with the concomitant expenditure of energy.
SUMMARY OF INVENTION
[0009] The present invention, in some embodiments thereof, is designed to utilize heat transfer in a new way in the process of regenerating its liquid desiccant thereby enhancing the overall efficiency of the system.
[0010] In a preferred embodiment of the invention a heat pump extracts heat from liquid desiccant, preferably in a humidity collector unit and transfers the heat to a heating coil in a regenerator unit thereby reducing the overall energy required by the system. In addition, this transfer of energy has the effect of cooling the desiccant which contacts the moist air that enters the system. Thus, dry air which exits the system is cooler than it would be in the absence of the heat transfer.
[0011] In addition, in preferred embodiments of the invention, heat energy in one or more of moisture laden air which exits the regenerator, heated desiccant which exits the regenerator and air which exits the dehumidifier is used to heat the desiccant to be regenerated either on its way to or in the regenerator tank.
[0012] According to an aspect of some preferred embodiment of the invention, a dehumidifier is provided in which the relative humidity of treated air is self regulating, such that the relative humidity of the air exiting the dehumidifier remains relatively constant as the temperature or humidity of the air entering the dehumidifier drops. The air temperature of the exiting air preferably depends on the input air conditions, with the exit air temperature dropping with lower input temperature/relative humidity. There is thus provided, in accordance with a preferred embodiment of the invention, a dehumidifier system comprising:
[0013] a dehumidifying chamber into which moist air is introduced and from which less moist air is removed after dehumidification;
[0014] a desiccant solution situated in at least one reservoir;
[0015] a first conduit via which desiccant solution is transferred from the at least one reservoir to the dehumidifying chamber, said solution being returned to said at least one reservoir after absorbing moisture from the moist air;
[0016] a regenerator which receives desiccant solution from said at least one reservoir and removes moisture from it;
[0017] a second conduit via which desiccant is transferred from the at least one reservoir to the regenerator, said solution being returned to said at least one reservoir after moisture is removed from it; and
[0018] a heat pump that transfers heat from the solution in the first conduit to the solution in the second conduit.
[0019] Preferably, the heat pump comprises a first heat exchanger which receives heat from the solution in the first conduit, a second heat exchanger that receives heat from the solution in the second conduit and a compressor.
[0020] Preferably, the regenerator comprises a regenerator chamber in which moisture is removed from the solution by contact with air that is brought into the chamber. Preferably, the compressor is cooled by said air prior to its entry into the regenerator chamber, such that the moisture removal ability of the air is increased.
[0021] In a preferred embodiment of the invention, the heat pump includes an additional heat exchanger which transfers heat from a refrigerant after the refrigerant leaves the second heat exchanger. Preferably, the regenerator comprises a regenerator chamber in which moisture is removed from the solution by contact with air that is brought into the chamber. Preferably, the additional heat exchanger is cooled by said air prior to its entry into the regenerator chamber, such that the moisture removal ability of the air is increased.
[0022] In a preferred embodiment of the invention, the system includes a control that controls the amount of heat transferred by the heat pump.
[0023] In a preferred embodiment of the invention, the at least one reservoir comprises a first reservoir from which solution is transferred via the first conduit and a second reservoir from which solution is transferred via the second conduit. Preferably, a substantial temperature differential is maintained between the first and second reservoirs.
[0024] Preferably, the system includes a conduit that connects the first and second reservoirs, such that the level of solution in them is substantially the same.
[0025] There is further provided, in accordance with a preferred embodiment of the invention, a dehumidifier system comprising:
[0026] a dehumidifying chamber into which moist air is introduced and from which less moist air is removed after dehumidification;
[0027] a desiccant solution situated in a first reservoir;
[0028] a first conduit via which desiccant solution is transferred from the first reservoir to the dehumidifying chamber, said solution being returned to said at least one reservoir after absorbing moisture from the moist air;
[0029] a desiccant solution situated in a second reservoir;
[0030] a regenerator which receives desiccant solution from the second reservoir and removes moisture from it;
[0031] a second conduit via which desiccant is transferred from the second reservoir to the regenerator, said solution being returned to said second reservoir after moisture is removed from it; and
[0032] wherein a substantial temperature differential is maintained between the first and second reservoirs.
[0033] Preferably, the system includes a conduit connecting the first and second reservoirs such that the level of solution in them is substantially the same.
[0034] Preferably, the conduit provides for only limited mixing between the two reservoirs such that the substantial temperature differential is maintained between them. Preferably, the temperature differential is at least 5° C., such as at least 10° C. or at least 15° C.
[0035] Preferably, the system includes means for providing an additional limited amount of mixing between the two reservoirs.
[0036] There is further provided, in accordance with a preferred embodiment of the invention, an air modifying device, including:
[0037] an enclosure including apparatus for modifying air entering the apparatus via an air inlet and having an air outlet for the modified air;
[0038] a first conduit having an entrance for air and an exit communicating with the inlet;
[0039] a second conduit having an exit and an entrance communicating with the outlet; and
[0040] a mounting surface adapted for mounting the device on a partition such that the enclosure is on a first side of the partition and the entrance to the first conduit and the exit from the second conduit are situated on a second side of the partition.
[0041] Preferably, the conduits carry air from the first side of the partition to the second side of the partition. Preferably. the mounting surface is adapted for mounting on a window sill and the system includes a seal around the conduits that seals the first side of the partition from the second side of the partition when a window is closed on the conduits.
[0042] In a preferred embodiment of the invention, the apparatus for modifying air is a dehumidifier.
[0043] In a preferred embodiment of the invention, the apparatus for modifying air is an air conditioner including a heat pump that cools air entering the inlet by contact with a cold surface of the heat pump.
[0044] In a preferred embodiment of the invention, the apparatus for modifying air is a combination dehumidifier and an air conditioner including a heat pump that cools air entering the inlet by contact with a cold surface of the heat pump.
[0045] In a preferred embodiment of the invention, the dehumidifier is a dehumidifier system as described herein.
BRIEF DESCRIPTION OF DRAWINGS
[0046] The present invention will be more clearly and fully understood from the following detailed description of the preferred embodiments thereof, in which the same reference numerals in different drawings correspond to the same features, read in conjunction with the drawings in which:
[0047] [0047]FIG. 1 schematically shows a dehumidifier unit, in accordance with a preferred embodiment of the invention;
[0048] [0048]FIG. 2 schematically shows a second dehumidifier unit, in accordance with an alternative preferred embodiment of the invention;
[0049] [0049]FIG. 3 schematically shows a system for wetting a sponge with desiccant solution, in accordance with a preferred embodiment of the invention; and
[0050] [0050]FIG. 4 shows a preferred construction for a window mounted dehumidifier unit in accordance with a preferred embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0051] A dehumidifying system 10 , in accordance with a preferred embodiment of the invention comprises, as its two main sections a dehumidifying chamber 12 and a regenerator unit 32 . Moist air enters dehumidifying chamber 12 via a moist air inlet 14 and dried air exits chamber 12 via a dry air outlet 16 .
[0052] In a preferred embodiment of the invention, desiccant 28 is pumped by a pump 20 from a desiccant reservoir 30 via a pipe 13 to a series of nozzles 22 . These nozzles shower a fine spray of the desiccant into the interior of chamber 12 , which is preferably filled with a cellulose sponge material 24 such as is generally used in the art for such purposes. The desiccant slowly percolates downward through the sponge material into reservoir 30 . Moist air entering the chamber via inlet 14 contacts the desiccant droplets. Since the desiccant is hygroscopic, it absorbs water vapor from the moist air and drier air is expelled through outlet 16 . Preferably, reservoir 30 is located on the bottom of chamber 12 so that the desiccant from sponge 24 falls directly into the reservoir.
[0053] In a preferred embodiment of the invention, a pump 35 and associated motor 37 pump desiccant from an extension of reservoir 30 into pipe 13 . A divider 38 receives desiccant from pipe 13 and sends part of the desiccant to nozzles 22 and part to regenerator unit 32 . A valve or constriction 39 (preferably a controllable valve or constriction) may be provided to control the proportion of the desiccant which is fed to regenerator 32 . If a controllable valve or constriction is used, the amount of desiccant is preferably controlled in response to the amount of moisture in the desiccant.
[0054] Chamber 34 includes a heat exchanger 36 which heats the desiccant to drive off part of the water vapor it has absorbed, thus regenerating it.
[0055] Regenerated liquid desiccant is transferred back to reservoir 30 via a pipe 40 and a tube 42 of sponge material such as that which fills chamber 12 . Tube 40 is preferably contained in a chamber 58 which has an inlet 60 and an outlet 62 . Air, generally from outside the area in which the air is being modified, enters the chamber via inlet 60 and carries away additional moisture which is evaporated from the still hot desiccant in tube 42 . the air exiting at exit 62 carries away this moisture and also moisture which was removed from the desiccant in the regenerator. Preferably a fan (not shown) at exit 62 sucks air from chamber 58 .
[0056] Alternatively or additionally, heat is transferred from the regenerated liquid desiccant to the desiccant entering or in the regenerator by bringing the two desiccant streams into thermal (but not physical) contact in a thermal transfer station (not shown). Alternatively or additionally, a heat pump may be used to transfer additional energy from the cooler desiccant leaving the regenerator to the hotter desiccant entering the regenerator, such that the desiccant returning to the reservoir is actually cooler than the desiccant which enters the chamber 34 .
[0057] In a preferred embodiment of the invention, a heat pump system 44 is provided which extracts heat from the desiccant in reservoir 30 to provide energy to heat exchanger 36 . Preferably, this heat pump includes (in addition to exchanger 36 which is the condenser of the system) a second heat exchanger 46 in reservoir 30 , which is the evaporator of the system, and an expansion valve 56 . This transfer of energy results in a reduced temperature of the desiccant which contacts the air being dried thus reducing the temperature of the dried air. Second, this transfer of energy reduces the overall requirement of energy for operating the regenerator, generally by up to a factor of 3. Since the energy utilized by the regeneration process is the major energy requirement for the system, this reduction in energy usage can have a major effect on the overall efficiency of the system. Additionally, this method of heating of the desiccant in the regenerator may be supplemented by direct heating, utilizing a heating coil.
[0058] It should be understood that the proportion of water vapor in the desiccant in reservoir 30 and in the regenerated desiccant must generally be within certain limits, which limits depend on the particular desiccant used. A lower limit on the required moisture level is that needed to dissolve the desiccant such that the desiccant is in solution in the moisture. However, when the moisture level is too high, the desiccant becomes inefficient in removing moisture from the air which enters chamber 12 . Thus, it is necessary that the moisture level be monitored and controlled. It should be noted that some desiccants are liquid even in the absence of absorbed moisture. The moisture level in these desiccants need not be so closely controlled. However, even in these cases the regeneration process (which uses energy) should only be performed when the moisture level in the desiccant is above some level.
[0059] This monitoring function is generally performed by measurement of the volume of desiccant, which increases with increasing moisture. A preferred method of measuring the volume of liquid in the reservoir is by measurement of the pressure in an inverted vessel 50 which has its opening placed in the liquid in the reservoir. A tube 52 leads from vessel 50 to a pressure gauge 52 . As the volume of desiccant increases from the absorption of moisture, the pressure measured by gauge 52 increases. Since the liquid in the chamber and in the regenerator is fairly constant, this gives a good indication of the amount of desiccant and thus of the amount of moisture entrained in the desiccant. When the moisture level increases above a preset value, the heat in chamber 34 is turned on. In a preferred embodiment of the invention, when the moisture level falls below some other, lower preset value, the heater is turned off.
[0060] Other factors which may influence the cut-in and cut-out points of the regeneration process are the temperature of the dry air, the regeneration efficiency and the heat pump efficiency. In some preferred embodiments of the invention, especially in cold air systems (as for ice-skating rinks) it may be advisable to provide some direct heating of desiccant in the regeneration process.
[0061] In other preferred embodiments of the invention heat pumps or other heat transfer means (not shown for simplicity) are provided to transfer heat from the dried air exiting chamber 12 and or from the heated moist air leaving regenerator chamber 34 , to heat the desiccant on its way to or in chamber 34 . If heat pumps are used, the source of the heat may be at a temperature lower than the desiccant to which it is transferred.
[0062] It should be understood that cooling of the desiccant in the reservoir can result in dried air leaving the dehumidifier which has the same, or preferably a lower temperature than the moist air entering the dehumidifier, even prior to any additional optional cooling of the dry air. This feature is especially useful where the dehumidifier is used in hot climates in which the ambient temperature is already high.
[0063] As indicated above, one of the problems with dehumidifier systems is the problem of determining the amount of water in the desiccant solution so that the dehumidifier solution water content may be kept in a proper range.
[0064] A dehumidifier 100 , in accordance with a preferred embodiment of the present invention, is shown in FIG. 2. This dehumidifier is self regulating with respect to water content of the desiccant solution and thus does not require any measurement of the volume or water content of the desiccant solution. Furthermore, the dehumidifier operates until a predetermined humidity is reached and then ceases to reduce the humidity, without any controls or cut-offs.
[0065] Dehumidifier 100 is similar to dehumidifier 10 of FIG. 1, with several significant differences. First, the system does not require any measurement of water content and thus does not have a volumetric measure for the desiccant. However, such a measurement may be provided as a safety measure if the solution becomes too concentrated.
[0066] Second, the heat pump transfers heat between two streams of desiccant solution being transferred from reservoir 30 (which is conveniently divided into two portions 30 A and 30 B connected by pipes 30 C), namely a first stream being pumped to nozzles 22 by a pump system 130 , via a conduit 102 and a second stream being pumped to regenerator unit 32 by a pump system 132 , via a conduit 104 .
[0067] Preferably, pipes 30 C (including the bypass pipes shown) are designed so that its major effect is to generate a common level of the solution in portions 30 A and 30 B. In general, it is desirable that the two reservoir portions have different temperatures. This necessarily results in different concentrations of desiccant. However, it is considered generally desirable to provide some mixing between the sections, by some pumping via the bypass pipes shown so as to transfer moisture from one portion to the other. In a preferred embodiment of the invention a temperature differential of 5° C. or more is maintained, more preferably, 10° C. or more and most preferably 15° C. or even more. Thus, in a preferred embodiment of the invention, reservoir portion 30 A is at a temperature of 300 C or more and reservoir portion 30 B is at a temperature of 15° C. or less.
[0068] In FIG. 2, a different construction for regenerator unit 32 is shown, which is similar to that of the dehumidifier section. Furthermore, in FIG. 2, neither section has a cellulose sponge material, which may be present or absent from either the embodiment of FIG. 1 or that of FIG. 2.
[0069] In a preferred embodiment of the invention, applicable to either FIG. 1 or 2 , spray nozzles are not used. Rather, the spray nozzles are replaced by a dripper system from which liquid is dripped on the cellulose sponge to continuously wet the sponge.
[0070] [0070]FIG. 3 shows a preferred embodiment of a dripper system for wetting sponge 24 . In this system an open conduit 200 , preferably in the form of a serrated half-pipe is filled with desiccant solution 28 . The desiccant solution flow through serrations along the length of the conduit and uniformly wets the sponge. In most instances the use of a sponge, without spray is preferred since the use of a spray results in dispersion of desiccant solution in the air, which must be remover therefrom. Other methods of wetting sponge 24 will occur to persons of skill in the art and any such method may be used in the practice of the invention.
[0071] Returning to FIG. 2, heat pump system 44 extracts heat from the desiccant solution in conduit 102 and transfers it to the desiccant in conduit 104 . Heat pump system 44 preferably contains, in addition to the components contained in the embodiment of FIG. 1, an optional heat exchanger 136 to transfer some of the heat from the refrigerant leaving heat exchanger 104 to the regenerating air. Preferably, the compressor is also cooled by the regenerating air. However, when the air is very hot, additional air, not used in the regenerator, may be used for cooling the compressor and the refrigerant. Alternatively, only such air is used for such cooling.
[0072] The resultant heating of the air entering the regenerator increases the ability of the air to remove moisture from the desiccant. Heat pump 44 is set to transfer a fixed amount of heat. In a preferred embodiment of the invention, the humidity set point is determined by controlling the amount of heat transferred between the two streams.
[0073] Consider the system shown in FIG. 2, with the air entering dehumidifier chamber 12 at 30 degrees C. and 100% humidity. Assume further that the amount of liquid removed from the air reduces its humidity to 35% without reducing the temperature. In this situation, the amount of heat transferred between the streams of desiccant solution would be equal to the heat of vaporization of the water removed from the air, so that the temperature of the desiccant solution falling into reservoir 20 from chamber 12 is at the same temperature as that which enters it, except that it has absorbed a certain amount of moisture from the air.
[0074] Assume further, that the regenerator is set up, such that at this same temperature and humidity, it removes the same amount of water from the desiccant solution. This may require an input of heat (additionally to the heat available from the heat pump).
[0075] Further assume that the air entering the dehumidifier chamber has a lower humidity, for example 80%. For this humidity, less liquid is removed (since the efficiency of water removal depends on the humidity) and thus, the temperature of the desiccant solution leaving the dehumidifier chamber also drops. However, since less water enters the desiccant solution from the dehumidifier chamber, the amount of water removed from the solution in the regenerator also drops. This results in a new balance with less water removed and the desiccant solution at a lower temperature. A lower temperature desiccant results in cooler air. Thus, the temperature of the exiting air is also reduced. However, the relative humidity remains substantially the same. It should be understood that a reduction of input air temperature has substantially the same effect.
[0076] In a preferred embodiment of the invention, the system is self regulating, with the dehumidifying action cutting off at some humidity level. The humidity level at which this takes place will depend on the capacity of the solution sprayed from nozzles 22 to absorb moisture and the ability of the solution and on the capacity of the solution sprayed from nozzles 22 ′ to release moisture.
[0077] In general as the air at inlet 14 becomes less humid (relative humidity) the dehumidifier becomes less able to remove moisture from it. Thus, the solution is cooled on each transit through the conduit 102 and the percentage of desiccant in the solution in 30 B reaches some level. Similarly, as less moisture is removed from the air, the solution in 30 A becomes more concentrated and less moisture is removed from it (all that happens is that it gets heated. At some point, both removal and absorption of moisture by the solution stop since they respective sprayed solution is stability with the air to which or from which moisture is transferred.
[0078] It should be understood that this humidity point can be adjusted by changing the amount of heat transferred between the solutions in conduits 102 and 104 . If greater heat is transferred, the transfer ability of both the dehumidifying chamber and the regenerator are increased and the humidity balance point is lowered. For less heat pumped, a higher humidity will result. In addition, the set-point will depend somewhat on the relative humidity of the air entering the regenerator.
[0079] [0079]FIG. 4 schematically shows a window mounted dehumidifier system 110 , in accordance with preferred embodiments of the invention. In this embodiment, the entire unit shown in FIG. 1 or 2 is contained in an enclosure 112 which hangs outside a window 114 of a room. Preferably, system 110 further includes a U-shaped support unit which rests on window sill 118 and is firmly attached to enclosure 112 . Passing through window 112 are two conduits, 14 and 15 corresponding to air inlet 14 and dehumidified air outlet 16 of FIGS. 1 and 2. The window closes on the top of the conduits to seal the room from the outside. A power cord 120 , plugs into a power outlet inside the window and supplies power to the dehumidifier unit. Preferably, a panel is situated inside the window on which controls are mounted and which provides a suitable grill for inlet 14 and outlet 16 . FIG. 3 also shows inlet 60 and outlet 62 used to carry away moisture laden warm air. Additionally, inlet 60 can provide a controllable amount of fresh air to the room.
[0080] In a further preferred embodiment of the invention the configuration of FIG. 4 is used for a combination air conditioner and dehumidifier or for a conventional air conditioning mechanism including a heat pump that cools air entering the inlet by contact with a cold surface of the heat pump. For an air conditioner both heat exchangers would be outside the window with air from the room being fed to the air conditioner's condenser via conduit 14 and from it via conduit 16 to the room to be cooled.
[0081] Units such as those shown in FIG. 4 provide for the low noise of split air conditioning units with the convenience of window mounting.
[0082] When used in the following claims, the terms “comprise” or “include” or their conjugates mean “including but not necessarily limited to.”
[0083] The present invention has been described utilizing a preferred embodiment thereof. It should be understood that many variations of the preferred embodiment within the scope of the invention, as defined in the following claims, are possible and will occur to a person of skill in the art. | A dehumidifier system comprising:
a dehumidifier into which moist air is introduced and contacted with a liquid desiccant solution associated with the dehumidifier to remove moisture therefrom;
a regenerator having a liquid desiccant solution associated therewith and contacted with air which removes moisture therefrom, said liquid desiccant solution being in liquid communication with the liquid desiccant solution associated with the dehumidifier;
a refrigeration system that comprises a plurality of heat exchangers, a refrigerant and a compressor, wherein the refrigerant passes through the heat exchangers, the heat exchangers including a first heat exchanger in thermal contact with the liquid desiccant solution associated with said dehumidifier, a second heat exchanger in thermal contact with the desiccant solution associated with said regenerator and a third heat exchanger that is not in contact with said desiccant solutions. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. 119 to U.S. Provisional Application No. 60/893,271, entitled, “METHOD FOR FORMING AND SELLING CANDLES,” filed on Mar. 6, 2007, the contents of which are incorporated herein as if set forth in full.
FIELD
[0002] The present invention relates generally to candles and more specifically to a method and apparatus for making candles and method for marketing and selling individualized candles.
BACKGROUND
[0003] Candles are used as sources of light and often as attractive ornaments. Such candles are typically made from solidified wax or wax-like compositions. For instance, opaque candles may be made from paraffin or stearic acid. Often, a mixture of paraffin and stearic acid is used.
[0004] Because candles are also used as decorative ornaments, processes for enhancing their appearance have been developed. For instance, colorants and dyes are often mixed into the structure of candles to provide a candle having a desired color. Further, it is common to decorate the outside surfaces of larger candles. For example, it is known to screen print on candles to provide a pattern or picture on an outside surface thereof. Candles may also have multiple colored layers to provide a decorative effect. For instance, a plurality of wax pieces may be shaped and stacked and/or melted together to form a decorative candle body.
[0005] In addition to colorants and dyes, various items may be placed within the structure of candles. For instance, oils and/or scents/perfumes may be disposed within the structure of a candle such that the candle provides an aromatic smell when utilized. Further, objects may be placed within the structure of the candle such that those objects become visible as the candle melts, are visible through at least partially translucent structures of the candle, and/or extend through edge surfaces of the candle.
[0006] While many types of ornate candles are produced today, such candles are typically pre-made. That is, consumers do not have the ability to individualize an ornamental candle to their own liking.
SUMMARY
[0007] In order to allow for individualized candle making, provided herein is an apparatus that may be utilized to quickly and conveniently melt candle materials such as paraffin, stearic acid, natural wax, etc. (hereinafter wax). Generally, the apparatus utilizes a heated inclined surface on which wax may be placed to melt. This allows for surface melting of wax, which reduces or eliminates the need to melt a reservoir of wax. Accordingly, small amounts of wax may be melted on the inclined surface and the melted wax may be directed into a candle mold. Other material may be mixed with the wax and/or different colors of wax may be mixed on the surface of the apparatus.
[0008] To provide for easier use and functionality, the slope of the heated inclined surface may be selectively adjustable by a user. For instance, it may be desirable to position the surface at a level slope when melting and/or blending the candle materials, and to position the surface at an inclined slope such that the melted materials may be poured into a candle mold. Additionally, the height of the apparatus may be selectively adjustable. In this regard, it may be desirable to adjust the height of the apparatus to accommodate users of different height. Additionally or alternatively, the height of the apparatus may be adjusted, for example, such that the apparatus may be positioned on a table or a floor.
[0009] To provide a means for directing the melted candle materials into a candle mold, the apparatus may further include a drip spout. The drip spout may be any mechanism that is suitable to channel the materials from the heated surface into a candle mold. For example, in one embodiment, the drip spout is formed by first and second lips disposed on adjacent edges of the heated surface.
[0010] The apparatus or more traditional candle making apparatuses (e.g., reservoir type candle makers) may be utilized in one or more methods. For instance, consumers may be enticed to make their own candles in, for example, a retail setting. In such a situation, the consumer may rent time on the apparatus and have access to candle making materials. Alternatively, the apparatuses may be provided and consumers may select and purchase candle making goods that are provided for purchase. Alternatively, the apparatus may be provided in a kit with, for example, a predetermined amount of candle making goods. Consumers may then purchase additional materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates a plan front view of one embodiment of an apparatus in accordance with the present invention.
[0012] FIG. 2 . illustrates a plan side view of the apparatus of FIG. 1 .
[0013] FIG. 3 illustrates a process flow sheet.
DETAILED DESCRIPTION
[0014] Provided herein is an apparatus that allows an individual to melt and mold wax or wax-like materials (hereafter wax) in order to form a candle. In conjunction with such melting and molding, the individual may be allowed to mix various different types of waxes (e.g., having different colors) and/or add objects into the wax to provide desired characteristics to the resulting candle. In addition, a method for marketing such candles is provided. For instance, such marketing may include providing locations where consumers may be enticed to form their own individual candles in, for example, a retail setting.
[0015] Reference will now be made to the accompanying drawings, which assist in illustrating the various pertinent features of the candle-making apparatus and methods. The following description is presented for the purposes of illustration and inscription and is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications consummate with the following teachings, in skill and knowledge of the relevant art, are within the scope of the present disclosure.
[0016] FIGS. 1 and 2 show front and side views, respectively, of a candle making apparatus 10 . The candle making apparatus 10 utilizes a heated surface to melt wax, which may drip from the heated surface into a candle mold 50 .
[0017] As shown, the apparatus 10 includes an elevated plate 20 . The elevated plate 20 is suspended above the base member 30 by one or more support members 32 . The elevated plate 20 is disposed at an angle relative to the base member 30 . The plate member 20 further includes a heater element 40 that is operative to heat the plate member 20 (e.g., via conductive, radiative and/or convective contact). Any heating element may be utilized, and the heating element may be thermostat or rheostat controlled. Further, a control mechanism may be included to manage the rate at which the candle materials melt. In this regard, the heating element may be controlled to melt different materials at different temperatures. What is important is that the heating element 40 is operative to apply heat to the plate member 20 . As shown, the heating element 40 is thermally connected to a bottom surface of the elevated plate number 20 .
[0018] The plate member 20 is formed from a conductive material such as steel or aluminum. Accordingly, heat applied to the plate member 20 (e.g., through its bottom surface) is conducted to top surface of the plate number 20 . Wax for use in forming a candle may be set on top of the plate member 20 where the heat from the heating element causes the wax to melt. Do the slope of the elevated plate member 20 , the melted wax runs down the top surface of the elevated plate member 20 to a drip spout 26 . As shown, the plate member 20 includes first and second lips 22 , 24 that are disposed along the lower forward edges of the plate member 20 . These lips 22 , 24 channel melted wax towards the drip spout 26 . Accordingly, the melted wax drips from the drip spout 26 into a candle mold 50 . It will be appreciated that the first and second lips 22 , 24 in addition to channeling wax towards the drip spout may also be utilized to restrain unmelted wax (e.g., blocks of wax) on the surface of the plate member 20 , for instance, when such materials are melting.
[0019] The present arrangement provides a number of benefits over existing candle making apparatuses. For instance, prior apparatuses for making candles typically utilize a reservoir in which a predetermined amount of wax is melted. Once the wax in the reservoir is melted, a spigot or other valve may be opened to allow the wax to pour into a candle mold. While effective for filling a candle mold with wax, previous apparatuses for making candles do not permit the rapid change of wax types/colors. In contrast, the surface melting system described herein permits small amounts of candle making materials (e.g., wax, dyes, perfumes, etc.) to be melted and/or blended on the surface of the plate member 20 . For instance, a first set of materials (e.g., wax shavings of a first color) may be melted on the surface of the plate and a second set of materials may be subsequently melted and/or intermixed with the first color shavings. Accordingly, a user is able to freely design the characteristics of their candle.
[0020] It will be appreciated that variations may be made to the apparatus of FIGS. 1 and 2 . For instance, the plate number 20 may be pivotally attached to the support members 32 . In such an arrangement, the angle of the plate member may be selected by a user.
[0021] This may allow a user to displace the plate between, for example, a horizontal position to a steeply angled position. In this regard, a user may be allowed to place the plate in a substantially horizontal position in order to maintain melted wax on the surface of the plate member 20 in order to better mix, for example, different waxes and/or objects within the wax.
[0022] In a further arrangement, a melt pan (not shown) may be disposed on the surface of the plate member 20 . Such a melt pan may be restrained on the surface of the plate member 20 by the first and second lips 22 , 24 . Such a melt pan may be formed of a conductive material such as steel or aluminum. The melt pan may enhance the ability to blend materials with wax melted within the pan. Accordingly, once the desired materials are mixed within melted wax disposed within such a melt pan, the wax may be poured directly into the mold 50 or poured onto the surface of the plate member 20 such that it may drip into the mold 50 from the drip spout 26 . Alternatively, a stop plug may be provided for disposition between the lips 22 , 24 that is operable to inhibit the passage of candle materials from the inclined surface of the plate member. For example the stop plug may be configured to prevent candle materials from passing through the drip spout 26 . Additionally, the apparatus may include a screen to filter out candle materials that are greater in size than the holes in the screen. In a further arrangement, the support member 32 may be adjustable in height such that the height of the drip spout 26 may be adjusted to accommodate differently sized molds 50 .
[0023] Though illustrated as utilizing a flat plate having first and second lips for directing melted wax, it will be appreciated that many variations of the candle making apparatus are envisioned. What is important is that a surface melting system is provided allows for channeling melted wax into a mold. In this regard, the use of surface melting allows for rapid changing of candle components. That is, as opposed to previous candle making systems that utilize a reservoir of melted wax and a spigot, the present apparatus allows for surface melting of small or large amounts of wax.
[0024] The wax/wax-like material utilized to form the candle may be any appropriate material, including natural and synthetic materials. Non-limiting examples of such materials include beeswax, paraffin, soy wax, and palm wax. Further, it will be appreciated that these wax-like materials may be in any form. For instance, these materials may be in block form such that they may be set on the plate member 20 . Alternatively, pellets, shavings, powders, and even liquid forms of material may be utilized. Accordingly, such wax-like materials, in any form, may be uncolored or colored. For uncolored materials, it will be appreciated that coloring additive may be included such that a user may mix the colorant with the melting wax. A non-inclusive list of objects that may be mixed with the melted wax material includes scents, perfumes, oils, stearic acid, candle dyes (in any form), and/or vybar.
[0025] A second aspect is direct to a method of use of the candle making apparatus 10 . Generally, a method is provided where the apparatus and various candle making materials may be provided to a user. A user of the apparatus 11 may then select (e.g., purchase) different candle making materials. The user may then selectively melt, mix and/or blend these materials on the plate member 20 and hence permit and direct their distribution into a candle mold 50 . Accordingly, the user may alternate different materials and or add additional materials (e.g., rose petals, perfumes, etc) directly to the surface of the plate 20 and/or into the mold 50 . Accordingly, the apparatus allows for a method wherein a candle making apparatuses is provided and candle contents are sold to users who may then form their own personalized/individualized candles utilizing materials purchased from the vendor.
[0026] FIG. 3 illustrates one embodiment of such a method 100 where the candle-making apparatus or apparatuses may be provided ( 110 ) in a location (e.g., in a retail setting) to entice users/consumers to form and purchase an individualized candle. For instance, such a location may be a kiosk at a mall and/or a festival or fair setting, and/or any retail setting whether part of a larger operation or intended solely for this business. In this regard, a number of sample candles may be displayed, and the opportunity to form a candle may be presented ( 120 ) to consumers. That is, consumers may be invited to utilize the apparatus or apparatuses to form their individual candles. Accordingly, candle-making components may be purchased ( 130 ), and consumers may have the opportunity to select and purchase ( 140 ) individual components for their candle, including, without limitation, waxes and/or objects to be disposed within the wax. Alternatively, consumers may purchase the opportunity to form a single candle and, in conjunction with such, purchase the allowed, utilized any materials supplied by the retail outlet. In this latter regard, the consumer may be effectively renting the opportunity to utilize the apparatus to form, for example, a single candle.
[0027] In a further embodiment, individual candle-making apparatuses may be sold to consumers. In such an embodiment, consumers may have the opportunity to buy prepackaged candle-making materials. Alternatively, the apparatus and materials to make a predetermined number of candles may be provided in a kit. Accordingly, consumers may then have the opportunity to purchase replacement candle-making components for use with their apparatus.
[0028] The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the present invention. The embodiments described hereinabove are further intended to explain best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art. | A method and apparatus (“utility”) for quickly and conveniently melting and blending candle materials to form a candle is provided. The utility utilizes a heated inclined surface on which the candle materials may be placed to melt. The melted candle materials may be directed into a candle mold. The utility includes a drip spout for directing the candle materials into a candle mold. A method for providing consumers with the opportunity to make individualized candles is also provided. The method includes enticing consumers to make their own candles, as well as providing an apparatus and/or materials to make candles. The apparatus and candle materials may be purchased and/or rented by consumers. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention generally relates to a reversible weft knit fabric and its method of production. More specifically, the invention relates to a reversible weft knit fabric which has a different color on each of the fabric faces so as to provide a visually distinct appearance to each, and a knitting process for producing the fabric.
2. Description of the Prior Art
Knit fabrics are well known for their ease of manufacture, and are commonly used in the production of apparel. In particular, such fabrics are commonly used to make athletic apparel, because they generally are comfortable to wear and provide a good degree of breathability. One such use of knit fabrics is in the production of jerseys worn during athletic competitions.
In team athletic competitions, it is desirable that the competitors of one team be readily distinguishable from those of the other team. This is commonly achieved by the players of one team wearing apparel of one color while the players of the other wear differently-colored apparel. This can present a particular problem when it is desired that the player composition of the teams be varied, as it requires that either the players each have one item of each of the respectively colored items of apparel, or that players exchange shirts with each other as the teams change so that the members of each respective team are similarly attired. As can be readily recognized, this would be particularly undesirable where the composition of the teams is desired to be changed after some warm-up or play has occurred, since individuals would be forced to don the apparel worn by and perhaps perspired in by another player. As a result, teams often end up playing "shirts and skins", where the teams are distinguished by the fact that one team has on shirts while the other plays bare-chested.
One method which has been employed in an attempt to overcome the above-described disadvantages is the production of items of apparel (and in particular shirts) made from two overlying pieces of knit fabric such that one forms the inside layer of the item of apparel and the other forms the outside apparel layer. While this construction enables the ready switching by a player from one color of shirt to another as his or her team affiliation changes, the garments are generally labor intensive to produce, not capable of easy mass production, and therefore are relatively expensive to produce. Furthermore, such garments are generally heavier than otherwise required.
Thus, it would be desirable to provide a material which could be selectively reversed (that is, turned inside-out) by a player, so that they can readily and easily be identified with either of two teams.
SUMMARY OF THE INVENTION
The instant invention achieves the foregoing advantage through the provision of a knit fabric construction having a first surface of a first color, and a second surface with a second color which is distinct from and readily distinguishable from that of the first color. In addition, the fabric of the invention has good durability,
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C combined illustrate the knitting pattern used to knit a fabric according to the process of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
FIGS. 1A, 1B and 1C together illustrate the knitting stitch pattern used to perform the process of the instant invention to produce the fabric thereof. As illustrated, the process utilizes a dual-bed knitting machine, preferably of the circular knitting machine variety having cylinder and dial needle beds. However, as will be recognized by those of ordinary skill in the art, other forms of flat bed machines could also be used to produce the fabric, within the scope of the instant invention. In any event, circular knitting machines are preferred due to their speed, availability and the ease in which they can be set up to knit the fabric of the invention.
The knitting machine is also desirably arranged so that the respective first and second needle beds are in a rib-gating set up. As will be understood by those of skill in the art, this means that the respective needle beds are offset relative to each other, so that adjacent needles from the individual beds can be in motion at the same time, as opposed to interlock gating where the needles of one bed are directly opposite those of the other bed, such that only one needle at each position can be in operation at a given time.
Furthermore, each of the needle beds includes a plurality of needles positioned in a side-by-side arrangement, with each of the needles desirably being individually controllable for motion throughout the knitting cycle. For purposes of illustration and designation within the claims, the plurality of needles in each of the respective needle beds includes alternating odd-numbered needles separated by alternating even-numbered needles. In other words, where it is desired that only every other needle be operational (i.e. activated) during the production of a given course, it will be the case that only the even-numbered needles or the odd-numbered needles will be employed for the given knit course. In a preferred form of the invention, each of the needle beds will be arranged with alternating long and short needles (e.g. the long needles will be arranged as the even-numbered needles, while the short needles will be arranged as the odd-numbered needles.) As will be readily recognized by those of ordinary skill in the art, such an arrangement assists in the needle selection process and cam set-up during the knitting operations. For purposes of discussion, the needles will be described as cylinder and dial needles, and short and long needles, although the invention is not to be limited to only circular knitting machines or short/long needle arrangements, as described above.
The knitting sequence includes 24 feeds, each of which knits a course as follows:
Feed 1 knits on all of the needles of the first needle bed (i.e. the dial), while tucking on only the short needles of the second needle bed (i.e. the cylinder). The yarn fed has a first color, which will be described more specifically below with respect to the fabric.
Feed 2 then knits on all of the needles of the second needle bed (i.e. the cylinder) only, and does not knit or tuck behind any of the needles of the first needle bed. The yarn fed at Feed 2 desirably has a second color which is visually distinct from the first color, as will be described more fully below.
Feed 3 then knits a pattern like that of Feed 1, i.e. it knits on all of the needles of the first needle bed (i.e. the dial), while tucking behind only the odd needles (i.e. every other needle: in the illustration, the short needles) of the second needle bed (i.e. the cylinder). The yarn fed at Feed 3 is desirably of the first color, which is the same color as fed at Feed 1.
Feed 4 knits a yarn on all needles of the second needle bed (i.e. the cylinder bed), but does not cross over to the first needle bed (i.e. the dial bed). As a result, it will only appear on one of the surfaces of the knit fabric structure. The yarn fed at Feed 4 is desirably the second color (as was fed at Feed 2.)
Feed 5 knits a yarn of the first color on all needles of the first needle bed (i.e. the dial bed.)
Feed 6 knits a yarn of the second color on all needles of the second needle bed (i.e the cylinder bed), but does not cross to the first needle bed.
Feed 7 knits on all needles of the first needle bed (i.e. the dial needle bed) using a yarn having the first color.
Feed 8 knits on all of the needles of the second needle bed (i.e. the cylinder bed), and tucks behind the even numbered needles on the first needle bed (i.e. tucks behind the long needles on the dial bed), using a yarn having the second color.
Feed 9 knits on all needles of the first needle bed (i.e. the dial), using a yarn having the first color.
Feed 10, like Feed 8, knits on all needles of the second needle bed (i.e the cylinder needle bed), and tucks behind even-numbered needles on the first needle bed (i.e. the long needles on the dial needle bed) using a yarn having the second color.
Feed 11 knits a yarn of the first color on all of the needles of the first needle bed only (i.e. the dial bed.)
Feed 12 knits a yarn of the second color on all needles of the second needle bed (i.e. the cylinder needle bed) only.
Feed 13 knits a yarn of the first color on all needles of the first needle bed (i.e. the dial needle bed), while tucking behind the even-numbered needles on the second needle bed (i.e. tucking behind the long needles on the cylinder needle bed.)
Feed 14 knits a yarn of the second color on all needles of the second needle bed only (i.e. the cylinder needle bed.)
Feed 15 knits a yarn of the first color on all needles of the first needle bed, while tucking on the even-numbered needles on the second needle bed (i.e. tucking on the long needles of the cylinder needle bed.)
Feed 16 knits a yarn of the second color on all needles of the second needle bed only (i.e .the cylinder needle bed.)
Feed 17 knits a yarn of the first color on all needles of the first needle bed only (i.e. the dial needle bed.)
Feed 18 knits a yarn of the second color on all needles of the second needle bed only (i.e. the cylinder needle bed.)
Feed 19 knits a yarn of the first color on all needles of the first needle bed (i.e. the dial needle bed.)
Feed 20 knits a yarn of the second color such that it knits on all needles of the second needle bed (i.e the cylinder bed) and tucks on odd-numbered needles on the first needle bed (i.e. tucks behind the short needles on the dial needle bed.)
Feed 21 knits on all needles of the first needle bed (i.e. the dial needle bed) a yarn of the first color.
Feed 22 knits a yarn in the manner of Feed 20, that is, it knits on all needles of the second needle bed (i.e. the cylinder bed) and tucks on oddnumbered needles on the first needle bed (i.e. tucks behind the short needles on the dial needle bed.)
Feed 23 knits a yarn of the first color on all needles of the first needle bed (i.e. the dial needle bed.)
Feed 24 knits a yarn of the second color on all needles of the second needle bed (i.e. the cylinder needle bed.)
As will be readily appreciated by those having ordinary skill in the art, the courses which are knit on only a single one of the needle beds appear on a single side of the resulting knit fabric, while the courses which are knit on the needles of one needle bed and alternately tucked behind certain needles of the opposite needle bed tie the single-bed courses to the structure. As a result, a unique fabric structure having differently-colored faces is achieved. Furthermore, because of the unique knit-and-tuck pattern arrangement (i.e. where particular feeds tuck on particular alternate needles of a second needle bed), the resulting fabric has a unique arrangement of cellular-type openings on each of the two fabric surfaces. These openings provide the fabric with good ventilation capabilities, rendering it particularly advantageous for use in athletic apparel.
As noted, the fabric has good air permeability capabilities and, depending on the yarns used, a somewhat meshy appearance defined by the uniform arrangement of cellular-like openings. In addition, the fabric has good elasticity properties, is durable, and remains stable when pulled or stretched. Furthermore, the fabric has good washability characteristics, and dries quickly due to its airy nature. As a result, the fabric has particular advantages in the manufacture of athletic apparel, such as that used in running, tennis, golf, soccer, basketball, volleyball, baseball, field hockey, and other sports. In addition, the thus-produced fabrics have good hand and aesthetic characteristics, and provide comfort to a wearer when worn as a garment.
As described above, the odd-numbered feeds utilize a yarn or yarns of a first color, while the even-numbered feeds use a yarn or yarns of a second color which is visually distinct from the first color. As a result, the fabric has a first side which is a first color (corresponding to one of the two yarn colors), while the second side of the fabric is of the second color of yarn. Although described as "first" and "second" colors for purposes of clarity of description, it is to be noted that each of the first and second colors can include more than one color. For example, if desired, the second yarn color could include alternating yarns of more than one color, so as to produce a fabric having a first solid-colored side and a second striped side. Stated differently, the first time a "second color" yarn is provided, it could be of a certain shade while the second time a "second color" yarn is provided, it could be of a different shade from that of the "second color" yarn fed previously and preferably, also different from that of the first color yarn. Also, the difference in colors between the first and second colored yarns can be provided by any known means which enables the yarns forming the respective fabric surfaces to appear visually distinct from each other.
Virtually any type of yarn which can be used on a knitting machine can be used in the instant invention, including, but not limited to natural or synthetic yarns or blends thereof, textured or non-textured yarns, spun or continuous filament yarns, single or multifilament yarns, bulky or non-bulky yarns, micro-denier or non-micro-denier yarns, yarns of a single material or blended yarns, yarns of varying twist and size, etc. Furthermore, the fibers forming a part of the yarns can be of any variety and cross-sectional shape, including circular, triangular, polygonal, C-shaped, Y-shaped, petal shaped, or the like. In addition, the yarns can be treated to impart specific properties to the finished fabric, such as by processing with a hygroscopic treatment such as a surface-active agent to enhance the moisture absorbing ability of the yarns.
Also, the process can be performed on any typed of dual bed knitting machinery regardless of cut or gauge.
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A reversible knit fabric having a first surface of a first color and a second surface of a second color is described. The fabric is integrally knit on a dual-bed weft knitting machine so that each of the surfaces of the fabric is visually distinct from the other. The fabric also includes an arrangement of cellular-like mesh openings on each face thereof, so as to provide a fabric which has good breathability and appearance. In addition, the fabric has good durability, elasticity, and washability. As a result, the fabric is particularly useful in the manufacture of athletic apparel. Furthermore, because the fabric has a visually distinct appearance on each of its two sides, it can be used to produce reversible garments such as jerseys for use in scrimmages.
A process for knitting the fabric is also described. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to a grinding unit for grinding machines and a method for mounting the same.
BACKGROUND OF THE INVENTION
[0002] Grindstones are used in grinding units, whereby not only the grindstones but also a workpiece to be ground revolve during grinding operation. The shape of the grindstones varies depending upon the face and position of a workpiece to be ground. For example, cylindrical surfaces are ground with the faces of revolution of grindstones formed into the disc shape, while flat surfaces are ground by rotating a plural number of rectangular grindstones being arranged in a circle in such a manner that grinding may be effected with an end face of each grindstone.
[0003] Regarding the shape of grinding units to be mounted on a grinding machine, in the case of cylindrical grinding, disc grindstones are fixed by a holder and mounted on a grinding wheel spindle, whereas in the surface grinding operation, a plural number of rectangular grindstones are fixed on the circumference of a rotary cylinder attached on the wheel spindle.
[0004] FIGS. 4 (A), (B) and (C) are a front view (in part) and sectional view and a partly enlarged perspective view illustrating a conventional grinding unit mounted around a cylinder of a grinding machine. Rectangular grindstones 27 are set to a cradle 29 of a cylinder 12 A, and wedge-formed metal fixtures 30 are inserted between the two adjacent grindstones 27 . When locking bolts 32 are fastened, the wedge 31 is moved toward the center of the cylinder (along the direction of the arrow), while the grindstones 27 are simultaneously forced away right and left, thereby causing the gaps to be narrowed to effect fixing.
[0005] All of the rectangular grindstones 27 , which are interrelated with the metal fixtures 30 , get positioned only after fastening of the locking bolts 32 of the metal fixtures. The number of grindstones mounted on the large-size grinding tool amounts up to 50 or so, and it requires a lot of time and labor to set all of so many grindstones in position, followed by fixing with wedge-shaped fixtures. Such tedious work adversely affects the rate of operation of a grinding machine in question and is undesirable. In addition, the face of each metal fixture protrudes beyond the surfaces of the grindstones, and inevitably interferes with metal fixtures 26 of a workpiece to be ground (refer to FIG. 3).
[0006] Since the rectangular grindstone 27 is not resistant to shock, adequate care is required when handling such grindstones. As wear advances, furthermore, such grindstones become difficult to be fixed with wedge-type metal fixtures, if they are oversized relative to the metal fixtures used. In light of the fact that raw materials for grindstones are costly, a method of using grindstones in a non-efficient manner pushes up the machining costs and is undesirable.
[0007] [0007]FIG. 5 is a side view illustrating the state of use of another conventional grindstone in grinding a boss 25 a of a disc brake 25 . A rectangular grinding unit 27 A consisting of angled grindstones 2 A bonded to the tip of a grindstone holder 3 A are mounted around a rotary cylinder 12 A of a grinding machine 11 A by use of wedge-type metal fixtures. The angled tip of grindstone 2 A that brings about variations in thickness tends to break off, resulting in severe damage to the service life of grindstones 2 A.
[0008] When the outer face of the wedge-type metal fixture 30 (see FIG. 4), which protrudes beyond the outer face of the grindstone 2 A, approaches to a metal fixture 26 of the disc brake 25 , their mutual interference (i.e. collision) is inevitable depending upon the positional conditions of the wedge-type metal fixture 30 . For this reason, the grinding unit 27 A is slanted when used, as shown in FIG. 5.
[0009] The object of the present invention is to provide a grinding unit and a method for mounting the grinding unit that have solved the above-mentioned problems.
BRIEF SUMMARY OF THE INVENTION
[0010] In the first aspect, the present invention is a grinding unit, a plurality of which is placed around a cylinder of a grinding machine. Each grinding unit comprises a grindstone holder having on one side face at least a positioning cutout, and a thinly cut grindstone attached to one end of the grindstone holder.
[0011] In the second aspect, the present invention is a grinding unit assembly, a plurality of which is placed around a cylinder of a grinding machine. Each assembly comprises a grinding unit having a grindstone holder having on one side face at least a positioning cutout and a thinly cut grindstone attached to one end of the grindstone holder, and a metal fixture having a metal body having a protrusion adapted to fit in the cutout and a locking bolt
[0012] In the third aspect, the present invention is a method for mounting a grinding unit assembly to a cylinder of a grinding machine, comprising the steps of: setting to a cradle of the rotary cylinder a corresponding portion of the grindstone holder having a cutout, engaging the right and left protrusions of a body of the metal fixture individually into the cutouts of two adjacent grindstone holders, compressing the grindstone holders with the protrusions, and fastening the metal fixture with the locking bolts.
[0013] Preferably, the outer face of the metal fixture and outer face of a head of the locking bolt are housed inside an outer face of the grindstone holder.
[0014] The grinding unit according to the present invention, which consists of thinly cut grindstones fixed through bonding to a grindstone holder, gets the grindstones subjected to forces in the vertical and horizontal directions alone during grinding operation, and therefore eliminates the risk of breaking or tearing, unlike the counterparts consisting of rectangular grindstones. As a result, this can contribute to uniform wearing and efficient utilization of grindstones.
[0015] In the grinding unit and the mounting method for the same according to the present invention, a thinly cut grindstone is fixed through bonding to a grindstone holder. This can prevent the grindstones from breaking and tearing, whereby full advantage is taken of cutouts provided on a grindstone holder to suppress metal fixtures from protruding out of the surface of grindstones. In addition, the need for using angled grindstones is eliminated in the corner grinding for root portions of projections and the like. These enable grindstones to wear uniformly and also facilitate the grinding units to be mounted on a grinding machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Some of the object and advantages of the present invention having been stated, others will appear as the description proceeds when considered in conjunction with the accompanying drawings, in which:
[0017] FIGS. 1 (A), 1 (B) and 1 (C) are individually a front view and bottom view of a grinding unit consisting of a grindstone 2 and a grindstone holder 3 , and a sectional view taken along the line a-a of FIG. 1(A);
[0018] FIGS. 2 (A), 2 (B) and 2 (C) are a front view of a grinding machine consisting of grinding units 3 mounted around a rotary cylinder 12 , a sectional view taken along the line b-b of 2 (A) and a partly enlarged perspective view of grinding units 3 and metal fixtures 16 , respectively;
[0019] [0019]FIG. 3 is a side view of a grindstone in use for grinding a disc brake having a boss;
[0020] FIGS. 4 (A), 4 (B) and 4 (C), which are concerned with Prior Art 1, are a front view of a grinding machine consisting of grinding units mounted around a rotary cylinder, a sectional view taken along the line c-c of 4 (A) and a partly enlarged perspective view of grinding units and metal fixtures, respectively;
[0021] [0021]FIG. 5, which is concerned with Prior Art 2, is a side view illustrating the state of use of a grindstone for grinding bosses of a disc brake having a boss.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] As illustrated in FIGS. 1 (A), 1 (B) and 1 (C), a thinly cut grindstone 2 is bonded to a grindstone holder 3 . The external and internal surfaces of the grindstone holder 3 are formed in the arc and plane shapes, respectively. The grindstone 2 , which is usually shorter than the grindstone holder 3 , is subjected mainly to compressing force in the vertical direction and frictional force in the horizontal direction, with the remaining forces substantially acting to the grindstone holder 3 . A larger-sized grindstone extending from the edge of the grindstone holder, however, enables its outer face to carry out corner grinding of projections, etc. (see FIG. 3), thus eliminating the need for the grindstone to be angled.
[0023] The thin grindstone 2 bonded to a grindstone holder 3 , as compared with rectangular grinding unit consisting solely of grindstones 27 (see FIG. 4), is more resistant to impact and shock during grinding operation, and has no risk of failing or damaging, thus contributing to uniform grinding work. The grindstone holder 3 may be of any metal plate structures but can be advantageously fabricated by die cast molding to give a high-precision and lightweight structure.
[0024] As is shown in FIGS. 2 (A), 2 (B) and 2 (C), surface grinding can be effected by a grinding machine 11 which has a large number of grinding units 1 arranged around a rotary cylinder 12 . The grindstones 2 are positioned by applying the inner face 4 of the grindstone holder 3 to the rotary cylinder 12 and setting one end of the projection 18 of the metal fixture 16 to either upper or lower end 8 or 9 of the cutout 7 provided on the side of adjacent grindstone holder 3 .
[0025] The grinding unit 1 of the present invention, in which the outer face 19 of the metal fixture 16 is placed inside the outer face of the grindstone holder, is constructed so as to allow the head 22 of the locking bolt 21 not to stand out of the hole 20 of the bolt. By virtue of the above construction, a disc brake 25 with a boss 25 a as shown in FIG. 3 can be ground without interference of a metal fixture 16 of the grindstone 2 with a metal fixture 26 of the disc brake 25 placed on the working bench 14 . As a result, the grinding range is maintained without being adversely affected.
[0026] Surface grinding is classified into one-side grinding and double-side grinding. In the former, the grinding unit 1 is only disposed on one side of a workpiece, whereas in the latter, the grinding units are disposed to act on both sides of a workpiece to thereby grind both the face and back sides simultaneously. In the latter case, positioning may be easily made, when the downwardly acting grindstones 2 are placed relative to the upper end 8 of the cutout (as is illustrated in FIG. 2(C)) and the upwardly acting grindstones are placed relative to the lower end 9 of the cutout.
[0027] The grindstone holders 3 are positioned by setting to a cradle 13 of the rotary cylinder 12 a corresponding portion of the grindstone holder 3 and then engaging the right and left protrusions 18 of a body 17 of the metal fixture 16 individually into the cutouts of two grindstone holders 3 . Then, the grindstone holders 3 are compressed with the protrusions 18 , and the locking bolts 21 are fastened to thereby effect provisional fixing of two adjacent grindstone holders 3 .
[0028] The mounting method of the present invention, which involves compressing the grinding unit 1 from above, facilitates reliable mounting to be effected, as compared with the wedge mounting method mentioned above, thereby realizing a reduction in required length of time for mounting all of the grinding units 1 . Vertical force as well as horizontal force owing to rotation mainly act on the grindstones 2 in operation, which makes grindstones undergo uniform wearing, without causing abnormal wearing, thereby contributing to efficient utilization of expensive grindstones.
MERITORIOUS EFFECTS OF THE INVENTION
[0029] The grinding units and the mounting method for the grinding units according to the present invention can produce the following effects:
[0030] (1) The use of a grindstone holder 3 makes grindstones 2 thinner and is useful in providing grindstones with uniform wear
[0031] (2) The use of a grindstone holder 3 eliminates the accident of grindstone breaking;
[0032] (3) The use of a grindstone holder 3 prolongs the service life of grindstones 2 , and enables expensive grindstones to be utilized more efficiently;
[0033] (4) The cutout of the grindstone holder 3 maintains the outer face of a metal fixture inside the outer face of a grindstone, thereby getting rid of interference with the metal fixtures of a workpiece and preventing reduction in the range of grinding.
[0034] (5) The grinding unit 1 is mounted for fixing by pressing cutouts with the protrusions of metal fixtures in place of pressing directly the grindstone, thereby reducing a length of time required for mounting the grinding unit as compared with the wedge-type metal fixtures
[0035] (6) No interference takes place among the metal fixtures, thus eliminating the need for angularly shaped grindstones to be used in grinding corners of bosses. | A grinding unit assembly, a plurality of which is placed around a cylinder ( 12 ) of a grinding machine. Each assembly comprises a grindstone unit ( 1 ) and a metal fixture ( 16 ). The grindstone holder ( 3 ) has on one side face a positioning cutout ( 7 ), and a thinly cut grindstone ( 2 ) attached to one end of the grindstone holder ( 3 ). The metal fixture ( 16 ) has a metal body ( 17 ) having a protrusion ( 18 ) adapted to fit in the cutout ( 7 ) and a locking bolt ( 21 ). | 1 |
PRIORITY
[0001] This application claims priority to U.S. Provisional Application No. 61/309,675 filed Mar. 2, 2010, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to devices used to hold fishing poles. More particularly, it relates to a device used for ice fishing that holds a fishing pole, indicates a strike by tipping down, and releases the fishing line.
[0004] 2. Related Art
[0005] As with other forms of fishing, an ice fisherman is alerted to a fish taking his bait by the fishing rod end tipping downward. This is caused by the fish pulling on the bait and the fishing line. Various devices have been devised to hold a fishing rod in place and signal a fish strike or bite. One type is generally referred to as a tip-up and provides a flag or similar signal that is caused to go up when a bite is felt on the line. A second type is generally referred to a tip-down. A tip-down allows the fishing rod to move from pointing somewhat upward to somewhat downward using the downward force of the fish strike to move the rod.
Outline of Basic and Other Advantageous Features
[0006] It would be desirable to provide a fishing rod mounting or the like of a type disclosed in the present application that includes any one or more of these or other advantageous features:
A tip-down that releases the line as soon as the pole is tipped down; A tip-down that allows line to be released as the fish swims rather than pulling the bait away from the fish; and A tip-down that is easily stored and transported.
SUMMARY
[0010] An exemplary embodiment relates to a tip-down, comprising a pivoting support structure for holding a fishing pole and a fishing line clamp wherein the pivoting support structure is capable of pivoting between an up position and a down position and wherein a tip of a fishing pole in the pivoting support structure would be noticeably higher in the first position than the tip would be in the second position.
[0011] These and other features and advantages of various embodiments of systems and methods according to this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of various devices, structures, and/or methods according to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various exemplary embodiments of the systems and methods according to the present disclosure will be described in detail, with reference to the following figures, wherein:
[0013] FIG. 1 is a front perspective view of an exemplary embodiment of a tip-down according to the present disclosure;
[0014] FIG. 2 is a front view of the embodiment of FIG. 1 with a fishing pole in a tipped-up position;
[0015] FIG. 3 is a front view of the embodiment of FIG. 1 with a fishing pole in an intermediate position between a tipped-up position and tipped-down position;
[0016] FIG. 4 is a front view of the embodiment of FIG. 1 with a fishing pole in a tipped-down position; and
[0017] FIG. 5 is a from view of an exemplary embodiment of a pivot plate for a tip-down according to the present disclosure.
[0018] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0019] With conventional tip-downs, the hook and line can move to the extent the pole is allowed to move. Once the rod is down, the fish cannot pull the bait further unless it is strong enough to overcome the resistance of the fishing reel to turning. However, this resistance is generally not strong enough to set the hook in the mouth of the fish so it is necessary for the fisherman to react quickly to a strike by taking the fishing rod and setting the hook. Because ice fishing of necessity is done in cold weather on the surface of a frozen water body, the fisherman may be in a warmer location (e.g., a portable but or a vehicle) rather than near the pole. In addition to removing the necessity to constantly hold the pole, such devices allow a single fisherman to fish with multiple poles in different holes.
[0020] With a and conventional tip-down, after the pole has tipped down the bait cannot easily be pulled further and may be pulled away from the fish's mouth as it swims away. When a fish strikes the bait, initially the hook is often not deep into the fish's mouth. If the hook is not set into the fish's mouth, the fish may escape. To set the hook, a fisherman will give the pole a hard, fast yank. With conventional tip-downs, the line will limit where a fish may take the bait, but the force from a fish pulling the bait away from the pole is rarely enough to set the hook and the fish may release the bait and hook in response to the pull of the line on the bait. This combination of factors creates a small window of opportunity for the fisherman to react and set the hook, which time may be too short if the user is tending another pole or for any other reason not close enough to the pole and tip-down. Because of this, many fish strikes do not result in the fish being hooked and caught.
[0021] In various exemplary embodiments, as shown in FIG. 1 , tip-down 100 includes a base 101 , a support member 102 , and a pivoting support structure 110 . In various exemplary embodiments, the pivoting support structure 110 includes a plate 111 that is pivotally connected to the support member 102 . The plate 111 pivots between two different positions, referred to herein as an up position and a down position. In the up position, a fishing pole 120 placed in the tip-down 100 is pointed somewhat upward, as illustrated in FIG. 2 . In the down position, a fishing pole 120 placed in the tip-down 100 is pointed somewhat downward, as illustrated in FIG. 4 . In various exemplary embodiments, the pivot plate 111 is attached to the support member 102 such that it pivots around a point 112 (“pivot point”) other than its center of mass (“center point”). For example, the pivot point 112 may be located somewhat above or below the center point. In such exemplary embodiments, the force of gravity will pull the pivot plate 111 toward either the up position or the down position. No precise pivot point 112 is required and the choice of where to place the pivot point 112 will also be affected by the weight of the plate 111 , the weight of the pole 120 , and the location of the support pegs 114 and 115 and reel support peg 117 .
[0022] In various exemplary embodiments, as shown in FIG. 1 , three pegs extend from the pivot plate 111 : a front support peg 114 , a back support peg 115 , and a reel support peg 117 . As shown in FIG. 1 , the front and back support pegs 114 and 115 are placed further from the center of the pivot plate 111 . In various exemplary embodiments, as shown in FIGS. 2-4 , the fishing pole is placed on and supported by the two support pegs 114 and 115 with the front support peg 114 closer to the tip of the pole and the back support peg 115 closer to the bottom or handle of the pole 120 (shown in FIGS. 2-4 ). In various exemplary embodiments, the reel support peg 117 is placed roughly between the support pegs 114 and 115 , but below an imaginary line passing through the front and back support pegs 114 and 115 . In various exemplary embodiments, the reel support peg 117 may be centered between the support pegs 114 and 115 or be somewhat closer to one or the other support peg 114 or 115 . It should be appreciated that the designation of the support pegs 114 and 115 as front and hack is for the purpose of aiding in the description of the use of the device. A pole 120 (shown in FIGS. 2-4 ) may placed as shown in the drawings or its direction may be reversed with the front support peg 114 functioning as the back support peg 115 and vice versa. A fishing pole 120 may be oriented in either direction as desired (e.g., so that the handle of the reel 121 (shown in FIGS. 2-4 ) is away from the plate 111 ). Reversing the orientation of the tip-down 110 permits the tip-down 110 to be used with the pole 120 to either the right-hand or left-hand side.
[0023] In various exemplary embodiments, one or both of the support pegs 114 and 115 include a groove 116 into which the fishing rod 120 is placed. The groove(s) 116 provide greater stability to the fishing rod 120 while in the tip-down 100 , which may be particularly important in harsh weather (e.g., wind or storms) or during a powerful fish strike.
[0024] As shown in FIG. 2 , a fishing pole 120 is placed on the tip-down 100 by resting the pole 120 on the support pegs 114 and 115 with the reel 121 preferably between the support pegs 114 and 115 . The reel is preferably located between the reel support peg 117 and the back support peg 115 , but may be placed to either side of the reel support peg 117 . In the preferred position, the reel rests against the back support peg 115 when in the up position and, the reel conies to rest against the reel support peg 117 when in the down position. In various exemplary embodiments, the reel may instead be placed between the reel support peg 117 and the front support peg 114 and the choice may depend in part on the length and weight of the pole 120 being used.
[0025] In various exemplary embodiments, the plate 111 is pivotally coupled to the support leg such that the plate 111 will remain in the up position until a downward force is applied. The plate 111 will also remain in the down position until an upward force is applied. In various exemplary embodiments, the plate 111 is most stable in the extreme positions (i.e., toward the up and down positions) and tends to pivot away from an intermediary position. This may be accomplished by locating the pivot point 112 away from the pivot plate's center of gravity.
[0026] In various exemplary embodiments, as shown in FIGS. 2-4 , a stop 104 projects from the support leg 102 just below the pivot plate 111 . The plate 111 is shaped such that it comes into contact with a stop 104 at the up position and down position, which prevents the pivot plate 111 from pivoting too far in either direction.
[0027] In various exemplary embodiments, as shown in FIGS. 1-4 , the tip-down 100 also includes a line clamp 103 , FIG. 2 shows the line clamp 103 and reel as positioned while waiting for a fish strike. The tip-down 100 is in the up position and the reel is open, but line is not released because it is held in place by the lime clamp 103 . When a fish strikes, the pole is pulled downward and the pivot plate 111 rotates from the up toward the down position, as illustrated by FIG. 3 .
[0028] FIG. 3 shows the tip-down 100 immediately following a fish strike. The pivot plate 111 has rotated to or very near to the down position. The line is shown still held by the line clamp 103 , but the force of the fish strike will pull the line free of the line clamp 103 at least by the time the pivot plate 111 is fully rotated to the down position, as shown in FIG. 4 . In various exemplary embodiments, the line clamp 103 is oriented pointed significantly more downward than horizontal. With a conventional tip-down 100 , the reel would be closed and the fish would feel resistance from the bait. In various exemplary embodiments of the disclosed tip-down 100 , the fish will not feel any significant resistance from the bait because the reel is open and will be much less likely to lose the bait. At this point, the user can see that a fish strike has occurred and can react appropriately.
[0029] FIG. 5 shows an exemplary embodiment of a pivot plate 111 . In various exemplary embodiments, the pivot plate 111 is generally symmetrical around vertical axis 118 , which passes through pivot point 112 , in various embodiments, the pivot plate 111 includes a cut-out or slot 113 . As shown in FIGS. 3-4 , slot 113 interacts with stop 104 to control the extent to which the pivot plate 111 can rotate.
[0030] In various exemplary embodiments, the base 101 comprises one or more horizontal pieces. In various exemplary embodiments, the base, pieces rotate relative to the support leg so that they are parallel to the support leg. This makes it easier to store or transport the tip-down 100 (e.g., ice fishermen often transport equipment in buckets). In various exemplary embodiments, the tip-down 100 includes a mechanism to lock the base pieces in place relative to the support leg in the open (i.e., in use) and/or closed (i.e., for storage) position. In various exemplary embodiments, the tip-down 100 may include additional pieces attached to the support leg or base pieces to provide additional support and stability, which may be beneficial when a fish strikes or in windy conditions.
[0031] In various exemplary embodiments, the tip-down 100 may be used left-handed or right-handed. In other words, the tip-down 100 may be rotated so that, from the perspective of the user, the rod may be placed to the right or to the left of the pivot plate 111 . Thus, either support peg may be the front or the back support peg, depending on how the pole is oriented.
[0032] Although the tip-down has been described in connection with ice fishing, in various exemplary embodiments, the tip-down may be used for fishing at any time of year. For example, the tip-down may be used for shoreline fishing. The tip-down is used as described after casting. In such uses, the tip-down will function as described and allow a striking fish to draw out fishing line without significant resistance until the user intervenes. In various exemplary embodiments, the tip-down may be used with a variety of fishing rods from very short ones to rods at least as long as six feet.
[0033] For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.
[0034] It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.
[0035] As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.
[0036] It is also important to note that the construction and arrangement of the tip-down, as shown in the various exemplary embodiments, is illustrative only. While the tip-down, according to this invention, has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent. Accordingly, the exemplary embodiments of the tip-down, according to this invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Therefore, the description provided above is intended to embrace all known or later-developed alternatives, modifications, variations, improvements, and/or substantial equivalents. | The present disclosure relates to tip-down devices used in fishing and particularly adapted for use in ice fishing. In various exemplary embodiments, the tip down includes a pivoting rod holder wherein the fishing rod pivots between two positions and automatically moves away from intermediate positions, the two positions differing in the tip of the fishing rod being held upward or downward. In various exemplary embodiments, the disclosed tip-down includes a line clip, which is used to temporarily hold the fishing line in place (e.g., at a point between the reel and the first eye of the fishing rod). The disclosed tip-down the fishing rod to be set up in a way that allows a fish to take the bait and attempt to swim away without resistance from the fishing line or rod while still indicating a strike and allowing the user, who may be remote from the fishing rod, time to respond. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to prototyping of integrated systems.
Background to the Invention
[0002] To prototype a system it is convenient to have a processor on-chip running at its normal speed, and the logic or other off-chip resources which are ultimately to be integrated onto the chip as an off-chip circuit for prototyping purposes. The off-chip circuit can be for example in the form of an FPGA or emulator and can provide memory resources.
[0003] Currently, this involves either bonding-out the processor core so that its signals are available off-chip or using one of the existing off-chip communication ports which are already provided on the chip on which the processor is situated. Such ports are generally serial ports or reduced pin-out ports such as debug ports, and in any event are not provided as dedicated ports for prototyping but have some already existing function.
[0004] In a situation where the processor core is bonded-out, there are a number of problems. In the first place, bonding-out of a processor's on-chip interface uses a lot of pins. The processor has to be run at a reduced speed in order for the bond-out interface to function reliably. The limitation on the use of pins means that it is difficult to support platform prototyping where some resources are integrated on-chip and some are not.
[0005] Where an existing off-chip communication port is used, there are also difficulties. Many such ports require software assistance to function. This software is not required in the integrated system which is under prototype, which means that the prototype software in the final software will have to be different. In effect, the final software cannot run on the prototype and therefore any testing of the prototype cannot completely match the final product.
[0006] Many such ports have an address map footprint which implies that the prototype address map is different from the final integrated address map. This also means that the final software cannot run on the prototype.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention there is provided an integrated circuit comprising: a processor operable to issue memory access requests, each memory access request identifying an address in memory to which the request is directed; at least one on-chip resource falling within the address space addressable by the processor; an interface for directing packets off-chip and addressable within the address space of the processor; and a request directing unit for receiving said memory access requests and directing them in accordance with a selected one of first and second address maps, wherein said first address map has a first range of addresses allocated to said at least one on-chip resource and a second range of addresses allocated to said interface, and in said second memory address map said first range of addresses are also allocated to the interface.
[0008] According to another aspect of the invention there is provided a prototype system comprising an integrated circuit comprising: a processor operable to issue memory access requests, each memory access request identifying an address in memory to which the request is directed; at least one on-chip memory resource falling within the address space addressable by the processor; an interface for directing packets off-chip and addressable within the address space of the processor; a request directing unit for receiving said memory access requests and directing them in accordance with a selected one of first and second address maps, wherein said first address map has a first range of addresses allocated to said at least one memory resource and a second range of addresses allocated to said interface, and the second memory address map said first range of addresses are also allocated to the interface; and an off-chip circuit connected to said interface and including at least one off-chip memory resource.
[0009] According to another aspect of the invention there is provided a method of evaluating a prototype system comprising an integrated circuit including an on-chip processor associated with at least one on-chip memory resource and an off-chip circuit associated with at least one off-chip memory resource, the method comprising: executing a computer program on the on-chip processor, said program causing the generation of memory access requests, each memory access request including an address identifying an address in memory to which the request is directed; and in accordance with a selected mode of operation, selectively supplying said memory access requests to at least one of said first and second memory address maps, and directing the memory access requests selectively to said on-chip memory resource or said off-chip circuit in dependence on the selected one of said first and second address maps.
[0010] For a better understanding of the present invention and so show how the same may be carried into effect, reference will now be made by way of example to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic diagram of an integrated system;
[0012] FIG. 2 shows a memory access packet;
[0013] FIG. 3 shows the addressing configuration of a first address map;
[0014] FIG. 4 shows the addressing configuration of a second address map; and
[0015] FIG. 5 shows the decode logic of the memory management unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] FIG. 1 is a schematic diagram of a system to be prototyped. The system comprises an integrated circuit in the form of chip 2 on which is implemented a communication path 4 which takes the form of a packet router. The described embodiment implements a SuperHyway interconnect, but the present invention can be applied to any form of bus architecture.
[0017] The router 4 is connected to a CPU 6 and to a plurality of other functional modules. The CPU 6 has a cache memory 8 , a memory management unit MMU 14 and control registers CR.
[0018] There are a plurality of resource modules 10 , 12 of which only two (Resource1, Resource2) are shown, though it will be appreciated that there may be any number of resource modules. Each resource module is a memory mapped peripheral, e.g. a graphics block, direct memory access (DMA) or other memory access module. As an example of a memory access module, there is illustrated an external memory interface EMI 16 connected to off-chip memory devices 17 . Other memory access modules, such as FEMI (Flash EMI) may also be present. It will be appreciated that there will be other functional modules and possibly including other processor modules connected to the router 4 . Some of those modules are referred to later but are not shown in FIG. 1 .
[0019] Each module includes control registers CR associated with that particular module. The chip 2 also includes ports (not shown) connected to the router 4 , e.g. peripheral bridge ePBR etc. In addition the integrated circuit 2 includes a SuperHyway off-chip (SHOC) interface 20 . The interface 20 has first and second wide bi-directional ports 22 , 24 connected to the router 4 on the circuit-side of the interface 20 and first and second narrow off-chip ports which are unidirectional, outgoing being referenced 26 and incoming being referenced 28 . The interface 20 communicates with a similar interface 30 on an off-chip circuit 32 which forms part of the system under prototype and which includes off-chip resources 34 .
[0020] The off-chip resources 34 can include off-chip memory, control registers or any other resources.
[0021] The bi-directional wide ports 22 , 24 are high pin-out ports which are capable of transmitting packets between the router 4 and the interface 20 . The off-chip unidirectional ports 26 and 28 are each narrower in the sense that they have a smaller number of pins to allow off-chip communication. Communication over the router 4 is in the form of packets which in the described embodiment have a maximum length of 32 bytes. The interface 20 is capable of performing a chop and frame function on packets received from the router 4 for transmission off-chip so as to transmit the packet off-chip in a plurality of chunks via the off-chip communication path attached to the port 26 . Conversely, the interface can reassemble chunks which are received on the incoming data path attached to port 28 into packets for communication on the router 4 . The precise semantics of the interface 20 do not form part of the present invention and so are not discussed further herein. The invention can be implemented with any suitable form of off-chip port.
[0022] Memory access requests are issued by the CPU 6 in the form of packets. An example packet is shown in FIG. 2 which represents a memory access request packet. The packet comprises a lock field Ick, opcode field opc, source field src, transaction identifier field tid, address field addr, data field DATA, byte enable field be, end of packet field eop and a valid bit VALID. The important field to note herein is the address field which can be 4 bytes long and which identifies an address in memory to which the memory access requests relate. The opcode field opc identifies the memory operation, for example whether the memory access request is a read or write. If it is a write request, data is correspondingly sent in the packet. The address in the packet is interpreted by decode logic and arbitration logic 13 forming part of the router 4 . The decode logic is responsible for reading the address and comparing the address with predetermined address ranges which identify to which module the packets should be sent. The decode logic can operate in two modes. The first mode is termed platform mode and allocates the address space addressable by the address field addr in the memory access request packet across the on-chip memory resources 16 , 18 , 10 , 12 . In addition, part of the address space is reserved for the SHOC interface 20 to allow certain packets to be dispatched off-chip.
[0023] In the second mode, referred to as bond-out mode, the entire address space is mapped off-chip via the SHOC interface 20 . In this way, all memory access requests are directed off-chip and so all non-CPU resources are off-chip.
[0024] This allows two prototyping modes to be used depending on the nature of the system being developed, while utilising the same evaluation chip 2 . Platform mode allows a customer to preserve the address map of the evaluation chip 1 , and integrate their IP only into the memory space occupied by the SHOC port while bond-out mode allows the user to decide to use the evaluation chip 2 only as a CPU core, using the entire memory space for their own IP.
[0025] FIGS. 3 and 4 show examples for the memory maps in platform mode and bond-out mode respectively. In platform mode, the memory space is mapped as follows.
0x00 . . . EMI 0x0D0 . . . CPU 0x10 . . . Res1 0x40 . . . Res2 0x80 . . . Res3 (not shown)
[0031] In each case, the address given above is the beginning address of the mapped region for the particular resource in question. The address space illustrated in FIG. 3 is 0x00 . . . to 0xFF . . .
[0032] FIG. 4 shows how the address space is mapped in bond-out mode. In FIG. 4 , the 29 bit space is mapped only to the SHOC interface 20 and the CPU. The EMI 16 , Resource1 10 , Resource2 12 and Resource 3 (not shown) no longer have their own addresses, so that packets which would formerly have been sent to them are instead transmitted to the SHOC interface 20 and are sent off-chip. Although not illustrated, it will be appreciated that the control registers accessible in the CPU are also addressable. In the address map for platform mode, the CPU addresses include addresses of control registers associated with the on-chip resource.
[0033] The manner in which this altered mapping is implemented will now be explained with reference to FIG. 5 which illustrates the decode logic in the router 4 . The address field addr is supplied to a multiplexer 40 which is controlled responsive to a mode signal on line 42 . This mode signal can be implemented in any suitable way, but in particular can be taken out to a mode pin 46 shoc_mode on the chip which can be set to logic zero or logic one on power-up therefore to determine the memory address mode of the system under prototype. The decode logic includes an address map 48 for bond-out mode and an address map 50 for platform mode. According to the address map 50 , each of the address ranges against which the incoming address field addr is compared are mapped according to the mapping of FIG. 3 . Thus, there are address ranges for each resource Res1, Res2, Res3, the ePBR, the CPU and the SHOC part. In addition there is an address range associated with Core Support Peripherals (CSP) which are memory mapped to a target port belonging to the CPU but are nevertheless visible to other modules on the router 4 . The address map 48 maps these ranges in accordance with the address map of FIG. 4 . In particular in the address map 48 , there is a single address range including addresses for the various on-chip resources Res1, Res2, Res3, and the SHOC interface 20 . Note however that the ePBR, CPU and CSP remain individually mappable ports. A request vector is generated by the comparators in the operative one of the address maps 48 , 50 and is output via an output multiplexer 52 also controlled by the mode signal on the mode pin 46 . The request vector indicates to a system arbiter (not shown) that a request packet for a particular target is pending, and the arbiter routes the packet to the target if the target is available while indicating to other modules connected to the router 4 that the request packet is not for them. Note that in platform mode using address map 50 , packets may be routed to the on-chip resources 10 , 12 , Resource1, Resource2 etc, whereas using the address map 48 of bond-out mode addresses which would have been directed to these resources are now directed to the SHOC interface 20 .
[0034] It will be appreciated that a similar mapping technique to that described above could be used for routing response packets back to the initiator module that made the associated request. That is, in platform mode, the router directs responses to requests made from initiators on-chip (including the CPU) and initiators behind the SHOC interface 20 . In bond-out mode, responses made to the CPU are routed back to either the CPU initiator or to an initiator off-chip via the SHOC interface 20 . | A prototype system is described having an integrated circuit including an on-chip processor and an on-chip router connected to off-chip resources via an interface. A request directing unit on the chip receives memory access requests and directs them in accordance with either one of two address maps. In one of the address maps, a first range of addresses is allocated to at least one on-chip resource and a second range of addresses is allocated to the interface. In the other memory address map, the first range of addresses is also allocated to the interface. An integrated circuit including such a request directing unit is also described, together with a method for evaluating a prototype system. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application hereby incorporates by reference the complete text of application Ser. No. 08/897,336, entitled "REAGENTS FOR ISOTROPIC SIZE ENHANCEMENT", by inventors Ton That Hai, David E. Pereira and Deanna J. Nelson, filed on the same date as this application, Jul. 21, 1997.
FIELD OF THE INVENTION
This invention relates to hemoglobin compositions and other biopolymer substrates having isotropically increased size and isotropically distributed negative charge. The invention also relates to such isotropically modified hemoglobin compositions having oxygen binding affinity, viscosity and colloid osmotic pressure in therapeutically useful ranges.
BACKGROUND OF THE INVENTION
All vertebrate hemoglobins have the same molecular configuration. Hemoglobin is a protein made up of four polypeptide subunits, two alpha chains and two non-alpha chains. A natural cavity is defined by certain amino acids in each subunit. This cavity contains a heme prosthetic group, consisting of a porphyrin ring and an iron ion. Hemoglobin in the form capable of reversibly binding and releasing oxygen, the iron ion is in the +2 oxidation state, i.e., the ferrous form, and is sequestered by each porphyrin ring within the protein. In a hemoglobin tetramer, each alpha subunit is associated with a non-alpha subunit to form two stable alpha/non-alpha dimers, which in turn associate to form the tetramer. The subunits are noncovalently associated through Van der Waal's forces, hydrogen bonds and salt bridges. The molecular weight of native human hemoglobin is about 65,000 Daltons.
Hemoglobin can be collected from mammalian blood or derived from genetically engineered sources. However, even after stringent purification, unmodified vertebrate hemoglobin has no therapeutic utility. Free hemoglobin has an affinity for oxygen too high for release of oxygen to the tissues. Further, unmodified free vertebrate hemoglobin readily dissociates into alpha/non-alpha dimers in the circulation. High concentrations of these dimers overwhelm the haptoglobin scavenging system and accumulate in the tubules of the kidney, where they are nephrotoxic. Chemical modification of hemoglobin is necessary to overcome these deficiencies.
The tetrameric structure of hemoglobin may be stabilized by intramolecular covalent crosslinking between at least two of the subunits of the native hemoglobin. The molecular weight of the resulting hemoglobin composition is about 65,000 Daltons, similar to that of the source hemoglobin. Moreover, the manner of intramolecular crosslinking may be selected to provide both stabilization of the tetrameric structure of hemoglobin and a change in hemoglobin conformation sufficient to impart oxygen binding characteristics similar to those in freshly collected red blood cells. For example, native hemoglobin may be extracted from red blood cells, purified, and intramolecularly crosslinked. Examples of crosslinked hemoglobins and methods for their preparation are described in U.S. Pat. Nos. 4,001,401 and 4,053,590, which disclose intramolecular crosslinking between an alpha and beta subunit of a hemoglobin tetramer utilizing compounds such as halogenated cycloalkanes, diepoxides, and diazobenzidines. WO 90/13309 (Staat der Nederlanden de Minister Van Defeuric) discloses a method for crosslinking hemoglobin through a beta-beta subunit linkage. In the present method, a preferred modified hemoglobin is crosslinked with bis(3,5-dibromosalicyl) fumarate to create a fumarate crosslink between the two alpha subunits. This crosslinked hemoglobin is more fully described, together with methods for its preparation, in U.S. Pat. Nos. 4,598,064, 4,600,531, RE 34,271, omitting the chromatography step. It is preferably manufactured under the conditions disclosed in U.S. Pat. No. 5,128,452 (Hai) to prevent crosslinking between the beta chains. The preferred diaspirin crosslinked hemoglobin will hereafter be referred to as "DCLHb". U.S. Pat. Nos. 4,598,064, 4,600,531, RE 34,271, and 5,128,452 are hereby incorporated by reference. In addition, the genes encoding subunits of a desired naturally occurring or mutant hemoglobin can be cloned, placed in a suitable expression vector and inserted into an organism, animal, or plant, or into cultured animal or plant calls or tissues. The hemoglobin produced therefrom can be expressed and collected as described, for example, in Hoffman, S. J. and Nagai, K. in U.S. Pat. No. 5,028,588. Transgenic animals can be produced that express non-endogenous hemoglobin (Logan, J. S. et al., PCT application WO 92/22646).
These intramolecularly crosslinked hemoglobin compositions have therapeutic utility both for humans and other mammals. See, for example, Sloan, Koenigsberg, and Bickell, "The Use of Diaspirin Cross-linked Hemoglobin (DCLHb) in the Hospital Management of Hemorrhagic Hypovolemic Shock", Academic Emerg Med 1995; 2(5): Abstract No. 78.
Hemoglobin compositions having a molecular weight of about 65,000 Daltons have a short half-life in the circulatory system, because they are able to traverse cellular pores in the membrane of the blood vessels and capillaries, entering the interstitial spaces between endothelial cells lining the lumen. Consequently, these hemoglobin compositions are lost from the circulation while they still retain therapeutic utility. The hemoglobin composition diaspirin crosslinked hemoglobin (DCLHb), which has a molecular weight of about 65,000 Daltons, has an elimination half-life of 2.5 hours for a 25- and 50-mg/kg dose and an elimination half-life of 3.3 hours for a 100 mg/kg dose. (Przybelski, et al., Crit Care Med 1996; 24(No. 12): 1993-2000.)
Further chemical modifications to hemoglobin which increase molecular weight have been used in attempts to extend the duration of circulation of the hemoglobin composition. See Bunn, H. F., Amer J Hematol 42:112-117, 1993. These additional modifications include conjugation and polymerization. In addition, modification to increase overall negative charge may also extend half-life in the circulation, since the negative charges in the vessel walls tends to repel hemoglobin with high negative charge.
Conjugated hemoglobin is hemoglobin to which a non-protein macromolecule is bound covalently. The properties of hemoglobins conjugated to polysaccharides have been reviewed by Dellacherie. (E. Dellacherie, "Polysaccharides in Oxygen-carrier Blood Substitutes", chapter 17 in Polysaccharides in Medicinal Applications, S. Dumitriu, ed. Marcel Dekker, Inc., New York, 1996, pages 525-545.) For example, hemoglobin may be conjugated to inulin in a process disclosed in U.S. Pat. No. 4,377,512 (Ajinomoto). Hemoglobin may be conjugated to a polysaccharide such as dextran in a process disclosed in U.S. Pat. No. 4,900,816 (Fisons). Macromolecular conjugates of hemoglobin and a substituted dextran, together with a process for its preparation, are provided in U.S. Pat. Nos. 5,079,337 and 5,110,909 (Merieux). A further example of a conjugated hemoglobin composition is a hemoglobin chemically modified by polyalkylene glycol, which is described together with a process for its preparation in WO 91/07190 (Enzon). An example of a hemoglobin conjugated to poly(alkylene oxide) and a process for its preparation are provided in U.S. Pat. Nos. 4,301,144, 4,412,989, and 4,670,417, and in Japanese Patent Nos. 59-104323 and 61-053223 (Ajinomoto).
A polymerized hemoglobin is one in which intermolecular crosslinking of hemoglobin tetrameres has been used to increase the molecular weight of the modified hemoglobin. An example of a polymerized hemoglobin and a process for its preparation are described in U.S. Pat. No. 4,777,244 which discloses a method for crosslinking and polymerizing with aliphatic dialdehydes.
A hemoglobin, modified by a combination of methods, is exemplified by the following. Hemoglobins modified by pyridoxal-5'-phosphate to adjust the oxygen affinity and by polyethylene glycol conjugation and processes for its preparation are described in Japanese Patent Nos. 59-089629, 59-103322 and 59-104323 (Ajinomoto). U.S. Pat. No. 5,248,766 discloses a crosslinking polymerizing strategy and a process for covalently interconnecting intramolecularly crosslinked tetrameric units with oxiranes to form polyhemoglobins with molecular weights in excess of 120,000 Daltons.
Even though conjugation and polymerization both increase the molecular weight of the constituent hemoglobin, these hemoglobin do not have isotropically increased size. This is illustrated in the ball and stick structures of FIG. 1. The process of polymerization with a bifunctional reagent such as glutaraldehyde generates a homologous series of hemoglobin polymers having, for the most part, linear structures analogous to barbells or beads on a string FIGS. 1a and 1b. Since the polymers comprise multiple hemoglobin units, the molecular weight of each of the component polymers is about (64,500)×n, where n has a value from 2 to 10 or more. If one considers the functional diameter of the polymeric hemoglobin stretched lengthwise along an arbitrary x-axis, it is larger than that of a single hemoglobin. However, if one considers the functional diameter of the polymeric hemoglobin from the perspective of either terminus (i.e., along the z-axis) as in FIG. 1c), this diameter is no greater than that of a single hemoglobin molecule. Therefore, the polymeric hemoglobins can still readily leak out of capillaries through the pores of the luminal membranes and interstitial junctions, thereby shortening the period of therapeutic effectiveness. Similarly, conjugation with a polysaccharide such as dextran or inulin generates a conjugated hemoglobin having a linear structure analogous to the barbell structure in FIG. 1a. Thus, conjugates of this type also are characterized by a functional diameter no greater than that of a single hemoglobin molecule.
Other problems arise in conventionally conjugated hemoglobin. Conjugation of hemoglobin with a polyalkylene oxide, such as polyethylene glycol (PEG) or polyoxyethylene, or polymerization of hemoglobin undesirably increases its viscosity (Winslow, R. M., "The Design of Blood Substitute Oxygen Carriers for Clinical Applications", In: Shock: From Molecular and Cellular Level to Whole Body, K. Okada et al., editors. Elsevier Science, 1996, pages 323-333). Viscous fluids are difficult to administer, and would unacceptably alter the fluid properties of the blood.
A hemoglobin uniformly greater in diameter than the diameters of the cellular pores would be retained for longer periods of time in the circulatory system, particularly if the surface modification also isotropically dispersed negative surface charge would be repulsed from the surface of endothelial cells lining the lumen of the circulatory system. See Rennke, Cotran, Venkatachalam, J Cell Biol 67:638, 1975. No known hemoglobin composition meets these criteria.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a hemoglobin composition having isotropically increased size and having isotropically dispersed negative surface charge. It is a further object of the invention to provide a hemoglobin composition having an unexpectedly low viscosity relative to its increased size.
Pharmaceutical formulations of the invention can be prepared for both clinical medicine and veterinary use. These formulations can be useful for, for example, subcutaneous, intravenous, intraperitoneal, or intramuscular injection, or topical or oral administration in small or large volumes. Said formulations of the invention can be administered by any conventional means such as by oral or aerosol administration, by transdermal, transmembrane or mucus membrane absorption, or by infusion.
In one embodiment, the compositions can be formulated pharmaceutically for use in therapeutic applications in clinical or veterinary medicine. For example, the formulations of the present invention can be used in compositions useful for the replenishment of the systemic circulating volume of fluid in a mammal, for the restoration of the systemic circulation in a mammal, for the restoration of oxygen delivery, and for the replenishment of the oxygen delivery capacity.
The compositions of the present invention can be formulated pharmaceutically for use for the replenishment of the systemic circulating volume of fluid in a mammal following hemorrhage, i.e., as volume expanders. These compositions provide both additional fluid volume and oncotic pressure due to the presence of the large hemoglobin protein molecule.
Such compositions formulated in a pharmaceutically compatible carrier fluid are useful as red blood cell replacement fluids and can be used for the treatment of hemorrhage and hypovolemic shock where blood volume is lost and both fluid volume and oxygen carrying capacity must be replaced. These compositions can also be used for replacement of blood lost during surgical procedures or where the patient's blood is removed and saved for reinfusion at the end of surgery or during recovery (i.e., acute normovolemic hemodilution or hemoaugmentation).
In a further embodiment, the formulation of the instant invention can be used to treat anemia, both by providing additional oxygen carry capacity in a patient that is suffering from anemia and by stimulating and supporting hematopoiesis.
In accordance with the present invention, oligosaccharide-biopolymer conjugates are provided for either masking biologically reactive sites or for isotropic size enhancement, the oligosaccharide moiety having the structure according to formula I:
B'-(A-B).sub.n -A'-NH-L-Y
wherein A and B are sugars which may be of N-acetylgalactosamine, N-acetylglucosamine, glucuronic acid, iduronic acid or glucose forming a repeating disaccharide unit in which A and B are joined covalently by a glycosidic bond between C-1 of sugar A and C-3 or C-4 of sugar B. The A-B disaccharide units are joined covalently to form an oligosaccharide by a glycosidic bond between C-1 of penultimate sugar B of a first disaccharide unit and C-3 or C-4 of sugar A in the next successive disaccharide unit. B' is a sugar at the non-reducing terminus of the oligosaccharide of ring structure identical to sugar B, and A' is a 1-amino, 1-amido, or 1-imino acyclic hexose joined covalently by a glycosidic bond between C-1 of sugar B at the terminus opposite the non-reducing terminus of said oligosaccharide and C-3 or C-4 of sugar A'. This structure is further joined covalently by a 1-amino, 1-amido, or 1-imino linkage to linker L comprising an aliphatic, acyclic carbon chain containing one or more moieties, which can be an ether, thio ether, or amide. The linker bridges sugar A' and one or more groups Y, which may be a methylene radical, β-hydroethylene radical, carboxyl radical, succinamide alpha radical, or nullity. These Y groups are the portions of the Z group described in copending patent application Ser. No. 08/897,336, remaining after reaction with the nucleophilic groups contained in the biopolymer. As used herein, the term "nullity" means the absence of any portion of the Z group which is lost as a leaving group upon reaction of the electrophilic group with the nucleophilic group of the biopolymer. The biopolymer, which may be a protein, carbohydrate, or polynucleotide is thereby covalently attached to the linker L.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a schematic of two protein molecules conjugated by covalent bonding through a bridging group.
FIG. 1b is a schematic showing the linear characteristics of poly-conjugated protein molecules.
FIG. 1c shows the directionality of the Z axis.
FIG. 2 shows a protein molecule decorated with surface displayed molecules.
FIG. 3 limits the decorated protein to hemoglobin.
FIG. 4 gives a schematic structure for disclosed compounds showing the configuration of the modified sugar A' at the reducing termini of the amino, amido, and imino forms.
FIG. 5 shows molecular formulae for three suitable linkers.
FIGS. 6a, 6b and 6c shows the chemistries of the reducing end moieties starting with three different native polysaccharides.
FIG. 7 gives the molecular structures for a number of possible Z groups useful in the disclosed compound, reagents prior to conjugation with a biopolymer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the conjugates of the present invention, an oligosaccharide-containing reagent having a terminal electrophilic Z group as shown in FIG. 7, reacts with a nucleophilic group, such as a free amino group, on a biopolymer to produce an oligosaccharide-biopolymer conjugate. The biopolymers may be proteins including enzymes, haptens, antibodies, polypeptides; polynucleotides; steroids, and other carbohydrates. In a preferred embodiment, the biopolymer is chemically modified hemoglobin, and most preferably, diaspirin cross-linked hemoglobin. It will be apparent that use of a branched linker with two or more reactive electrophilic groups, will result in multiple anchoring of the oligosaccharide to the substrate biopolymer. The biopolymer must, of course, display one or more nucleophilic groups, either naturally occurring, or created by conventional chemical techniques. The conjugate can be purified by conventional methods. In laboratory scale, gel exclusion will separate the reactants from the conjugates in one or two steps.
The oligosaccharide-containing reagent having a terminal Z group is disclosed in the figures. Referring to Formula I and FIG. 1, each ring structure A, A', B and B' is a sugar. Each sugar contains at least one substituent selected from the group consisting of --CO 2 - , --OSO 3 - , --NHCOCH 3 , and --NHSO 3 - . The remaining substituents on the sugar ring are selected from the group consisting of --H, glycosidic --O-- and --OH. The repeating unit of the oligosaccharide comprises sugar A and sugar B, wherein sugar A is covalently joined to sugar B by a glycosidic bond from carbon-1 of sugar A to carbon-3 or carbon-4 of sugar B, wherein sugar B is covalently joined to sugar A by a glycosidic bond from carbon-1 of sugar B to carbon-3 or carbon-4 of sugar A, and n is an integer from 2 to about 20. Sugar B', which is positioned at the non-reducing terminus of the oligosaccharide has a structure identical to that of sugar B, with the exception that it is not covalently joined by a glycosidic bond at carbon-3 or carbon-4 to any other sugar. Sugar A', the erstwhile reducing sugar of the oligosaccharide, has a structure identical to that of sugar A, with the exception that the latent aldehyde that was present at carbon-1 of the sugar has been modified by reductive amination or imination to enable covalent joining to one terminus of a linker L.
The sugars A, A', B, and B' which are useful in the present invention may be commonly named as, for example, N-acetylglucosamine, glucuronic acid, N-acetylgalactosamine, iduronic acid, and glucose.
Linker L is an organic bridge having a length of from about 10 Å to about 300 Å and having a plurality of termini, one of which is covalently joined as an amine or imine to carbon-1 of sugar A' and each of the remainder of which terminates as and is covalently joined to Z, an organic functionality which provides a reaction group for covalent coupling to a nucleophile.
The organic bridge of linker L may be an acyclic, aliphatic carbon chain containing ether, thioether, or amide moieties and has a linear portion extending from sugar A' and a linear or branched portion that incorporates the remaining terminus or termini.
The purpose of the linker is to position the reactive group away from the oligosaccharide chain so as to avoid steric hinderance of the coupling reaction forming the conjugated macromolecule. It is important that the linker be aliphatic and acyclic with an absence of double bonds or aromatic rings. The incorporation of ethylene or diethylene glycol moieties, amide bonds, and thioether groups reduces antigenicity and provides for water solubility. The linker may contain one or more of these moieties as illustrated in the structures set forth in FIG. 5. The linker may be completely linear or may be branched at the terminus opposite its point of covalent attachment to sugar A'. The branched termini may each end in a Z group, to create a plurality of attachment points between the macromolecular surface and the oligosaccharide strand.
An organic functionality Z is covalently joined to each free terminus of linker L of the electrophilic reagent joined to sugar A' as shown in FIG. 5. Functionality Z will react with a nucleophile to form a covalent bond between a reagent of the present invention and the nucleophile. For example, if Z is an aldehyde, an activated ester of a carboxylic acid, a maleimide, an epoxide, a tosyl or tresyl ester, or a halide, such a reagent of the present invention will react with an amine nucleophile to yield a product in which the said reagent is covalently joined to an amine nucleophile as an imine or amine (after reduction), an amide, an amine-substituted maleimide, a beta-hydroxy amine, or an amine, respectively (see FIG. 7 for typical reactives). A Z halide, maleimide, or epoxide, will also react with a sulfhydryl nucleophile to yield a product covalently joined to the sulfhydryl nucleophile as a sulfide, a thio-substituted maleimide, or a beta-hydroxy sulfide, respectively. In the biopolymer conjugate, the Z group may be present as a residual methylene radical, β-hydroethylene radical, carboxyl radical, a succinamide alpha radical, or be absent entirely with direct joining of the linker to the biopolymer (nullity).
Many examples of these chemistries are given in Chemistry of Protein Conjugation and Cross-linking, S. Wong, CRC Press, Inc. (1991) which is incorporated by reference herein.
The molecular weight of the reagent of Formula 1 is from about 1,000 to about 15,000 Daltons, more preferably from about 1,000 to about 10,000 Daltons, and most preferably about 5,000 Daltons. The oligosaccharide component of Formula I may be synthesized de novo or may be derived from natural sources. In a preferred embodiment, the oligosaccharide is a hydrolysate of chondroitin sulfate. The hydrolysis is carried out conventionally, and the fragments may be sorted by known sizing methods to produce a population of desired length having less than five percent contamination by oligosaccharides of a length different from the desired length.
Substrates suitable for modification by the present reagents include peptides, proteins, nucleotides, polynucleotides, pharmaceutic agents, diagnostic agents, and polymers which have at least one nucleophilic functional group capable of forming a covalent bond with the terminus of the linker. One substrate of interest is diaspirin crosslinked hemoglobin (DCLHb) described in U.S. Pat. Nos. 4,598,064, 4,600,531, RE 34,271.
FIGS. 6a, 6b and 6c are flow diagrams showing structures of compounds provided in the reaction pathway in the synthesis of three reagent compounds. In FIG. 3a the starting material is an acid hydrolysate (polyanionic oligosaccharides) derived from chondroitin-4-sulfate. The terminal sulfate sugar is converted by reductive amination or imination to the structures shown, and then further reacted with the linker moiety containing a Z reaction group. Z reaction groups comprise an aldehyde, activated ester of a carboxylic acid, maleimide, tosyl ester, tresyl ester, halide, or epoxide. As depicted in the equation shown in FIG. 7, the Z group reacts with either an amino nucleophile or sulfhydryl nucleophile to form a bond covalently coupling the oligosaccharide linker moiety to the protein or other macromolecule.
The polyanionic oligosaccharide portion of the reagents is selected to mimic the structure and properties of glycosaminoglycans found naturally in the extracellular matrix. Thus, the polyanionic oligosaccharides are linear sugars, have a non-reducing terminus and a terminus opposite the non-reducing terminus, and are constructed from a repeating disaccharide unit. The two sugars of the disaccharide unit are joined covalently by a glycosidic bond between C-1 of one sugar and C-3 or C-4 of a second sugar and each sugar of each repeating disaccharide unit is joined covalently by a glycosidic bond to another sugar.
The oligosaccharide portion of the reagents may be obtained by acid or enzyme catalyzed hydrolysis of natural polysaccharides or may be synthesized de novo. For example, the polyanionic polysaccharides chondroitin 6-sulfate, chondroitin-4-sulfate or hyaluronic acid may be hydrolyzed with acid catalysis to a mixture of polyanionic oligosaccharides and the fragments may be sorted by known sizing methods to produce a population of desired length. In the case of chondroitin-6-sulfate the repeating disaccharide is N-acetylgalactosamine-6-sulfate joined covalently by a glycosidic bond to glucuronic acid.
In the case of chondroitin-4-sulfate the repeating disaccharide is N-acetylgalactosamine-4-sulfate joined covalently by a glycosidic bond to glucuronic acid. In the case of hyaluronic acid the repeating disaccharide is N-acetylglucosamine joined covalently by a glycosidic bond to glucuronic acid.
Likewise, starch may be hydrolyzed with acid or enzyme catalysis to a mixture of oligosaccharides and the fragments may be sorted by known sizing methods to produce a population of desired length. The selected population of fragments may be sulfated by conventional means to produce a polyanionic oligosaccharide having repeating disaccharide units comprised of glucose and sulfated glucose joined covalently by glycosidic bonds.
FIGS. 6b and 6c show the reaction and compounds formed where the starting materials are acid hydrolyzed chondroitin-6-sulfate and hyaluronic acid, respectively. In each case, a linker has a reaction Z group at its non-sugar terminus.
The conjugates of the present invention are represented schematically by Formula II:
B'-(A-B).sub.n -A'-NH-L-Y-Biopolymer
in which the letters common to Formula I and II have the same range of identity as disclosed for Formula I. Y herein represents either a nullity (i.e., a covalent bond links the --NH group to the biopolymer) (wherein the electrophilic group Z is a leaving group, as in halide) or that portion of Z which is incorporated into the conjugate upon reaction with the nucleophilic group on the biopolymer.
Because of the broad distribution in the body, the hemoglobin compositions of the instant invention can also be used therapeutically to deliver drugs and for in vivo imaging. Moreover, the properties of fluorescence and oxygen-binding which are inherent to hemoglobins are maintained in the hemoglobin compositions of the present invention. Therefore, the compositions are useful for photodynamic therapy, in vivo monitoring by magnetic resonance and fluorescence, and for the generation of oxygen radical species by irradiation.
Because the hemoglobin composition of the instant invention can be formulated in a balanced, physiological electrolyte vehicle which will have osmolality, onconicity, and solution pH in physiologically useful ranges and which will maintain the capability for oxygen transport and delivery in extravascular circuits, said hemoglobin compositions can be useful for the perfusion of organs and tissues isolated from the normal vasculature. In these cases, the hemoglobin composition of the present invention can supply oxygen for the maintenance of metabolic function in said organs and tissues and can remove non-oxygen ligands that may be released from said organs and tissues.
A typical dose of the hemoglobin composition of the instant invention formulated as a blood replacement fluid is from about 10 mg to 20 g or more of acellular hemoglobin per kilogram of patient body weight. Thus, a typical dose for a human patient might be from a few grams to over 300 grams of acellular hemoglobin. It will be appreciated that the unit content of active ingredients contained in an individual dose of each dosage form need not in itself constitute an effective amount, since the necessary effective amount could be reached by administration of a plurality of administrations as injections, etc. The selection of dosage depends upon the dosage form utilized, the condition being treated, and the particular purpose to be achieved according to the determination of the ordinarily skilled artisan in the field.
Administration of an acellular hemoglobin composition can occur for a period of seconds to hours depending on the purpose of the hemoglobin usage. For example, as a blood delivery vehicle, the usual time course of administration is as rapid as possible. Typical infusion rates for hemoglobin solutions as blood substitutes replacements can be from about 100 mL to 3000 mL/hour. However, when used to stimulate hematopoiesis, administration can last only seconds to five minutes and therefore administration rates can be slower because the dosage of hemoglobin is much smaller than dosages that can be required to treat hemorrhage.
The composition of the present invention can also be used for a number of in vitro applications. Non-pharmaceutical compositions of the invention can be used as, for example, reference standards for analytical instrumentation or methods, reagent solutions, means for control of gas content of cultures of cells or microorganisms, and means for removal of oxygen from solutions. For example, the delivery of oxygen by the composition of the instant invention can be used for the enhancement of cell growth in cell culture by maintaining oxygen levels in vitro. Moreover, the hemoglobin of the instant invention can be used to remove oxygen from solutions requiring the removal of oxygen, and as reference standards for analytical assays and instrumentation.
The following examples are provided by way of describing specific embodiments of the present invention.
Example 1
Preparation of Representative Oligosaccharides
In the examples, two chromatographic methods were used to monitor reactions and to characterize the products. Size-exclusion chromatography (SEC) was performed using SUPERDEX™ 200 column (Pharmacia), a mobile phase consisting of 50 mM phosphate, pH 7.0, containing 0.15 M NaCl, delivered at a flow rate of 0.7 mL/min., and analyte detection at 214 nm for oligosaccharide reagents and at 280 nm for modified peptide or protein. In this assay, materials elute from the stationary phase in the order from largest to smallest in size, i.e., larger entities elute with shorter retention times and smaller entities elute with longer retention times. Reversed-phase high performance liquid chromatography (RP-HPLC) was performed using a Vydac Protein C-4 column, with elution using mobile phases (A) and (B) delivered at 1 mL/min. as a linear gradient having the following compositions over time: 1) 50% B to 55% B over 20 minutes; 2) 55% B to 75% B over 10 minutes; 3) 75% B to 85% B over 10 minutes. Mobile phase (A) consisted of CH 3 CN/H 2 O/TFA, 20:80:0.1, by volume. Mobile phase (B) consisted of CH 3 CN/H 2 O/TFA, 60:40:0.1, by volume. Analytes were monitored at 280 nm.
A. Preparation of a Representative Oligosaccharide from Chondroitin-4-Sulfate.
Chondroitin-4-sulfate (400.8 g) was dissolved in 5 L of 0.5 N HCl. The solution was heated to 65° C. for about 24 hours and then cooled to ambient temperatures using an external ice bath. The solution pH was adjusted to 7.6 by the addition of 5 N NaOH. To the solution was added 12 L of ethanol. An oily precipitate formed. The solvent was decanted, and 4 L of ethanol was added. The mixture was stirred to obtain a granular solid. The solid was collected by filtration and washed successively with ethanol (2×500 mL) and ethyl ether (1×500 mL). The solid was dried under vacuum to give 343.5 g of product having an SEC retention time of about 27 minutes. This material was identified by the acronym "C4S-4K".
B. Preparation of a Representative Oligosaccharide from Chondroitin-6-Sulfate.
Chondroitin sulfate, Type C (18.4 g; from shark cartilage, reported molecular weight of 25-50 kiloDaltons; Maruha Corporation) was dissolved in 0.5 N HCl (230 mL), and the stirred solution was heated at 65° C. for 24 hours. The reaction mixture was cooled to room temperature, and then the solution pH was adjusted to pH 7.4 with 5 N NaOH (25 mL). The stirred solution was slowly diluted with ethanol (600 mL) and then maintained at 5° C. for three hours before the supernatant was removed by decantation. The oily residue was stirred with ethanol (200 mL) for 10 minutes and the supernatant was discarded. The residue was stirred vigorously with ethanol (400 mL) to precipitate the product, which was collected by filtration, washed successively with ethanol and ethyl ether and dried under high vacuum. The product (18.12 g) has a SEC profile characterized by a peak having a retention time (at the peak maximum) of about 27 minutes. This material was identified by the acronym "C6S-4K".
C. Preparation of a Representative Oligosaccharide from Hyaluronic Acid.
A viscous slurry of hyaluronic acid (18.4 g, Bioiberica) in 0.5 N HCl (300 mL) was stirred vigorously at 65° C. The reaction was monitored by SEC. After heating at 65° C. for 19 hours, the reaction mixture was cooled to room temperature, and the solution pH was adjusted to 7.4 with 5 N NaOH (29 mL). The solution was filtered through 0.45μ pore-size filter membrane, and the filtrate volume was reduced to 180 mL by evaporation under high vacuum. The solution was stirred during slow dilution with ethanol (750 mL) to give an oily product. After discarding the supernatant, the oily product was stirred with fresh ethanol (300 mL) to give a granular solid (14 g), which was collected by filtration, washed with ethanol and then ethyl ether, and dried under high vacuum. The product was characterized by an SEC retention time (peak maximum) of 26 minutes. This material was identified by the acronym "HA-4K".
Example 2
Reductive Amination of Representative Oligosaccharides
A. Preparation of C4S-4K-DGBE.
The reagent, diethylene glycol bis(3-aminopropyl)ether mono-t-butyl carbonate (DGBE-BOC) was prepared by known methods from diethylene glycol bis(3-aminopropyl)ether (DGBE) and di-t-butyl carbonate.
C4S-4K (222.0 g, 55.0 mmol) and DGBE-BOC (150.1 g, 470.5 mmol) were dissolved in 1.2 L of Sterile Water for Irrigation, USP, and the pH of the solution was adjusted to 8.31 by the addition of 1.00 N HCl. Ethanol (600 mL) was added to clarify the solution. Borane-pyridine complex (8 M, 57 mL) was added to the solution. The reaction was monitored by TLC (silica gel; eluent: 2-propanol:NH 4 OH:H 2 O, 6:1:3, by volume; detection by exposure to 2,3,5-triphenyltetrazolium chloride). The solution was heated at 40° C. for four days and then cooled to ambient temperatures. The solution pH was adjusted to 10.03 by the addition of 5.00 and 1.00 N NaOH. Ethanol (12 L) was added, and the resulting slurry was stirred for three hours. The precipitate was allowed to settle for about one hour, the solvent was decanted, and the solid was collected by filtration and washed successively with ethanol (2×500 mL) and ethyl ether (1×500 mL). The solid was dried under vacuum to constant weight (210.7 g). This material was identified by the acronym "C4S-4K-DGBE-BOC". Removal of the BOC group was achieved by treatment of C4S-4K-DGBE-BOC with fifteen equivalents of HCl in water at pH 0.8 for 24 hours to afford the desired product, which was identified by the acronym "C4S-4K-DGBE".
B. Preparation of C6S-4K-DGBE.
A solution of C6S-4K (17 g, 4.25 mmol) and BOC-DGBE (13.62 g, 42.5 mmol) in deionized water (85 mL) was adjusted to pH 8.4 with 1 N HCl (38 mL). Borane-pyridine complex (8 M, 42.5 mmol, 5.31 mL) and ethanol (30 mL) were added successively, and the clear solution was stirred at 40° C. The reaction was monitored by TLC (silica gel; eluent: 2-propanol:NH 4 OH:H 2 O, 6:1:3, by volume; detection by exposure to 2,3,5-triphenyltetrazolium chloride). After four days, the reaction mixture was cooled to room temperature, and the solution pH was adjusted to 10.0 with 1 N NaOH (22 mL). Water (25 mL) was added, and the solution slowly was diluted with ethanol (1 L) to precipitate the product, which was identified by the acronym "C6S-4K-DGBE-BOC". The latter (15.8 g) was collected by filtration, washed successively with ethanol and ethyl ether and dried under high vacuum. Dilute (1 N) HCl (52.2 mL) was added to a solution of C6S-4K-DGBE-BOC (13.9 g) in water (50 mL) to give a solution having a pH of 0.80. After stirring at room temperature for 24 hours, the solution was evaporated to dryness. The residue was dried under high vacuum to give solidified product (13.2 g), which was identified by the acronym "C6S-4K-DGBE".
C. Preparation of HA-4K-DGBE.
HA-4K (10.0 g, 2.5 mmol) and BOC-DGBE (7.3 g, 23.8 mmol) were combined in 50 mL of water. The pH was adjusted to 8.25 with 1.00 N HCl. Borane-pyridine complex (8 M, 3.0 mL) was added, followed by 25 mL of ethanol. The solution was heated at 40° C. for five days. The solution was cooled to ambient temperature, and the pH was adjusted to 10.00 with 1.00 N NaOH. To the solution was added 500 mL of ethanol. The solid was collected after stirring for two hours. The solid was washed with ethanol (50 mL) and then with 100 mL of ethyl ether. The solid was dried under reduced pressure to give 9.5 g of the desired product, which was identified by the acronym "HA-4K-DGBE-BOC". An 8.5 g portion of this BOC-derivative was dissolved in 35 mL of water, and 35 mL of 1.00 N HCl was added. The pH of the solution was 0.85. The solution was stirred at room temperature for about 24 hours and then concentrated under vacuum to a volume of about 100 mL. Ethanol (800 mL) was added. The mixture was stirred, and after about 1.5 hours the solid was collected and washed with ethyl ether (25 mL). The solid was dried under reduced pressure to give 6.3 g of the desired product, which was identified by the acronym "HA-4K-DGBE".
D. Preparation of C4S-4K-NH 2 .
Borane-pyridine complex (4.7 mL, 8 M, 37.5 mmol) and ethanol (50 mL) were added to a solution of C4S-4K (15 g, 3.75 mmol) and an ammonium salt (168.75 mmol) such as ammonium acetate, ammonium bicarbonate, ammonium carbonate, ammonium carbamate or ammonium formate, for example, in water (100 mL). The solution was stirred and heated at 40-50° C. for four days. Analysis of the product mixture by TLC showed that the product mixture was negative to 2,3,5-triphenyltetrazolium chloride (a reagent for the detection of reducing sugars) and positive to ninhydrin. Then the reaction mixture was concentrated under vacuum to dryness and the residue was successively treated with water (100 mL) and concentrated under vacuum to dryness (3 times) to remove excess ammonium salt. The residue was dissolved in water (150 mL) and the solution was diluted with ethanol (600 mL) to give an oily product which was isolated by decantation. The oily product was stirred with ethanol (400 mL) to solidify the product, which was isolated by filtration, washed with ethyl ether, and dried under vacuum to constant weight (13.5 g). This material was identified by the acronym "C4S-4K-NH 2" .
E. Preparation of C6S-4K-NH 2 .
It is chemically reasonable to predict that treatment of C6S-4K with an ammonium salt in the presence of a reducing agent such as borane-pyridine in the manner described above will yield the amine "C6S-4K-NH 2 ".
F. Preparation of HA-4K-NH 2 .
Borane-pyridine complex (BP; 2.12 mL; 8 M; molar ratio of BP/HA-4K of 10) and ethanol (25 mL) were added to a solution of HA-4K (6.8 g; 1.7 mmol; assumed MW of 4000) and ammonium carbonate (7.35 g, 76.5 mmol) in water (60 mL). The solution was stirred at 40° C. for five days and evaporated to dryness. The residue was dissolved in water (50 mL), and the solution was extracted with chloroform (3×50 mL) to remove excess boranepyridine. The aqueous solution was concentrated under vacuum to dryness, and the residue was treated with water (4×50 mL) and reconcentrated to dryness to remove residual ammonium carbonate. The resulting residue was dissolved in water (50 mL), the solution was filtered through 0.45 μ pore-size filter membrane, and the filtrate was diluted with ethanol (250 mL) to give an oily product. The supernatant was removed by decantation. The oily product was stirred with ethanol to give a solid (5.8 g), which was collected by filtration, washed successively with ethanol and ethyl ether and dried under high vacuum. This material was identified by the acronym "HA-4K-NH 2 ".
Example 3
Preparation of Representative Reagents of the Instant Invention
A. Synthesis of the Aldehyde Derivative C4S-4K-DGBE-TPA.
N-Succinimidyl-4-thia-7-diethoxyheptanoate was prepared from 4-thia-7-diethoxyheptanoic acid using known methods. 4-Thia-7-diethoxyheptanoic acid was prepared by the condensation of methyl 3-mercaptopropionate (120.0 g, 1.0 mol) with 3-chloropropionaldehyde diethyl acetal in the presence of potassium carbonate (250.0 g, 1.8 mol) in 1 L of DMF and base-catalyzed hydrolysis of the ester using known methods.
C4S-4K-DGBE (140.0 g, 35.0 mmol) was dissolved in 1.2 L of water. The pH of the solution was adjusted to 9.10 with 5.00 NaOH. N-Succinimidyl 4-thia-7-diethoxyheptanoate (58.8 g, 170.0 mmol) in 500 mL of DMF was added dropwise. After the addition was complete, the solution was stirred four hours at ambient temperatures. The volume of solvent was reduced to about 500 mL by rotary evaporation. Ethanol (4 L) was added to the residual concentrate. The solution was decanted. Ethanol (4 L) was added and the mixture was kept at 5° C. The solvent was decanted. The resulting mixture was centrifuged to give a gel-like pellet. The pellet was diluted with acetone and evaporated to a semi-solid. Ethyl ether was added and the mixture was allowed to stand for one hour. The mixture was filtered and the gel-like solid was dried under vacuum at ambient temperatures. The solid was collected to give 104.7 g of product, an acetal which was identified by the acronym "C4S-4K-DGBE-TPDA".
C4S-4K-DGBE-TPDA (104.3 g) was dissolved in 750 mL of sterile water and 750 mL of 1.00 N HCl. The pH of the solution was adjusted to 2.00 with 1.00 N HCl. The solution was stirred for 3.5 hours. The reaction solution was concentrated under vacuum to a volume of about 100 mL. Acetone (250 mL) was added to precipitate the product as an oil. The solvent was decanted and an additional 250 mL of acetone was added. The mixture was agitated and the solvent was decanted. To the resulting semi-solid was added an additional 250 mL of acetone. The mixture was allowed to stand for one hour. The resulting solid was collected and washed with 100 mL of acetone. The solid was dried under vacuum to give 113.6 g of product, which was identified by the acronym "C4S-4K-DGBE-TPA". The product exists in the aldehyde and hydrated form and contains residual solvent.
B. Synthesis of the Aldehyde Derivative C4S-4K-DGBE-SBA.
C4S-4K-DGBE (10.0 g, 2.5 mmol) was dissolved in 100 mL of water, and the solution pH was adjusted to 9.31 with 1.00 N NaOH. N-Oxysuccinimidyl N-(4-diethoxy)butyrylsuccinamate (4.5 g, 12.5 mmol) in 10 mL DMF was added to the reaction solution. The solution was stirred for 3 hours at room temperature. The solution was reduced in volume under vacuum to about 25 mL. To the solution was added 1 L of ethanol. The slurry was cooled to 5° C. overnight. The solvent was decanted, and the solid was collected by filtration. The solid was washed with ethanol (25 mL) and then ethyl ether (2×25 mL). The solid was dried under vacuum to give 6.8 g of product, which was identified by the acronym "C4S-4K-DGBE-SBDA". A 5.5 g (1.4 mmol) portion of this material was dissolved in 25 mL of water, and the solution pH was adjusted to 1.50 with 1.00 N HCl. The solution was stirred at room temperature for four hours. The volume of solution was reduced to about 10 mL by evaporation under vacuum. Acetone (50 mL) was added. The solvent was decanted, and an additional 50 mL of acetone was added. The solvent was decanted and 50 mL of acetone was added. The mixture was stirred, and the solid was collected by filtration. The solid was dried to give 5.0 g of the desired product. This material was identified by the acronym "C4S-4K-DGBE-SBA".
C. Synthesis of the Maleimide Derivative C4S-4K-DGBE-MP.
A solution of C4S-4K-DGBE (7 g, 1.75 mmol) in water (46 mL) and N,N-dimethylformamide (DMF; 23 mL) was added to a stirred solution of N-succinimidyl maleimidopropionate (SMP; 2.78 g, 10.5 mmol) in DMF(140 mL) and water (10 mL) at a rate of 4.5 mL/minute. After the addition was complete, the solution was stirred for an additional one hour. The reaction mixture was evaporated to dryness. The residue was dissolved in water and filtered to removed an insoluble material. The filtrate was diluted with ethanol to precipitate the product (5.83 g), which was identified by the acronym "C4S-4K-DGBE-MP".
D. Synthesis of the Aldehyde Derivative C6S-4K-DGBE-TPA.
The pH of a solution of C6S-4K-DGBE (12 g, 3.0 mmol) in water (75 mL) was adjusted to pH 10.0 with 1 N NaOH (43 mL). To this stirred solution was added, dropwise a solution of N-succinimidyl 4-thia-7-diethoxy-heptanoate (6.06 g, 18 mmol) in DMF (150 mL). After the addition was completed, the reaction mixture was stirred for three hours at room temperature. Then the solvent was removed by rotary evaporation. Water (100 mL) was added, and the solution was diluted with ethanol (400 mL) to precipitate the product (10 g), an acetal derivative which was identified by the acronym "C6S-4K-DGBE-TPDA". This product was collected by filtration, washed successively with ethanol and ethyl ether and dried under vacuum. Then a 10 g portion was dissolved in 0.1 N HCl (189 mL) to give a solution having a pH of 2.0. The solution was stirred at room temperature for three hours and then evaporated to dryness. The residue was dried under high vacuum at 35° C. to give solidified product (identified by the acronym "C6S-4K-DGBE-TPA; 9.8 g) which existed as a hydrated aldehyde.
E. Synthesis of the Aldehyde Derivative HA-4K-DGBE-TPA.
HA-4K-DGBE (6.0 g, 1.5 mmol) was dissolved in 50 mL of water, and the solution pH was adjusted to 9.15 with 5 N NaOH. N-Oxysuccinimidyl 4-thia-7-diethoxyheptanoate (2.7 g, 9 mmol) in N,N-dimethylformamide (20 mL) was added. The solution was stirred for three hours. The solution was evaporated to about 10 mL. Water (20 mL) was added and the solution was evaporated to 10 mL. Ethanol (500 mL) was added and the solution was stirred. The mixture was kept at 5° C. overnight. The solvent was decanted and the solid was collected by filtration. The solid was washed with ethanol (2×25 mL) and then with ethyl ether. The solid was dried under reduced pressure to give 6.6 g of the desired protected aldehyde, which was identified by the acronym "HA-4K-DGBE-TPDA". A 5.0 g portion of said protected aldehyde was dissolved in 35 mL of water. The pH was adjusted to 1.50 with 1.00 N HCl. After about 2.5 hours, the solution was evaporated to about 10 mL. Ethanol (400 mL) was added. The solid was collected and washed with acetone. ( 1 H-NMR indicated that the acetal was not reformed due to the use of ethanol.) The solid was dried under reduced pressure to give 3.6 g of the desired product, which was identified by the acronym "HA-4K-DGBE-TPA".
F. Synthesis of the Aldehyde Derivative C4S-4K-TPA.
C4S-4K-NH 2 (13.12 g, 3.28 mmol) was dissolved in water (140 mL) to give a solution having a pH of 8.16. The solution pH was adjusted to 9.0 with 1 N NaOH (4.5 mL). To this solution was added a solution of N-succinimidyl-4-thia-7-diethoxyheptanoate (6.62 g, 19.68 mmol) in DMF (140 mL). The reaction mixture was stirred at room temperature for four hours and then evaporated to dryness. The residue was dissolved in water (100 mL) and the solution diluted with ethanol (500 mL) to give an oily product, which was isolated by decantation. Vigorous stirring of the oily product with ethanol gave a solid product (9.3 g), which was isolated by filtration, washed with ethyl ether and dried under high vacuum. This intermediate was identified by the acronym "C4S-4K-TPDA".
C4S-4K-TPDA (8.87 g) was dissolved in water (35 mL) to give a solution having a pH of 4.37. The solution pH was adjusted to 2.0 with 1 N HCl, and the solution was stirred at room temperature. Monitoring the reaction by 1 H-NMR indicated that the reaction was completed after four hours. The reaction mixture was concentrated under reduced pressure at 35° C. to 1/4 of its original volume and diluted with acetone (100 mL) to give an oily product. The latter was isolated by decantation and triturated with acetone to afford a solid product (7.75 g), which was isolated by filtration and dried under high vacuum. NMR data indicated that the product, which was identified by the acronym "C4S-4K-TPA", existed as hydrated aldehyde form.
G. Synthesis of the Aldehyde Reagent C4S-4K-ABA.
Chondroitin-4-sulfate (22.2 g, 5.55 mmol) and 4-aminobutyraldehyde diethoxyacetal (7.6 g, 47.0 mmol) were combined in 120 mL of water. The pH was adjusted to 8.35 with 1.00 N HCl. Ethanol (60 mL) was added followed by borane-pyridine complex (5.7 mL). The solution was heated at 40° C. for six days. The solution was cooled and the pH was adjusted to 10.00 with 5.00 N NaOH. To the stirred solution was added 1 L of ethanol. The mixture was stirred for two hours, and the precipitate was collected by filtration. The solid was washed with ethanol (75 mL) followed by ethyl ether (75 mL). The solid was dried under vacuum to give 21.5 g of product, which was identified by the acronym "C4S-4K-ABDA". The product was negative to 2,3,5-triphenyltetrazolium chloride, indicating that coupling between C4S-4K and 4-aminobutyraldehyde diethoxyacetal was successful. C4S-4K-ABDA (6.1 g, 1.5 mmol) was dissolved in 40 mL of water, and the solution pH was adjusted to 1.50 with 1.00 N HCl. After 2.5 hours, the volume of solution was reduced to about 15 mL by evaporation under vacuum. Acetone (150 mL) was added to the solution, and the resulting mixture was stirred for 30 minutes. The solvent was decanted, and an additional 150 mL of acetone was added. The mixture was stirred to give a solid. The solid was collected and dried under reduced pressure to 6.0 g of the desired product, which was identified by the acronym "C4S-4K-ABA".
H. Synthesis of the Aldehyde Reagent HA-4K-TPA.
HA-4K-NH 2 (9.0 g, 2.25 mmol) was dissolved in 90 mL, of water and the pH was adjusted to 9.15 with 1 N NaOH. N-Oxysuccinimidyl 4-thia-7-diethoxyheptanoate (3.6 g, 11.9 mmol) in DMF (20 mL) was added in one portion. An additional 20 mL of water was added. The solution was stirred for 4.5 hours, and then the volume was reduced to about 25 mL by evaporation under vacuum. Ethanol was added, and the resulting slurry was stirred for two hours. The solid was collected by filtration and was washed with ethanol (25 mL) and then with ethyl ether (25 mL). The solid was dried under reduced pressure to give 9.5 g of product, HA-4K-TPDA. A 9.5 g portion was dissolved in 65 mL of water. The pH was adjusted to 1.50 with 1.00 N HCl. After about 2 hours, the solution was filtered through a 0.2 μm pore-size nylon filter membrane, and the volume of filtrate was reduced by evaporation under vacuum to about 15 mL. Acetone (250 mL) was added, and after 30 minutes the solvent was decanted. An additional 250 mL of acetone was added. The solid was collected and washed acetone (50 mL). The solid was dried under reduced pressure to give 8.9 g of HA-4K-TPA.
I. Synthesis of the Aldehyde Reagent C4S-4K-AOA-DGBE-MP.
Both [(t-butyl-oxycarbonyl)amino]oxy]acetic acid and its activated ester derivative N-succinimidyl [[(t-butyloxycarbonyl)amino]oxy]acetate were prepared by known methods. N-Benzyl-oxycarbonyl-N'-[[[(t-Butyloxycarbonyl)amino]oxy]acetyl]-diethylene glycol bis(3-aminopropyl) ether (t-BOC-NHOCH 2 CO-DGBE-Z) was prepared by the condensation of benzyloxycarbonyl DGBE (17.8 g, 50.4 mmol) with N-succinimidyl [[(t-butyloxycarbonyl)amino]oxy]acetate (13.2 g, 45.8 mmol) in 300 mL of chloroform in the presence of triethylamine (7.0 mL, 50.4 mmol). N-Benzyloxycarbonyl-N'-(aminoxyacetyl)-diethylene glycol bis(3-aminopropyl) ether (H 2 NOCH 2 CO-DGBE-Z) was prepared by treatment of t-BOC-NHOCH 2 CO-DGBE-Z with trifluoroacetic acid in methylene chloride. Both N-succinimidyl 3-maleimidopropionate (SMP) and 3-maleimidopropionic acid were prepared by known methods.
C4S-4K (12.1 g) was dissolved in 40 mL of water, and a solution of H 2 NOCH 2 CO-DGBE-Z (17.5 g) in 20 mL of ethanol was added. The solution pH was adjusted to 4.5 (pH strips 0.0-6.0) using 1.00 N NaOH. The solution was heated at 40° C. for two days. The solution was allowed to return to ambient temperature, and the solution pH was adjusted to 10.5 by the addition of sodium hydroxide solution. Ethanol (800 mL) was added to the solution to precipitate the product. The solid was isolated by filtration and washed with ethanol. The solid was air dried to give 16.1 g of product, which was identified by the acronym "C4S-4K-AOA-DGBE-Z".
C4S-4K-AOA-DGBE-Z (5.075 g) was dissolved in 100 mL of water. Pd/C (0.408 g) was added, and the resulting slurry was exposed to hydrogen overnight. The reaction mixture was filtered through a pad of Celite 521, and the filtrate was evaporated to a semi-solid. The semi-solid was dissolved in about 25 mL of water. Ethanol was added to precipitate the product. The product was collected and washed with ethanol and dried under vacuum to give 4.1 g of product, which was identified by the acronym "C4S-4K-AOA-DGBE".
C4S-4K-AOA-DGBE (4.0 g, 1.0 mmol) in 60 mL of water was added dropwise to a solution of N-succinimidyl maleimidopropionate (SMP) in 100 mL of DMF. Water (15 mL) was added to achieve a homogeneous solution. The solution was stirred for one hour and the solvent was evaporated under vacuum. The residue was combined with 40 mL of water and filtered. The filtrate was combined with 600 mL of ethanol. The mixture was left to stand at ambient temperature overnight. The solid was collected and washed with ethanol (2×10 mL). The solid was dried to give 3.5 g of product, which was identified by the acronym "C4S-4K-AOA-DGBE-MP".
Example 4
In vitro Exposure of Oligosaccharide-Modified Diaspirin Crosslinked DCLHb to Red Cell Preparations.
Approximately 20 mL of human blood was freshly collected from each of several donors into an evacuated container containing ethylenediaminetetraacetate (EDTA). The blood samples from several donors were pooled in a 50 mL centrifuge tube. One milliliter portions were dispensed into several test tubes. Then a volume of electrolyte diluent (negative control) and a volume of a second test or control solution was added such that the final concentration of the test or control article was that shown in the following table. Another modified hemoglobin which is known to cause red cell aggregation in this test was employed as a positive control. The test tubes were incubated for one hour. A specimen was removed from each test tube, and a slide was prepared from that specimen and stained. Each slide was observed for red cell aggregation and scored on a scale from zero to three, where zero indicated that no aggregation was observed and three indicated that extensive, irreversible aggregation was observed, i.e., disaggregation was not observed following the addition of normal saline solution to the sample.
TABLE 1______________________________________Results of in vitro Red Cell Aggregation Testing Negative Control Article and Test Article and Relative Relative Concentration by Concentration by Extent of Red Volume Volume Cell Aggregation______________________________________50% Electrolyte No aggregation Diluent observed (0) 10% Positive Few aggregates Control observed (1) 30% Positive Many red cell Control aggregates (1+) 50% Positive Extensive red Control cell aggregation and some small platelet clumps observed (2+) 10% C4S-4K-DCLHb None seen (0) 30% C4S-4K-DCLHb None seen (0) 50% C4S-4K-DCLHb None seen (0)______________________________________
This test was repeated using each of four C4S-4K-DGBE-TPA-DCLHb test articles having differing extents of hemoglobin modification. In each test, no red cell aggregation was observed in test solutions containing the oligosaccharide reagent-modified hemoglobin. The negative and positive control solutions gave characteristic responses.
Example 5
Hyperyolemic-hemodilution During Cerebral Ischemia in a Spontaneous Hypertensive Rat Model of Middle Cerebral Artery Occlusion
Hemodilution has been proposed as both a prophylactic and resuscitative therapy for focal cerebral ischemia. One basis for its therapeutic benefit may be a decrease in blood viscosity and augmentation of cerebral blood flow (CBF) to the area of ischemia. When nonoxygenating fluids are employed for hemodilution, changes in hematocrit are limited to modest decreases. In contrast, when an oxygen-carrying hemoglobin solution is used, greater hemodilution may be achieved, since the oxygen delivery capacity and capabilities are maintained.
A rat model of middle cerebral artery occlusion (MCAo) and reperfusion has been used to assess the effectiveness of hemodilution with hemoglobin compositions of the present invention. In this model, spontaneously hypertensive rats were anesthetized, intubated, and mechanically ventilated. Femoral arterial and venous lines wee placed to enable monitoring of physiological parameters. An incision was made in the left cheek of the animal, and an area of temporal bone was cleared of sufficient size to visualize the MCA. A 10-0 monofilament nylon suture was used to loop around the MCA in two places, one proximal to the olfactory tract (including the rostral branch) and the second at the level of the cerebral vein. Then each rat was randomized to one of the following groups for which the blood volume was increased by 8.0 mL (˜30%) and hematocrit (Hct) maintained at the desired value throughout the MCAo. In the control group, the hematocrit was not manipulated; each animal received 4 mL of 10% albumin solution and 4 mL of whole blood. In the test groups, animals were given a 3 mL exchange of infusion of the test article at a rate of 0.5 mL/min, followed by a 7.5 mL topload at a rate of 0.5 mL/min. Immediately after delivering the final volume, both loops around the MCA were secured until the MCA blanched, mimicking MCAo. The vessels in the area of the MCA were visualized, and any aggregation, clumping and/or other red cell distinction were noted. After three hours of occlusion, both sutures were cut and removed, and MCA was stroked to re-establish perfusion. The extent of reperfusion and visible red cell aggregation were noted. After two hours of reperfusion, the animal was deeply anesthetized, a thoracotomy was performed, during which 20 mL of 2& 2,3,5-triphenyltetrazolium chloride (TTC) was administered, and the descending aorta was clamped. At the completion of TTC infusion, the animal is left undisturbed for ten minutes, and then a lethal dose of a mixture of 12.5% glutaraldehyde/10% buffered formalin was administered. The animal was decapitated, and the brain was removed. The cerebrum was isolated and fixed, and tissue slices were prepared and photographed on both sides. A DUMAS Image Analysis program (Drexel University) was used to quantitate and average the extent of tissue staining by the TTC. The raw data were analyzed statistically, and final percentages were adjusted for swelling and averaged for the entire brain.
Three test articles were used in this study. DCLHb (Diaspirin Crosslinked Hemoglobin) was the negative control hemoglobin composition. PASS-DCLHb, a polymerized hemoglobin, was the positive control hemoglobin composition; PASS-DCLHb is known to cause red cell aggregation and typically demonstrates no reduction in infarct volume following MCAo. The term "CS-DCLHb" was used to identify a hemoglobin composition of the present invention (Example 4.C.) Experimental data are summarized in the Table below.
The results of this experiment may be summarized as follows. Compared to the Control group, hemodilution with DCLHb, the negative control hemoglobin composition, resulted in no red cell aggregation or other distinction and effected an approximately 50% reduction in infarct size. In contrast, hemodilution with PASS-DCLHb, the positive control hemoglobin composition, resulted in severe red cell aggregation and effected no reduction in infarct size, relative to that observed in the Control group. As was observed after hemodilution with DCLHb, hypervolemic hemodilution with the hemoglobin composition of the present invention, CS-DCLHb, caused no red cell aggregation or other distinction and effected an approximately 50% reduction in infarct size.
In addition, it was noted that CS-DCLHb seemed to have less of a detrimental effect on the percent oxygen in the blood as compared to DCLHb. Thus, animals in the DCLHb group required higher flows of oxygen than did those in the CS-DCLHb group. Moreover, the hemodilutive effect of CS-DCLHb was slightly greater and lasted longer than that of DCLHb.
TABLE 2______________________________________Effectiveness of Hemoglobin Compositions in Reduction of Infarct Size Following Middle Cerebral Artery Occlusion in a Spontaneously Hypertensive Rat Model. Experimental Group PASS- Experimental Parameter Control DCLHb CS-DCLHb DCLHb______________________________________Approximate volume of hemisphere ipsilateral to MCAo Infarct volume, mm.sup.3 140 70 70 140 Extent of red cell aggregation or blood flow abnormality: Immediately post-MCAo None None None Severe After perfusion re- None None None Moderate established______________________________________ | Novel polysaccharide compounds are disclosed for decorating biomolecular surfaces to increase isotropic size and mask antigenicity. The oligosaccharides may be synthesized as repeating disaccharide units, or may be derived by acid hydrolysis of naturally occurring polysaccharides. Such natural sources include chondroitins obtained from shark cartilage, or hyaluronic acid. The polyanionic sulfate groups contained in the sugar moieties impart negative charges which repel the molecules from the negatively charged wall of capillaries, to lengthen retention times of decorated drug molecules, such as crosslinked hemoglobin, in the peripheral circulation. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus that is used as, for instance, a copying machine.
2. Description of the Related Art
In recent years, in digital copying machines having a high processing speed, the photo-conductive drum having a large diameter is used. So, it is difficult to separate a paper from the photo-conductive drum by the paper's stickiness after the transferring of the developed image onto the paper from the photo-conductive drum surface.
For instance, U.S. Pat. No. 5,585,906 (Dec. 17, 1996; Takahashi et al.) shows a method to electrostatically adsorb a paper to a transfer belt by using it as a transfer member.
In case of a belt transfer system, as a paper is conveyed as being adsorbed on a transfer belt, a paper must be separated from the transfer belt at the most downstream side of the transfer belt after conveyed. Normally, a transfer belt is supported by rollers in diameter 12-40 mm and paper can be separated by its stickiness.
However, depending on kind of paper, disturbance of image is generated (remarkable on tracing paper). This image disturbance is conspicuous when a half-tone image is printed and is generated especially on the leading edge and trailing edge of a paper in a low humidity environment (especially conspicuous at the trailing edge).
One cause of this image disturbance is considered to be unnecessary discharge generated when the trailing edge of a paper leaped when it is separated from a transfer belt. As a result of this discharge, discharge traces in a pattern like foot marks of a crow are formed on the leading and trailing edge portions of a paper as shown in FIG. 2. These discharge traces appear remarkably especially on a half-tone image portion.
It is known that this phenomenon becomes inconspicuous gradually when increasing transfer voltage (current value).
However, if the transfer voltage is increased unnecessarily, drop of transfer efficiency, uneven transfer and other defects are caused. It is therefore difficult to simply increase transfer voltage uniformly.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above-mentioned circumstances and it is an object of the present invention to provide an image forming apparatus capable of obtaining a satisfactory image without discharge traces on the leading and trailing edge portions of a paper by increasing transfer bias at the leading and trailing edge portions of a paper, wherein discharge traces tend to be generated, higher than the middle portion of a paper.
According to the present invention, an image forming apparatus is provided, which comprising image forming means for forming a developer image on an image carrier, transfer means for transferring the developer image on an image receiving medium, conveying means provided in contact with the transfer means for conveying the image receiving medium, voltage applying means for applying voltage to the transfer means, and control means for controlling the voltage to be applied to at least one of a leading edge and a trailing edge in the conveying direction of the image receiving medium so as to make the voltage larger than voltage that is applied to the middle portion in the conveying direction of the image receiving medium.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a first embodiment of an image forming apparatus of the present invention;
FIG. 2 is a plan view showing discharge traces at the leading edge portion and the trailing edge portion of a paper;
FIG. 3 is a graph showing the density of residual toner left on a photo-conductive drum when transfer current was changed in a low temperature and low humidity environment;
FIG. 4 is a graph showing the density of residual toner left on a photo-conductive drum when transfer current was changed in a normal temperature and normal humidity environment;
FIG. 5 is a graph showing the density of residual toner left on a photo-conductive drum when transfer current was changed in a high temperature and high humidity environment;
FIG. 6 is a plan view showing the state of transfer current applied to a paper;
FIG. 7 is a flowchart showing the image forming operation;
FIG. 8 is a graph showing the density of residual toner left on a photo-conductive drum when transfer current was changed in a low temperature and low humidity environment;
FIG. 9 is a graph showing the density of residual toner left on a photo-conductive drum when transfer current was changed in a normal temperature and normal humidity environment; and
FIG. 10 is a graph showing the density of residual toner let on a photo-conductive drum when transfer current was changed in a high temperature and high humidity environment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, a first embodiment of the present invention will be described with reference to the attached drawings.
FIG. 1 shows a copying machine as an image forming apparatus.
A photo-conductive drum 1 is uniformly applied with -500 V to -800 V surface potential by a main charger 2. Further, this first embodiment is described taking a negatively charged photo-conductive drum as an example and the same is applied to a positively charged photo-conductive drum as the difference is only the polarity that is reversed. An electrostatic latent image is formed on the photo-conductive drum 1 applied with the surface potential by an exposure unit 3 which is an image forming means. This electrostatic latent image becomes a toner image and is visualized when a toner that was negatively charged by a developing device 4 is supplied.
A transfer belt 5 which is a conveying member is pushed against the photo-conductive drum 1 and a paper P as an image receiving medium is put between the transfer belt 5 and the photo-conductive drum 1. Further, bias (+300 to 5 kV) is applied to the transfer belt 5 by a high voltage supply 9 which is a voltage applying means and a toner image formed on the photo-conductive drum 1 is transferred on the paper P. Voltage applied by the high voltage supply 9 is controlled by a controller 17.
The transfer belt 5 is an elastic belt having the volume resistance 10 8 -10 12 Ω·cm, put over a driving roller 7a and a driven roller 7b and runs at almost the same surface moving speed as the photo-conductive drum 1. At the back side of the area where the transfer belt 5 is kept in contact with the photo-conductive drum 1, an electric power supply roller 8 which is an electric power supply member (a transfer means) is kept in contact with the transfer belt 5 so as to be able to supply electric power through the back of the transfer belt 5. The electric power supply roller 8 is composed of an elastic roller having the volume resistance 10 2 -10 8 Ω·cm.
In the ordinary printing, the transfer belt 5 and the photo-conductive drum 1 are driven in the state where they are kept separated from each other and after their surface moving speeds become nearly the same, they are brought in contact with each other. Then, at the same time when the transfer bias voltage is applied to the electric power supply roller 8, the paper P is conveyed to the transfer nipping area. After passing through the transfer nipping area, the paper P is adsorbed electrostatically on the transfer belt 5 and the leading edge of the paper P is separated from the transfer belt 5 at the most downstream side in the traveling direction of the transfer belt 5 because the radius of curvature of the transfer belt 5 on the driving roller 7a is small (normally, approximately 12-40 mm). The paper P separated from the transfer belt 5 is conveyed to a fixer 11 after passing through a guide member 10.
After transferring a toner image, the toner left on the photo-conductive drum 1 is removed by a cleaner 13. After removing this residual toner, the surface of the photo-conductive drum 1 is discharged by a charge eliminator 14 for the next processing.
Now, when a half-tone image is printed in a low humidity environment on the copying machine that is in said structure, discharge traces (image disturbance) are produced at the leading and trailing edges of the paper P as shown in FIG. 2.
TABLE 1__________________________________________________________________________Image Printing ResultsEnvironment Kind of Paper Kind of Chart 30 μA 50 μA 75 μA 100 μA 125 150__________________________________________________________________________ μAL/L 64 g Paper Character Chart Defective transfer ◯ ◯ ◯Environment Half-tone Chart Many discharge traces Few discharge traces Few discharge traces ◯ ◯ ◯ Tracing Paper Character Chart Defective transfer ◯ ◯ ◯ Half-tone Chart Many discharge traces Few discharge traces Few discharge traces ◯ ◯ ◯N/N 64 g Paper Character Chart Defective transfer ◯ ◯ ◯Environment Half-tone Chart ◯ ◯ ◯ ◯ Tracing Paper Character Chart Defective transfer ◯ ◯ ◯ Half-tone Chart Many discharge traces Few discharge traces Few discharge traces ◯H/H 64 g Paper Character Chart ◯ ◯ ◯ ◯Environment Half-tone Chart ◯ ◯ ◯ ◯ ◯ Tracing Paper Character Chart ◯ Half-tone Chart ◯ ◯ ◯ ◯ ◯ ◯__________________________________________________________________________ ◯: No discharge trace appears and a formed image is satisfactory.
The discharge traces appear remarkably on a thin paper containing much resin component and become not noticeable with the increase of transfer current.
Table 1 shows the results of images printed on a 64 g paper (ordinary paper) and a tracing paper under the so-called constant current control; that is, bias current applied to the electric power supply roller 8 is changed by the controller 17 in the environments of low temperature/low humidity (10° C., 20%), normal temperature/normal humidity (21° C., 50%) and high temperature/high humidity (30° C., 85%).
As a testing machine, a copying machine using a reversal developing with a process speed 400 mm/sec, equipped with a negatively charged photo-conductive drum 1 (approximately 100 mm) was used at charging potential -600 V and developing bias -400 V.
The transfer belt 5 used is a semi-conductive rubber made belt having the volume resistance 10 9 Ω·cm coated with a surface layer. The surface layer has a resistance that is greater than the resistance of rubber. The surface layer has a thickness of 3-10 μm. Further, the electric power supply roller 8 used was a roller having the volume resistance about 10 5 Ω·cm and hardness 40° (Asker-C).
According to the test results, the discharge traces were recognized remarkably on the half-tone image portion of a tracing paper at the transfer current around 50 μA but became considerably inconspicuous at 100 μA.
In the L/L (10° C., 20%), N/N (21° C., 50%) and H/H (30° C., 85%) environments, residual toners left on the photo-conductive drum 1 were taken by a tape. FIG. 3 through FIG. 5 show the reflection densities of the toners thus taken on tapes which were then put on a white paper. The more low this density is, the better the transfer efficiency.
According to the test results, the amount of residual toner left on the photo-conductive drum was less and satisfactory at the transfer current around 50 μA except the line image in the H/H environment. However, if the transfer current higher than 100 μA was applied, the amount of residual toner increases on a whole. In particular, in case of a full solid image, a transferred image is spotted and its image quality is deteriorated.
So, in this first embodiment, the bias voltage applied to the electric power supply roller 8 was increased so as to make the transfer current applied by the controller 17 to the leading and trailing edges only of the paper P where the discharge traces tend to be produced larger than other image areas as shown in FIG. 6.
As a result, it becomes possible to make the discharge traces inconspicuous without giving a large effect to the normal naked eye although the amount of residual transfer toner on the photo-conductive drum except the line image in the H/H environment. However, the satisfactory image transfer performance can be obtained at the central portion of the paper P.
In the test, the central portion of the paper P was constantly controlled at the transfer current 50 μA and the 15 mm wide areas only of the leading and trailing edges of a paper P were controlled at 75-100 μA.
FIG. 7 is a diagram showing the flowchart of the image forming operation.
When forming an image, size of the paper P is first detected (STEP ST71). Then, at the same time when the main charger 2 is turned ON, the photo-conductive drum 1 is rotated and further, the transfer belt 5 is run (STEP ST72). Then, when the rotating speed of the photo-conductive drum 1 becomes equal to the running speed of the transfer belt 5, the transfer belt 5 is brought in contact with the photo-conductive drum 1 (STEP ST73). Thereafter, the paper P is conveyed between the transfer belt 5 and the photo-conductive drum 1 and is applied with the transfer bias voltage. The transfer bias voltage is applied so that the transfer current 75 μA flows through the 15 mm wide area of the leading edge portion, 50 μA through the central portion and 100 μA through the 15 mm wide area of the trailing edge portion of the paper P. When the transfer belt 5 runs and the paper P is separated from the photo-conductive drum 1, the application of the transfer bias voltage is turned OFF (STEP ST74). After turning off the transfer bias voltage, the transfer belt 5 is separated from the photo-conductive drum 1 (STEP ST75) and then, the photo-conductive drum 1 is stopped to rotate and the transfer belt 5 is stopped to run (STEP ST76).
TABLE 2__________________________________________________________________________Discharge traces generating state when transfer currrent valuesat the leading and trailing edges of paper are changed*Transfer currert was fixed at 50 μA for the middle portion otherthanthe 15 mm wide porbon of the leading and trailing edges of paper From Trailing Edge To 15 mm Point 50 μA 75 μA 100 μA__________________________________________________________________________From Leading 50 μA Generated at both the Generated at both the Generated at the leadingEdge To 15 mm leading and trailing edge leading and trailing edge edge portionPoint portions portions 74 μA Generated at the trailing Generated at the trailing Not generated edge portion edge portion (inconspicuous) 100 μA Generated at the trailing Generated at the trailing Nor generated edge portion edge portion (inconspicuous)__________________________________________________________________________
Table 2 shows the discharge traces generating state.
The discharge traces at the leading edge portion of the paper P become inconspicuous at the transfer current 75 μA and those at the trailing edge portion becomes almost not recognizable at 100 μA.
Therefore, when the transfer current is controlled minutely to 75 μA at the leading edge portion of the paper P, 50 μA at the prime image portion (that is, the middle portion and 100 μA at the trailing edge portion,) it becomes possible to make the discharge traces at the leading and trailing edge portions of the paper P inconspicuous while reducing a residual toner left on the photo-conductive drum.
As the discharge traces are conspicuous in the area of about 10 mm from the edge at both the leading and trailing edge portions of the paper P, when the transfer current is intensified, it is effective even in the width of about 10 mm. However, as the whole discharge traces are not always confined in the width of 10 mm, it is desirable to make the width to about 15 mm.
Further, if the electric field of transfer current is intensified suddenly, the transfer efficiency may change when switched and streaks may be produced on an image. So, it is preferable to control the current so as to increase it at the position of 15 mm from the trailing edge of the paper P and terminate to increase it when the position of about 10 mm is reached.
Next, a second embodiment of the present invention will be described.
When the constant current control is made, a proper transfer current value changes according to a transfer image area.
TABLE 3__________________________________________________________________________Transfer voltage according to difference in printing state(Voltage applied to the electric power supply roller at the constantcurrent control) Transfer Bias Voltage (kV) 30 μA 50 μA 75 μA 100 μA 125 μA__________________________________________________________________________L/L 64 g Paper White Print 1.75 2.5 3 3.5 3.85Environment Black Print 2.7 3.1 3.6 No Paper White Print 1.2 1.5 1.95 2.4 2.7H/H 64 g Paper White Print 1.05 1.45 1.85 2.05Environment Black Print 1.65 1.95 2.35 2.5 No Paper White Print 0.75 1.15 1.5 1.85__________________________________________________________________________
Table 3 shows the results of voltage values compared in the white and black prints using a test equipment.
According to Table 3, the transfer voltage in the black printing tends to become higher by about 500 V than the white printing (H/H Environment) and further, even when seeing the graphs of residual toner density left on the photo-conductive drum shown in FIG. 3 to FIG. 5, a proper current value in the black printing becomes lower than that in the white printing.
In this second embodiment, a charge elimination lamp 16 is provided as a charge elimination means at the location below the developing device 4. Only the parts of the photo-conductive drum 1 corresponding to the leading and trailing edge portions of the paper P or the trailing edge portion wherein the discharge traces are especially conspicuous are discharged by the charge elimination lamp 16 before transferring an image. Thus, a proper current value is made lower than a conventional half-tone image as a result so that the transfer voltage becomes high at the positions corresponding to the leading and trailing edge portions of a paper even when the applied current itself is not made high.
TABLE 4__________________________________________________________________________Discharge traces generating state when transfer current values for theleading andtrailing edge portions were made high and the pre-transfer chargeelimination was performed*Transfer current was fixed at 50 μA for the portion other than the 15mm wide portion ofthe leading and trailing edges of a paper Pre-Transfer Charge Pre-Transfer Charge No Pre-Transfer Charge Elimination for Trailing Elimination for Leading Elimination Edge Only & Trailing Edges__________________________________________________________________________From Leading & 50 μA Generated at both Number of discharge Number of dischargeTrailing Edges TO leading & trailing edge traces at leading edge traces at bothe leading15 mm Point portions portion was reduced & trailing edge portions was reduced 75 μA Generated in trailing Not gererated Not generated edge portions (inconspicuous) (inconspicuous) 100 μA Generated in trailing Not generated Not generated edge portions (inconspicuous) (inconspicuous)__________________________________________________________________________
Table 4 shows the discharge traces generating state.
The light of the charge elimination lamp was applied to the range of 15 mm of the parts of the photo-conductive drum 1 corresponding to the leading and trailing edges of the paper P using the pre-transfer charge eliminating lamp 16 that is the same as the charge eliminator 14 for the photo-conductive drum 1.
According to Table 4, the number of discharge traces was decreased without changing the transfer current value because the parts of the photo-conductive drum 1 corresponding to the leading and trailing edge portions were discharged before the transfer of image.
Further, there is a tendency that no discharge traces are produced in the leading and trailing edge portions of a paper when the pre-transfer charge elimination was made even if current increasing amount is less than that when the pre-transfer charge elimination was not performed. In this second embodiment, there is not a small effect although less than the first embodiment.
Further, when the pre-transfer charge elimination was made, the white ground potential of the photo-conductive drum 1 drops and therefore, a toner for the black character portion scatters to the white ground portion, generating a scattering of toner around characters. This scattering of toner around characters denotes the state of toner scattered and adhered around original characters and the contrast of characters to the ground became weak. However, this state will scarcely become a problem if it is generated only in the leading and trailing edge portions of a paper.
Next, a third embodiment of the present invention will be described.
As mentioned above, a proper current value changes according to an image area to be transferred in the constant current control. This is because the surface potential of the photo-conductive drum 1 differs on the white ground and the black ground and this can be solved when the surface potentials of the white and black grounds are brought close to each other.
The pre-transfer charge elimination is considered to be an effective means but, as a negative side effect, a scattering of toner around characters is generated during the image transfer.
In this third embodiment, the pre-transfer charge elimination is normally performed at an incomplete level of potential where the scattering of toner around characters is scarcely generated. Thus, the weak point of the constant current control is offset. In addition, the effect of the second embodiment is also obtained by discharging the leading and trailing edge portions or the trailing edge portion only of the paper P more strongly than the middle portion.
TABLE 5______________________________________Scattering of toner around characterswhen white ground potential was changedWhite GroundPotential (V) L/L Environment H/H Environment______________________________________-500 Normal condition Normal condition-400 No change No change-300 No change No change-200 Slight scattering Becomes thick generated-100 Scattering generated Scattering generated -20 Scattering generated Largely becom thick______________________________________ Transfer current was fixed at 50 μA
Table 5 shows the state of the scattering of toner around characters when the surface potential of the photo-conductive drum immediately before the image transfer was changed by changing the light quantity of the pre-transfer charge elimination. Further, "Becomes thick" shown in Table 5 means that the scattering of toner around characters becomes conspicuous and lines composing characters become thick.
According to Table 5, it is seen that the scattering of toner around characters becomes conspicuous when the white ground potential becomes below -200 V and it is scarcely generated when the white ground potential is above -300 V.
So, the quantity of light of the pre-transfer charge elimination lamp was adjusted so that the surface potential of the majority of the white ground becomes always -300 V and the white ground potential is completely discharged (about -20 V) at the 15 mm wide portions of the leading and trailing edges of the paper P.
In this case, as the leading and trailing edge portions of the paper P become the entirely same state as in the second embodiment, it is possible to make discharge traces inconspicuous and at the same time, offset the weak point of the constant current control by utilizing the specially mounted pre-transfer charge eliminating mechanism.
The result of comparison of density of residual toner left on the photo-conductive drum is shown in FIG. 8 through FIG. 10.
Shown by the dotted line in these figures is the density of residual toner on the photo-conductive drum when the white ground potential was made to -300 V using the pre-transfer charge elimination applied to a line figure and it can be seen that it is close to the characteristic of a full solid image when compared with a line image in the normal state shown by the solid line in all environments.
In such the construction, it becomes possible to offset a difference in amount of residual toner between the white ground and the black ground even in the area where no toner scattering around characteristics is produced and also, to make discharge traces inconspicuous at the leading and trailing edges of a paper as in the second embodiment.
In said first through the third embodiments, it is a principal object to make discharge traces generated mainly on a tracing paper inconspicuous in the low humidity environment. In the first and second embodiments, the transfer possibility is rather lowered partially if discharge traces are not produced.
So, if these operations can be limited as could as possible when tracing paper and the like are used instead of ordinary paper, it is very convenient.
For instance, on normal digital copying machines, tracing paper is not used by setting in a paper supply cassette but used almost 100% in the manual feeding mode.
Therefore, if the first through third embodiments are applied only in the manual feeding mode, ordinary paper is processed in the normal transfer processing in many cases and increase in residual toner or generation of uneven image transfer will become less even on the leading and trailing edges of a paper.
Further, although an image forming apparatus may become large in size, the first through third embodiments may be selected for application by detecting kind of paper to be used.
For instance, an apparatus may be so designed that kind of paper can be input by user by pushing a button, etc. and it is one of methods to perform such the control for only light permeable thin paper by detecting the transmission factor, etc. of paper.
In addition, as the generation of discharge traces is a matter occurred only in the low humidity environment, it may be better to provide a humidity sensor to a photographic apparatus so that one of the first through third embodiments is applied automatically when the humidity becomes below 30-50%.
Further, in case of a digital copying machine, the state of output image is variable largely according to the image processing.
In case of a half-tone image of resolution about 400 dpi, discharge traces become scarcely conspicuous depending on the method of processing.
Since discharge traces become conspicuous only in case of highly precise images and analog half-tone images, if the first through third embodiments are applied only when user desires to output a highly precise image close to a photograph, satisfactory printing can be made without generating such defects as increase in waste toner and the like in the normal character printing, etc.
In other words, various examples as follows are thought about.
That is, it is discriminated as to whether it is the photographic mode or not. In case of the photographic mode, it is discriminated as to whether it is the manual feeding mode. In case of the manual feeding mode, the present invention is applicable. If it is not the photographic mode nor the manual feeding mode, the process may be put in the normal process.
According to this embodiment, it is possible to print an image of high quality on a tracing paper relatively easily without using a large-scaled sensor, etc.
Further, it is discriminated as to whether a value of a humidity sensor is less than an established standard. If yes, it is then discriminated as to whether a transmission factor of paper is less than an established reference. When yes, the present invention is applicable. If a value of the humidity sensor and a transmission factor of paper are not less than an established standard, it is put in the normal process.
According to this embodiment, sensors for detecting a transmission factor and humidity of paper are required but unless an OHP having a high transmission factor, etc. are used in the low humidity environment, the present invention will never be applied unnecessarily.
As described above, according to the present invention, it is possible to obtain such effects to reduce disturbance of image by discharge traces on the leading and trailing edges of a paper that is generated in the low humidity environment and obtain a satisfactory image quality without specially requiring a charge eliminator of a paper such as a corona charger, etc. | An image forming apparatus of the present invention includes an image forming unit to form a developer image on an image carrier, a transfer unit to transfer a developer image on an image receiving medium, a conveyor belt provided in contact with the transfer unit to carry and convey the image receiving medium with a developer image transferred by the transfer unit and a voltage applying portion to apply voltage to the transfer unit. This image forming apparatus further includes a controller to control voltage to be applied by the voltage applying portion to at least either one of the leading edge portion and the trailing edge portion of the image receiving medium in the direction conveyed by the conveyor belt so that it becomes higher than voltage to be applied to the middle portion in the conveying direction of the image receiving medium. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to pipe lowering and lifting apparatus and particularly such apparatus that operates pipe or other tubular goods into and out of a pressurized well.
2. Description of the Prior Art
It is not uncommon in certain fields to drill through formations wherein effective well pressure conditions in excess of 3000 pounds per square inch are encountered, or to repair wells with pressure on the surface control equipment.
In order to operate tubular goods within a well in the presence of high pressure, it has become the practice to pack off, near the surface, the annular space between the casing and the drill pipe or other tubular goods operating within the casing and to install a check valve on the end or inside the drill pipe or other tube operating inside the casing. This check valve is installed to permit passage of fluid downward and prevent upward passage of fluid. In the process of lowering a drill pipe into the well, a continuous length is made up length by length. It may be evident that when the length of pipe in the hole with the check valve installed is such that its weight is less than that of the effective well pressure tending to lift it, the pipe must be forced down until sufficient lengths have been added to the top of the pipe to allow the force of gravity to sink it.
Moreover, when the pipe is retracted from the hole, immediately after the pressure balance point has been reached (that is, the point where the pipe has been shortened by lifting it and unjoining lengths from the top until the weight of the pipe left in the hole just balances the effective force of the well pressure tending to lift it), the well pressure tends to eject the pipe from the casing.
The forceful entry of the pipe until after the balance point is passed by adding sufficient pipe lengths to overcome the lifting force of the well pressure, is termed "snubbing in", and the control of the movement of the pipe under the influence of well pressure in coming out, is termed "snubbing out". The apparatus that is provided to permit control in snubbing in and snubbing out is referred to as snubbing apparatus or merely as the "snubber". It will be realized that with high well pressures, the lifting force exerted on the pipe may become tremendous and if not kept under control could easily result in damage causing great delays and even result in disaster.
To ensure control over a pipe in the above-described environment, it is conventional to employ unidirectional grippers referred to in the industry as "slips". Such slips are similar to a chuck and are used to hold the pipe against movement in either one direction or the other. When two sets of slips are placed back-to-back, they then hold the pipe against movement in either direction. It is further conventional to employ such sets or pairs of slips at two locations: (1) on a vertical traveling table or support (herein referred to as the traveling support) and (2) on a stationary platform or support. Hence, it may be seen, that during a snubbing operation the slips on the stationary support are released while the slips on the vertical traveling support are in their gripping state. Once the stroke is complete, then the slips on the stationary support are actuated to grip the pipe and the slips on the traveling support are released to allow for repositioning of the traveling support with respect to the pipe for another stroke.
In normal operation in the absence of pressure (or when the pipe is of sufficient length that operation is below the pressure balance point), there is no need to be able to apply downward pressure in addition to that applied by gravity to the pipe. The traveling support is suspended on the cable usually provided on a conventional drilling rig or rig used in well repair or servicing. The cable is reeled onto or off of a conventional winch drum complete with brake and clutches to enable the operator to lower or hoist the traveling support. This conventional winch with its accessories is commonly called the "draw works". The draw works provides adequate pipe hoisting and lowering capability when well pressure is not a factor. When well pressure is a factor, external means is applied to the pipe to push the pipe into the well. This pushing down is usually done by sophisticated machines under control of others than the rig operator.
For example, one common method employed to provide downward pressure is to provide a plug in the pipe, normally in the form of a check valve, and pump drilling fluid through the pipe. Pump pressure in excess of well pressure causes pumped fluid to enter the pipe and travel downward through the check valve. This method leaves the pipe at atmospheric pressure above the check valve and at well pressure below the check valve. Hence, succeeding lengths of pipe can be screwed together and forced into the well without loss of pressure through the bore of the pipe.
In the more sophisticated rigs, hydraulic, pneumatic or electrical driving means is provided for applying both upward as well as downward force to the pipe. In some hydraulic rigs, accumulators are used to provide energy storage of the hydraulic fluid during hydraulic piston retraction. This provides an energy saving that would not otherwise be available. Such rigs, although more automated than the more simple rigs described above, are usually much heavier and require more time to set up and take down. Further, in the event of malfunction, repairs are more time consuming and costly, causing expensive rig downtime, as well.
Further, control over the applied hydraulic pressure is via gauges observable to the operator, but not to others.
Therefore, it is a feature of the present invention to provide an improved snubbing apparatus that allows the rig operator to have control over applying positive pressure during both "snubbing in" and "snubbing out" operations.
It is still another feature of the present invention to provide an improved snubbing apparatus using a push-pull cable arrangement on the traveling support, the cables kept in constant tension, to provide visual means to the rig workers that operation of the traveling support is satisfactory.
It is yet another feature of the present invention to provide an improved snubbing apparatus for applying both downward and upward pressure and using hydraulic pistons cable-connected to the underneath side of the traveling support that work in conjunction with the cable from which the traveling support is suspended.
It is still another feature of the present invention to provide an improved snubbing apparatus which maintains a preset tension in operating cables, at least one cable being connected to a hydraulic piston, the piston, in turn, being connected to an accumulator to provide energy conservation to rig operation.
It is yet another feature of the present invention to provide an improved snubbing apparatus suitable for adapting to almost any conventional rig and providing positive control to the rig operator in the form of light-weight, highly efficient and easy to set up equipment.
SUMMARY OF THE INVENTION
To force pipe or other tubular goods into a well against pressure a vertically traveling support table is provided with two sets of back-to-back, unidirectional pipe grippers, or slips, that prevent the pipe from moving upwardly or downwardly with respect to the support table. The support table is connected for urging the table downwardly, and hence the held pipe into the well, by the use of hydraulic cylinders secured through cables to the underneath side of the traveling support table. Another cable is attached for upward movement of the support table to a drum or winch. To apply downward pressure on the pipe, fluid force or pressure is applied to the cylinders from an accumulator, thereby increasing the tension in the first-mentioned cables and moving the table in a downward direction. A pump or other prime mover maintains a suitable pressure charge on the accumulator. The fluid is normally oil or other suitable hydraulic fluid. Tension is maintained on the opposite cable (the one connected for upward movement) via the winch.
When the rig operator wishes to lift the pipe from the well, the winch is operated so that the tension of the winch cable increases, thereby overcoming the downward pressure and effecting the closing of the hydraulic cylinders. Fluid is forced into the accumulator from the closing cylinders until a predetermined pressure is reached therein, at which time a relief valve opens to dump the fluid back into a reservoir. Hence, the pressure in the accumulator cannot exceed a predetermined level, this level also preventing the tension in the cables operating with the cylinders from exceeding a predetermined or pre-set level.
Hence, the rig operator is in complete control of the snubbing apparatus. Moreover, he maintains visual assurance that the rig is operating properly without relying on gauges or other personnel and, via the accumulator, the horsepower requirements for the system are minimized.
BRIEF DESCRIPTION OF THE DRAWING
So that the manner in which the above-recited features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawing, which drawing forms a part of the specification. It is to be understood, however, that the appended drawing illustrates only a typical embodiment of the invention and is therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
In the drawing, the FIGURE illustrates, schematically, the invention in a snubbing apparatus as applied to a rig operating in conjunction with an oil or gas well.
DESCRIPTION OF PREFERRED EMBODIMENT
Now referring to the drawing, a well casing 10 in an oil or gas borehole is pressurized so as to require ingress and egress of tubular goods with respect to casing 10 via a conventional Christmas tree 12, which includes appropriate blow out preventers and/or stripping units and valves. The tubular goods operable in conjunction with rig about to be described include rods, drill pipe and the like. For convenience, all such tubular goods are referred to herein merely as "pipe".
The snubbing apparatus to be described hereinafter, which for simplicity may be referred to occasionally merely as "the rig", is mounted on a convenient support framework 14, which is stationary with respect to the casing head. Mounted on framework 14 over the casing head is stationary support 16, having an appropriate opening therein to permit holding and passage of a joint of pipe 18. Other openings, such as at opening 20, are provided in framework 14 to permit pipe 18 to be lowered into and removed from well casing 10.
Fixedly secured to stationary support 16 are two sets of grippers, or slips, 22 and 24. These slips may be of conventional structure. Slips 24 are mounted in such a manner to prevent pipe 18 from moving upwardly with respect thereto when in the engaged or gripping condition. Slips 22 are mounted "inverted" or back-to-back with respect to slips 24 so as to prevent pipe 18 from moving downwardly with respect thereto when they are in the engaged or gripping condition.
Traveling table or support 26 is positioned over stationary support 16, the platform or table portion 28 thereof having an opening therethrough to permit passage of pipe 18. Slips 30 and 32, respectively identical to slips 22 and 24, are fixedly secured to the traveling table.
Bracket 34 of traveling table 26 includes a connection 36 to which rig hoisting cable 38 is secured. Hence, cable 38, which may pass over a rig crown block 40, suspends traveling table 26 in the desired location. Cable 38 is wound about drum or rig winch 42, which includes power means for applying a lifting force to cable 38. Of course, the rig winch also includes an appropriate rig brake 44.
Located in the vicinity of the casing head, and along side thereof, are hydraulic cylinders 46. Although two are shown, the system is operable with only one. More than two may also be employed. Rods 48 with pistons 71 attached and inside cylinders 46 operate into and out of the top of cylinders 46. Cables 50 are connected to the exposed ends of rods 48 and are passed up through appropriate openings in framework 14 and stationary support 16 to be secured to the underneath side of platform 28 of traveling table 26.
Hydraulic lines are connected to both the top end and bottom end of cylinders 46, lines 52 connected to the top end of the cylinders leading to accumulator 54. The bottom end of the cylinders are connected by lines 56 to a reservoir or tank 58. This may be an oil supply tank in conventional hydraulic system.
Accumulator 54 is connected to an adjustable relief valve 60, which, in turn, has its high pressure side connected to accumulator 54 and its low pressure side connected to reservoir 58. A source supply line 62 to relief valve 60 is connected to hydraulic pump 64 through a check valve 66. Pump 64 is connected to draw fluid from reservoir 58. An appropriate gauge 68 may be provided to monitor the pressure supplied from pump 64. A convenient engine 70 or other prime mover supplies the required power for operating pump 64.
In operation to lower pipe 18 into the well casing, hydraulic pump 64 takes oil from reservoir 58 and pressurizes accumulator 54 through check valve 66 and relief valve 60. This causes fluid pressure to be applied through lines 52 to the pistons inside cylinders 46, which retracts rods 48. The retraction of rods 48 causes the tension in cables 50 to overcome the tension in cable 38 and the pressure in the well casing to lower traveling table 26 and to thereby force pipe 18 downward into the casing. To assist in the performance of this task, slips 30 and 32 are engaged and slips 22 and 24 are disengaged.
When the cylinders have been filled, and rods 48 fully retracted, the operation of the slips is reversed, i.e., slips 22 and 24 are engaged and slips 30 and 32 are disengaged. Traveling table 26 is lifted for a new stroke by increasing the force in cable 38 to be greater than the tension in cables 50 through winching of drum 42. When table 26 moves upward, rod 48 with pistons 71 attached move upward to thereby force oil from cylinders 46 through lines 52 back into accumulator 54.
Energy is stored in accumulator 54 in conventional fashion. Typically, gas is entrapped in the upper part of the accumulator. Pressure is applied back against relief valve 60, too, but this valve does not immediately open. Relief valve 60 does open, however, when a predetermined level has been reached, to dump surplus oil back into reservoir 58. Check valve 66 prevents back pressure from being applied to pump 64. Note that via gravity, fluid, not under pressure, is allowed to fill the lower end of cylinders 46 via lines to provide even lubricating action of these cylinders.
The pressure operation of relief valve 60 is adjustable, the setting determining the pressure to be applied through lines 52 and hence the tension in cables 50 to be overcome by the tension in cable 38 in order to move table 26 upwards thereagainst. The pressure setting of relief valve 60 actually causes a substantially constant preset tension in cables 50. The rig operator then increases or decreases the tension in cable 38 with respect thereto by spooling or unspooling the cable to cause lifting or lowering of table 26.
The above slip manipulation described stroking of the snubbing apparatus to lower the pipe. Reverse setting and releasing operating of the slips will cause raisings of the pipe.
It may be seen that a slacking in the tension of cables 50 will be an indication to the rig operator that there is a malfunction in the system. A greater than normal tension in cables 50 will likewise be sensed by the rig operator in operating opposing cable 38 in push-pull fashion to also indicate a malfunction of the system. All of this is evident without having to watch gauges, which would thereby distract the rig operator from observing the pipe manipulations.
It may be seen that the apparatus just described is simple and readily installable and adaptable for use on almost any drilling and/or workover rig.
While a particular embodiment of the invention has been shown and described, it will be understood that the invention, as shown and described, operating with cylinders 46 to pretension cables 50 is not limited thereto. This constant pretensioning of cables 50 may also be accomplished with hydraulic or air operated winch drums, and hence this constant pretensioning of cables 50 is not limited to action by cylinders 46. | Cable-operated snubbing apparatus having a pre-set tension applied to the cables therein via connections to fluid-operated pistons. The pistons are connected to an accumulator for accumulating fluid from the piston cylinders when the draw works of the snubbing apparatus is retracted, thus allowing control by a single rig operator and minimizing horsepower requirements. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional application Ser. No. 60/233,681 filed Sep. 19, 2000, entitled “Overfinish Application, Process, Apparatus and Product”.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to methods and devices for applying finish to yarns in motion at high speeds of about 3000 meters per minute (m/min) or greater, and to the products formed thereby.
[0004] 2. Description of the Related Art
[0005] Liquid finishes are typically complex mixtures of water, oils, polymers, and surfactants applied to yarns to achieve desired processability characteristics including lubricity and reduction of static electricity, and to improve end use properties. For some applications, such as tire cord yarns, more than one finish, is applied. A first finish is applied to facilitate drawing operations during yarn manufacture. A second finish or overfinish is applied to aid in bonding the yarn to rubber during tire construction.
[0006] The function of a finish applicator device is to apply finish at an even rate to a travelling yarn so that the filaments of the yarn are evenly coated with the finish. Conventionally, yarn finishes are applied by advancing a running yarn threadline in contact with the surface of a “kiss roll” rotated in a liquid reservoir containing the desired finish, or by means of applicator tips or sprays.
[0007] As used herein, “active finish application” refers to a method by which finish is supplied to the yarn using force, such as pressure or injection. The finish may be applied by impingement of a jet under pressure or by full immersion under pressure. Active finish application is in contrast to the prior art methods which are herein termed passive wherein the finish is provided at about atmospheric pressure on a roll or applicator tip and the yarn picks up some finish as it passes through a film of finish. As used herein, pressure means the highest pressure at the finish-yarn interface along the yarn path through an applicator device.
[0008] Prior art finish applicators are described for example in U.S. Pat. No. 2,294,870 to Kline et al.; U.S. Pat. No. 3,244,142 to Walker; U.S. Pat. No. 3,754,530 to Pierce; U.S. Pat. No. 3,988,086 to Marshall et al.; U.S. Pat. No. 4,325,322 to Louch et al.; U.S. Pat. No. 4,329,750 and U.S. Pat. No. 4,397,164 to Binnersley; U.S. Pat. No. 4,526,808 to Strohmaier; U.S. Pat. No. 4,544,579 and U.S. Pat. No. 4,565,154 to Mullins et al; U.S. Pat. No. 4,851,172 to Rowan et al.; U.S. Pat. No. 4,891,960 to Shah; U.S. Pat. No. 4,984,440 to McCall; U.S. Pat. No. 5,181,400 to Hodan; U.S. Pat. No. 5,679,158 and U.S. Pat. No. 6,067,928 to Holzer, Jr. et al.; United States Statutory Invention Registration H153 to Sadler et al.; and DD 122,108 to Henssler. However, difficulties with these devices arise when yarn speeds increase to about 3000 m/min or even less. In none of these devices was there an attempt to disengage or block an air boundary layer in motion with the yarn.
[0009] A running thread line entrains a boundary layer of the fluid, air or liquid, through which it passes. The boundary layer of fluid moves at the speed of the thread line at its surface. The mechanics of boundary layers have been analyzed most notably by H. Schlichting, Boundary Layer Theory , McGraw Hill, N.Y., 1960 and in the context of moving continuous surfaces by B. C. Sakiadis, A.l.Ch.E. Journal, 7(1,2 & 3), 26-28, 221-225, 467-472 (1961). A thread line moving at high speed in air, when brought into contact with a liquid, creates a violent turbulence at the intersection where the air boundary layer in motion with the thread line impinges on the liquid. In the context of application of liquid finishes to high speed running yarns by conventional kiss rolls and applicators, the air boundary layer limits the concentration of finish that is applied to the yarn, causes large variation in finish pickup and creates excessive spraying of finish to surrounding areas.
[0010] Prior art attempts to resolve these problems have been described for example in U.S. Pat. Nos. 4,253,416, 4,255,472, 4,255,473 and 4,268,550 to Williiams Jr.; and U.S. Pat. Nos. 4,675,142 and 4,855,099 to D'Andolfo et al.
[0011] EP 0195 156 A2 describes spinning and applying finish to yarns at speeds of about 4000 m/min by means of spray nozzles.
[0012] The disclosures of Williams Jr. attempt to ameliorate the effect of the air boundary layer on the finish supply without actually interrupting the air boundary layer. These disclosures qualitatively describe more uniform finish application by the patented devices but no quantitative information is provided regarding the concentration of finish on the yarn or the finish uniformity.
[0013] U.S. Pat. Nos. 4,675,142 and 4,855,099 to D'Andolfo et al. apply finish to the yarn by means of opposing spray nozzles. No attempt is made in D'Andolfo et al. to influence the air boundary layer prior to finish application. Instead, the excess finish sprayed from the yarn is captured in large fixed enclosures. In U.S. Pat. No. 4,675,142 finish concentrations on the yarn up to 1.36% by weight are reported but finish concentrations varied by 15% to 35% of the average value.
[0014] In a different area, U.S. Pat. No. 5,624,715 to Gueggi et al.; U.S. Pat. No. 6,146,690 to Kustermann; and U.S. Pat. No. 6,248,407 B1 to Hess describe methods of applying a coating to a moving planar surface involving interruption of the air boundary layer in motion with the surface.
[0015] A need exists for finish applicator devices capable of actively applying finish to one or more yarns running at speeds over 3000 m/min, uniformly and at sufficient concentrations. A further need is for these devices to contain the finish and prevent spraying and contamination of surrounding areas. A yet further need is for these devices to be small, portable and easily installed at a variety of positions on a fiber processing line.
[0016] In the manufacture of yarns for in-rubber applications, such as tires belts and hoses, it is necessary to apply an overfinish to facilitate bonding of the yarn to rubber. It appears to be an invariable practice to apply the overfinish after the yarn is drawn and immediately before winding. See for example U.S. Pat. No. 5,562,988. This practice results in winding a wet yarn where the finish can pool and cause subsequent variations in rubber adhesion. A need exists for a finish applicator device that may be placed in a position between heated rolls on a yarn draw panel to permit drying the overfinish before winding.
SUMMARY OF THE INVENTION
[0017] The invention provides methods and devices to actively apply finish to one or more yarns in motion at speeds greater than about 3000 m/min, to achieve a finish application of 0.2 wt. % or more, and with a coefficient of variation of finish concentration of 10% or less. The devices are compact, portable and readily installed at a variety of positions on a fiber processing line. The devices of the invention contain the finish so that contamination of the surrounding areas is prevented.
[0018] The devices may be used to provide an overfinish to a moving yarn between heated godet rolls. The so-provided heating may be used to dry the yarn and to promote curing reactions in the finish and between the yarn and finish compounds. As used herein, “curing” refers to any reaction, which may be accelerated by heat. Non-limiting examples include crosslinking reactions and polymerization reactions. Such curing reactions may serve to enhance properties of the yarn. Non-limiting examples of such enhanced properties are adhesion to rubber, fatigue resistance and cohesion.
[0019] In one embodiment, the invention is a method for applying a liquid finish to one or more running yarns at speeds greater than 3000 m/min comprising the steps of:
[0020] a) passing the yarns into a finish applicator device while substantially blocking the entry of the air boundary layers in motion with the yarns into said finish applicator device;
[0021] b) contacting the yarns with a liquid finish under pressure;
[0022] c) substantially disengaging the excess finish from the yarns; and
[0023] d) passing the yarns out of the applicator device.
[0024] In another embodiment, the invention is a method for applying a liquid finish to one or more running yarns at speeds greater than 3000 m/min comprising the steps of:
[0025] a) passing one or more running yarns into an finish applicator device;
[0026] b) substantially blocking and disengaging the air boundary layer in motion with each yarn and venting it to the exterior of said finish applicator device;
[0027] c) contacting the yarns with a liquid finish under pressure;
[0028] d) substantially disengaging the excess finish from the yarns; and
[0029] e) passing the yarns out of the applicator device.
[0030] The invention also includes a yarn manufacturing method comprising the steps of: applying a liquid finish to one or more yarns running at speeds greater than about 3000 m/min at a position between heated rolls on a draw panel; drying said finish between said rolls; and collecting a dry drawn yarn on a winder.
[0031] The invention further includes the devices utilized in the above methods. In one embodiment termed an “immersion applicator”, the invention is a device for applying a liquid finish to one or more high speed running yarns comprising an essentially box-like device having yarn entry openings constricted to substantially block entrance of the air boundary layer entrained by each yarn. The device is internally divided into two or more chambers along the yarn path connected by constricted passages. In at least one of these chambers, the yarn is contacted with finish liquid under pressure. Excess finish liquid is captured and drained from one or more succeeding chambers.
[0032] In another embodiment termed a “slotted applicator”, the invention is a device for applying a finish liquid to one or more high speed running yarns utilizing an essentially box-like device having yarn entry openings and ducts behind the yarn entry openings to divert and discharge the air boundary layers at the lateral surfaces of the device. Within the device, one or more pressurized jets of finish liquid impinge on the yarns traveling in a channel. Excess finish liquid is captured and drained from one or more internal downstream chambers.
[0033] The invention also includes the finished yarn products so produced. A yarn with improved finish uniformity is provided with an overfinish actively applied and dried on the draw bench before the first winding operation. The yarn products of the invention may be used in textile and leisure fiber applications, and in industrial fiber applications, such as in tires.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] In the accompanying drawing figures:
[0035] [0035]FIG. 1 shows a sectional sketch of a first finish applicator of the invention termed an “immersion applicator”.
[0036] [0036]FIG. 2 shows a sectional sketch of a second finish applicator of the invention termed a “slotted applicator”.
[0037] [0037]FIG. 3 shows a prior art draw panel with an prior art finish applicator located after the draw rolls and before a winder.
[0038] [0038]FIG. 4 shows a draw panel with an inventive overfinish applicator located before the final pair of draw rolls.
[0039] [0039]FIG. 5 shows the same draw panel as FIG. 4 with the inventive overfinish applicator and the adjacent draw rolls enclosed in a vented box.
DETAILED DESCRIPTION OF THE INVENTION
[0040] While the invention will be described with reference to the treatment of yarn, it should be understood that the invention can be used to treat, in single filaments or bundles of filaments, any type of yarn, string or thread. Similarly, while the invention will be described in terms of a finish, it would be understood that the invention can be used to treat yarn with a wide variety of treatment agents, such as for example, coatings of various types, dyes and chemical treatments.
[0041] The invention provides methods and devices to actively apply finish and/or overfinish to one or more yarns in motion at speeds greater than about 3000 m/min, to achieve 0.2 wt. % or more of finish application on the yarns, and with a coefficient of variation of finish concentration of 10% or less. As used herein throughout, finish concentrations are expressed as finish weight divided by the sum of finish weight and yarn weight. The methods and devices are also suitable to achieve 0.2 wt. % or more of finish application on one or more yarns with a coefficient of finish concentration of 10% or less at yarn speeds greater than about 5000 m/min and greater than about 8000 m/min.
[0042] In a first embodiment, the invention is a method for applying a liquid finish to one or running yarns at speeds greater than 3000 m/min comprising the steps of: passing the yarns into a finish applicator device while substantially blocking the entry of the air boundary layers in motion with the yarns into said finish applicator device; contacting the yarns with a liquid finish under pressure; substantially disengaging the excess finish from the yarns; and passing the yarns out of the applicator device.
[0043] For the purposes of each embodiment of this invention, the pressures at the finish/yarn interface are obtained from finite element analysis using the software designated CFDesign obtained from Blueridge Numerics Inc., Charlottesville, Va. For the purposes of the invention, such analysis is based on one phase flow of a liquid having a viscosity and density dependent only on temperature.
[0044] In one realization of the first embodiment a liquid finish is applied to one or more high speed running yarns utilizing an essentially box-like device having yarn entry openings constricted to substantially block entrance of the air boundary layer entrained by each yarn. The device is internally divided into two or more chambers along the yarn path connected by constricted passages. At least one of these chambers is positively fed with liquid finish. The yarn is contacted with the finish liquid under pressure. Excess finish liquid is captured and drained from one or more succeeding chambers.
[0045] More specifically, in this realization, the invention is a method for applying a liquid finish to running yarns at speeds greater than 3000 m/min as follows:
[0046] One or more running yarns is passed into a first chamber of an applicator device through constricted yarn entry openings that substantially block the air boundary layer entrained by each yarn.
[0047] A yarn passes from the first chamber through a constricted yarn passage into second and sequential chambers further connected by constricted yarn passages.
[0048] Liquid finish is positively fed from an external source to at least one of the chambers traversed by each yarn.
[0049] Each yarn is contacted with the liquid finish under pressure.
[0050] Excess finish liquid is substantially disengaged from each yarn in at least one of the chambers.
[0051] Excess liquid finish is drained to an external receptor.
[0052] The yarns are passed out of the last chamber of the applicator device through exit openings.
[0053] As used herein throughout, pressure means the highest pressure at the finish-yarn interface along the yarn path through the device. This highest pressure is expected to be localized in the vicinity of the restricted yarn passages (see below).
[0054] Preferably, the liquid finish contacts the yarn at a pressure at least about 10 psi (68.9 kPa). More preferably, the liquid finish contacts the yarn at a pressure at least about 20 psi (138 kPa). Most preferably, the liquid finish contacts the yarn at a pressure at least about 40 psi (276 kPa).
[0055] Preferably, the liquid finish is supplied continuously using a pump. Increasing the finish feed rate to the applicator device yields an increase in finish on the yarn at a given yarn speed. The finish feed rate required to apply a given level of finish at a particular yarn speed and for particular applicator dimensions is readily found by calibration of the device.
[0056] The finish applied to the yarn in traversing the applicator device is preferably about 0.2 wt. % to about 5 wt. % with a coefficient of variation (COV) less than about 10%. More preferably, the finish applied is about 0.4 to about 4 wt. % with a COV less than about 10%. Most preferably, the finish applied is about 0.5 wt. % to about 2 wt. % with a COV less than about 10%.
[0057] The invention includes the apparatus by which the above method may be practiced. In this embodiment termed an “immersion applicator” illustrated in part by a sectional sketch in FIG. 1, the invention is an applicator device for applying finish liquid to one or more high speed running yarns. The applicator device has a top portion ( 50 ) and a mated bottom portion ( 60 ) sealed to the top portion at its exterior surfaces. This seal may be provided by machining the top and bottom portions to close tolerances. However, separate sealing means such as seals or gaskets are preferred to be placed between the top and bottom portions to prevent external leakage at their mated surfaces.
[0058] The bottom portion has yarn entry openings in its front surface for each individual yarn ( 5 ) and exit openings ( 7 ) in its rear surface for each individual yarn. The yarn entry openings are constricted to substantially block air boundary layers entrained by each yarn.
[0059] The bottom portion has one or more interior walls dividing the bottom portion into two or more consecutive chambers ( 40 ). Each of the interior walls in the bottom portion has constricted yarn passages ( 6 ), individual for each yarn, connecting the preceding and succeeding chambers. The constricted yarn passages also serve as yarn guides and may be inserts made of materials such as ceramics different than the surrounding wall materials. Such passages are open at their intersections with the top surface of the bottom portion for ease of yarn string-up. In operation of the finish applicator device, the tops of the passages are closed by the bottom surface of the top portion.
[0060] At least one of the chambers in the bottom portion is in communication with external source of finish liquid through a finish liquid supply duct ( 11 ) to permit feeding liquid from below the yarn path. At least one of the chambers in the bottom portion is in communication with an external drain ( 20 ).
[0061] The top portion has one or more interior walls dividing the top portion into consecutive chambers ( 70 ) corresponding in number and location to mating chambers in the bottom portion. At least one of the chambers in the top portion is in communication with an external source of finish liquid ( 10 ).
[0062] The dimensions of the chambers in the top and bottom portions are chosen by compromise between desire for compactness and flexibility of operation. Greater chamber length in the direction of yarn travel accommodates higher levels of finish application or higher yarn speeds, but less compactness. It is preferred that the length of the chambers in the direction of yarn travel is between about 1 cm to about 10 cm, and more preferably is between about 1.25 cm and 7 cm. The width of the chambers is preferred to be between about 0.2 cm and 2 cm. The depth of the chambers is preferred to be between about 1 cm and about 7 cm.
[0063] It is preferred that finish liquid is fed to two or more sequential chambers and that excess finish liquid is disengaged from the yarn in two or more subsequent chambers.
[0064] There are also means (not shown) to hold the bottom surface of the top portion and said top surface of the bottom portion together in mated and sealed position.
[0065] Preferably, the top portion and the bottom portion are connected at one of their side surfaces by hinge means. Preferably, the top portion and the bottom portion are connected at the other of their side surfaces by quick opening clamps means. The finish applicator device is quickly and easily opened for yarn string-up along the bottom portion and quickly and easily closed and placed in service.
[0066] A two yarn-end applicator of this design has been fabricated.
[0067] Without being held to a particular theory of why the invention works, it is believed that the constriction of the yarn entry openings ( 5 ) and the constricted yarn passages between chambers ( 6 ) are essential features of the device. The constrictions of the yarn entry openings substantially block the air boundary layers surrounding the yarns from entry into the device. This minimizes interference of the air with contact between the yarn and the finish in the chambers. The high speed running yarn in contact with the liquid finish in a chamber entrains a liquid boundary layer. Stagnation of the high speed liquid boundary layer at the face of a constricted yarn passage converts kinetic energy into pressure head. Finite element modeling indicates such constriction of the yarn passages between the chambers gives rise to high localized contact pressures between the liquid finish and the yarn at the entrance of, and within the yarn passages. The contact pressures so generated are expected to be much higher than, and add to, the liquid finish pressure at the inlets to the device ( 10 , 11 ).
[0068] The cross-sections of the yarn passages into and through the device ( 5 , 6 , 7 ) may be circular, oval, rectangular or some more complex shape. Preferably, the yarn entry openings ( 5 ) have constant dimensions in the direction of yarn travel. The yarn passages within the device ( 6 ) may be straight, tapered or pulsatile. Preferably, the yarn entry openings ( 5 ), and the yarn passages ( 6 ) are so constricted as to have no dimension greater than about ten times the effective yarn diameter. More preferably, the yarn entry openings ( 5 ), and the yarn passages ( 6 ) are so constricted as to have no dimension greater than about six times the effective yarn diameter. The effective yarn diameter is obtained from the following relationship:
ED = 1.33 4 d 9 × 10 5 π ρ
[0069] where:
[0070] ED is the effective yarn diameter, cm
[0071] d is the yarn denier
[0072] ρ is the density of the polymer constituting the yarn filaments
[0073] (1.39 g/cm 3 for polyethylene terephthalate)
[0074] Preferably also, the dimensions of the yarn entry openings ( 5 ) are so constricted as to block at least about 75% of the cross-sectional area of the air boundary layer entrained with each yarn. For the purposes of this invention, the cross-sectional area of the air boundary layer is as calculated by Equations (26) to (31) of B. C. Sakiadis, A.I.Ch.E. Journal, 7(3) 467-472 (1961). The thickness of the air boundary layer calculated in this manner is believed to be a minimum bound (most conservative estimate) of the actual air boundary layer dimensions.
[0075] The dimensions of the air boundary layer depend on the denier of the yarn, the yarn speed and the distance along the yarn from the last solid surface traversed. Table I shows the air boundary layer thickness calculated by the above referenced Sakiadis relationships for poly(ethylene terephthalate) yarns of 50 to 3000 denier, yarn speeds of 3000 to 10,000 m/min, and distances from the last solid surface of 0.2 and 0.813 m. Also shown in Table I is the percentage of the air boundary layer cross-sectional area that is blocked by an applicator yarn entry opening having a cross-sectional area of 0.0335 cm 2 and no dimension greater than the boundary layer thickness.
TABLE I δ boundary % of Yarn Distance layer boundary Yarn velocity, along yarn, thickness, layer denier m/min M cm blocked 50 3000 0.2 0.233 81 50 3000 0.813 0.446 95 50 5400 0.2 0.218 78 50 5400 0.813 0.417 94 50 10000 0.2 0.203 75 50 10000 0.813 0.388 93 100 3000 0.2 0.269 86 100 3000 0.813 0.517 96 100 5400 0.2 0.251 84 100 5400 0.813 0.483 96 100 10000 0.2 0.234 81 100 10000 0.813 0.450 95 300 3000 0.2 0.336 91 300 3000 0.813 0.652 98 300 5400 0.2 0.313 90 300 5400 0.813 0.609 97 300 10000 0.2 0.291 88 300 10000 0.813 0.567 97 1000 3000 0.2 0.426 95 1000 3000 0.813 0.837 99 1000 5400 0.2 0.396 94 1000 5400 0.813 0.781 98 1000 10000 0.2 0.366 93 1000 10000 0.813 0.726 98 3000 3000 0.2 0.522 97 3000 3000 0.813 1.045 99 3000 5400 0.2 0.484 96 3000 5400 0.813 0.974 99 3000 10000 0.2 0.447 95 3000 10000 0.813 0.904 99
[0076] It will be seen from Table I that at least 75% of the cross-sectional area of the air boundary layer in motion with the yarn is blocked for all of the above combinations of yarn denier, speed and distance when the applicator yarn entry opening has a cross-sectional area of 0.0335 cm 2 . Preferably, the cross-sectional area of each yarn entry opening and each yarn passage is no greater than about 0.0335 cm 2.
[0077] In another embodiment, the invention is a method for applying a liquid finish to one or more high speed running yarns comprising the steps of:
[0078] passing one or more running yarns into a finish applicator device; substantially blocking and disengaging the air boundary layer in motion with each yarn and venting it to the exterior of said finish applicator device; contacting the yarns with a liquid finish under pressure; substantially disengaging the excess finish from the yarns; and passing the yarns out of the applicator device.
[0079] In one realization of this embodiment, the invention is a method for applying a finish liquid to one or more high speed running yarns utilizing an essentially box-like device having yarn entry openings and ducts behind the yarn entry openings to divert and discharge the air boundary layers at the lateral surfaces of the device. Within the device, one or more pressurized jets of finish liquid impinge on the yarns traveling in a channel. Excess finish liquid is captured and drained from one or more internal downstream chambers.
[0080] More specifically, in this realization, the invention is a method for applying a liquid finish to high speed running yarns as follows:
[0081] One or more running yarns are passed into an applicator device.
[0082] Each yarn is passed through a constricted passage within the applicator device that substantially blocks the air boundary layer entrained with the yarn.
[0083] The air boundary layer entrained by each yarn is vented to the exterior of the applicator device.
[0084] One or more jets of finish liquid supplied under pressure from an external source are impinged onto each yarn within the applicator device.
[0085] Each yarn passes into one or more sequential chambers in which excess liquid finish is substantially disengaged from the yarn.
[0086] Excess finish liquid is drained from the chambers to an external receptor.
[0087] The yarns are passed out of the last chamber of the applicator device.
[0088] Preferably, the liquid finish contacts the yarn at a pressure at least about 10 psi (68.9 kPa). More preferably, the liquid finish contacts the yarn at a pressure at least about 20 psi (138 kPa). Most preferably, the liquid finish contacts the yarn at a pressure at least about 40 psi (276 kPa).
[0089] The finish applied to the yarn in traversing the applicator device is preferably about 0.2 wt. % to about 5 wt. % with a coefficient of variation (COV) less than about 10%. More preferably, the finish applied is about 0.4 to about 4 wt. % with a COV less than about 10%. Most preferably, the finish applied is about 0.5 wt. % to about 2 wt. % with a COV less than about 10%.
[0090] Venting of the air boundary layer to the exterior of the device may optionally be aided by applying suction from an exterior vacuum producing means such as a vacuum pump or aspirator.
[0091] The invention includes the apparatus by which the above method may be practiced illustrated in part by a sectional sketch in FIG. 2. The invention is an applicator device termed a “slotted applicator” for applying finish liquid to one or more high speed running yarns. The applicator device has a top portion ( 50 ) and a mated bottom portion ( 60 ) sealed to the top portion. This seal may be provided by machining the top and bottom portions to close tolerances. However, it is preferred that separate sealing means such as seals or gaskets be provided between the top and bottom portions to prevent external leakage at their mated surfaces.
[0092] The top portion has grooved channels in its bottom surface, individual for each yarn, extending from the front surface of the top portion to a position intermediate of the distance to the rear surface of the top portion. The bottom portion has grooved channels in its top surface, individual for each yarn, extending from the front surface of the bottom portion to a position intermediate of the distance to the rear surface of the bottom portion. The grooved channels in the top surface of the bottom portion are aligned with the grooved channels in the mating bottom surface of the top portion. Yarn entry openings ( 5 ) are formed by the intersection of the aligned grooved channels in the top and bottom portions with their respective front surfaces.
[0093] The width of the grooved channels in the top and bottom portions is not critical. For compactness, the width of the channels is preferably between about 3 times and 20 times the effective diameter of the yarn to be treated. The depth of the channels is preferably between 1.5 times and 10 times the effective diameter of the yarn to be treated.
[0094] Air boundary layer diversion ducts ( 15 ) in the top portion communicate between each of the grooved channels and the top surface of the top portion. Air boundary layer diversion ducts ( 16 ) in the bottom portion communicate between each of the grooved channels and the bottom surface of the top portion. Each of the air boundary layer diversion ducts in the top portion and in the bottom portion intersect its corresponding grooved channel in the vicinity of the respective front surfaces of the top and bottom portions forming an acute angle of about 10° to about 50° with the corresponding grooved channel, said acute angles opening outward rearward.
[0095] A first restriction ( 30 ) in the dimensions of each grooved channel is placed rearward of, and in the proximity of the intersection of the air boundary layer diversion duct with the grooved channel. The dimensions of the first restriction are critical (see below).
[0096] One or more liquid supply ducts ( 10 ) communicates between each of the grooved channels and an external pressurized source of finish liquid. The liquid supply ducts are placed rearward of the first restriction in the dimensions of each grooved channel. The terminus of each liquid supply duct at its intersection with its corresponding grooved channel is constricted so as to form a jet nozzle. The terminus of each liquid supply duct at its intersection with its corresponding grooved channel also forms a second and subsequent restriction ( 8 ) in its corresponding channel.
[0097] The bottom portion has rearward of the most rearward liquid supply duct, one or more internal walls defining two or more chambers ( 70 ). The chambers communicate with an external drain ( 20 ).
[0098] The dimensions of the chambers are not critical. For compactness, it is preferred that the length of the chambers in the direction of yarn travel is between about 1 cm to about 10 cm, and more preferably is between about 1.25 cm and 7 cm. The width of the chambers is preferred to be between about 0.2 cm and 2 cm. The depth of the chambers is preferred to be between about 1 cm and about 7 cm. It is preferred that the excess finish is disengaged from the yarn in two or more sequential chambers.
[0099] An exit opening ( 7 ) for each yarn is present in the rear surface of the bottom portion.
[0100] Means (not shown) are provided to hold the top portion and the bottom portion together in sealed and mated position. Preferably, the top portion and the bottom portion are connected at one of their side surfaces by hinge means and are connected at the other of their side surfaces by quick opening clamps means.
[0101] The first restrictions ( 30 ) in the grooved channels are so dimensioned as to block at least about 75% of the cross-sectional area of the air boundary layer entrained with each yarn. Preferably, the cross-sectional area of the first restriction is less than about 0.0335 cm 2 . Preferably, the cross-sectional area of the second and subsequent restrictions ( 8 ) in the grooved channels are no more than about five times the cross-sectional area of the first restriction.
[0102] The first ( 30 ) and subsequent restrictions ( 8 ) in the grooved channels as well as the air boundary layer diversion ducts ( 15 and 16 ) are believed to be essential features of the device. The first restriction substantially blocks the air boundary layers in motion with the yarns. The air boundary layer diversion ducts vent the entrained air to the exterior of the device before the yarn contacts the finish. Finite element modeling indicates that the subsequent restrictions of the grooved channels give rise to high contact pressures between the liquid finish and the yarn at the entrance of, and within the restricted channels. Such pressures are expected to be much higher than, and add to, the liquid finish pressure at the inlets to the device ( 10 ).
[0103] A one yarn-end applicator of this design has been fabricated.
[0104] The finish applicator devices of the invention are advantageously used directly on a draw panel in-line with spinning. A representative prior art four-zone draw panel is shown in FIG. 3. After spinning (not shown), a yarn end ( 49 ) contacts a first finish kiss roll ( 71 ) which applies a first finish on the yarn intended to help processability and drawability. The yarn end is then fed in sequence to a first drawing zone between driven roll ( 51 ) and idler roll ( 53 ) and driven roll pair ( 55 & 57 ); to a draw assist device ( 73 ) such as a steam jet; to a second draw zone between roll pairs ( 55 & 57 ) and ( 59 & 61 ); and to third and fourth drawing zones using heated roll pairs ( 63 & 65 ) and ( 67 & 69 ), respectively. The yarn end ( 49 ) then contacts an overfinish applicator device ( 75 ) which may be similar to that described in U.S. Pat. No. 4,268,550 and the yarn is fed to a winder (not shown).
[0105] There are several difficulties with the prior art draw panel that are resolved by the present invention. First, the prior art overfinish applicators are unable to achieve necessary finish concentrations and uniformity at yarn speeds of about 3000 m/min and above. This limits process productivity. Second, the prior art finish applicators produce a spray of finish in the vicinity of the device, thus creating safety and environmental problems. Third, the spray problem is more severe when the overfinish is applied to a yarn running in a horizontal plane rather than in a vertical plane. This limits the ability to apply overfinish between the heated draw rolls in a conventional draw panel, and therefore to dry and cure the finish before the yarn reaches the winder. With the prior art finish applicator in the arrangement shown, the finish on the yarn may still be wet as the yarn reaches the winder. These difficulties reinforce one another creating an overall problem greater than the sum of its parts.
[0106] In contrast, a finish device of the invention may be located on a draw panel where the yarn runs in a horizontal plane between heated draw rolls as illustrated in FIG. 4. The draw panel may be either a four-zone or five-zone panel. In either configuration, the inventive finish device is preferably located in the final draw zone. Shown in FIG. 4 is the same four-zone draw panel as that in FIG. 3. The part numbers correspond in FIGS. 3 and 4. However, in FIG. 4, the prior art overfinish applicator has been removed and an inventive finish device is located between heated roll pairs ( 63 & 65 ) and ( 67 & 69 ). The inventive finish applicator provides the ability to overfinish the yarn to desired finish concentrations and uniformity, and with little or no spray. Equally significant, the finish on the yarn may now be dried and cured to enhance yarn properties on-line.
[0107] The invention includes a yarn finishing method comprising the steps of: applying a liquid finish to one or more yarns running at speeds greater than about 3000 m/min at a position between heated rolls on a draw panel; drying said finish during passage over said rolls; and collecting a dry drawn yarn on a winder.
[0108] It should be noted that as some overfinishes may contain substances that are hazardous when volatilized on the heated draw rolls, it may be necessary to evacuate the volatiles from the working area. This may be done by installing an exhaust hood above the last draw zone, or optionally, placing an vented enclosure ( 79 ) around the last draw zone as shown in FIG. 5.
[0109] The invention also includes an overfinished yarn product prepared by the process comprising the steps of:
[0110] a) actively applying an overfinish to a yarn at a position between heated rolls, at a yarn speed greater than about 3000 m/min at a concentration of about 0.2 wt. % to about 5 wt. %, with a coefficent of variation of concentration of 10% or less;
[0111] b) drying said overfinish during passage over said heated rolls.
[0112] Yarns suitable for use in the invention include any yarn to which finish is applied including yarn made of polyamides, polyesters, polyolefins, poly(aramides) and polybenzazoles. Specific polyamides include nylon-6 and nylon-6,6. Specific polyesters include poly(ethylene terephthalate), poly(trimethylene terephthalate) and poly(ethylene naphthalate). Specific polyolefins are polyethylene and polypropylene. Specific polyaramides include ortho-, meta- and para- poly (phenylene terepthalamide). Specific polybenzazoles include poly(benoxazole) and poly(benzthiazole).
[0113] Filaments may have round or other cross-sectional shapes.
[0114] Finish on the yarn (FOY) is routinely determined using NMR (nuclear magnetic resonance) previously calibrated against known standards. As used herein, FOY is the “total finish” and refers to the sum of a first finish and any overfinish on the yarn.
[0115] NMR offers rapid analysis but it is not a primary method. Primary standards are prepared for each spin finish and overfinish system that is used. FOY values for these standards are determined by extracting the finish with a known good solvent for the finish (e.g cyclohexane, methanol) and determining the weight of the extract after evaporation of the solvent. The NMR measurements are correlated with the extraction data.
[0116] The method of determining FOY using NMR is as follows: a yarn sample (about 2 grams) is weighed, placed in a glass tube and inserted into the NMR cavity. A strong magnetic field causes the protons (hydrogen atoms) in the oil portion of the finish to line up. A radio frequency pulse is then applied at the resonance frequency to produce a signal called a free induction decay. The magnitude of this signal is proportional to the number of protons in the finish and hence its concentration. The calibration standards are retained and used to check the stability of the calibration daily.
[0117] Unknown samples are measured in the same way as the standards. A sample of about 2 grams is placed in the glass tube and the NMR signal is measured. Since the relationship between NMR signal and FOY is thus known, FOY is calculated by the software and displayed by the instrument. An overfinish may also be analyzed by x-ray fluorescence (XRF) when the overfinish contains silicon. Such overfinishes are described for example, by U.S. Pat. Nos. 4,617,236 and 4,397,985, hereby incorporated by reference herein to the extent not incompatible herewith. Again the XRF method is not a primary method and must be calibrated against standard samples analyzed by extraction. However, the XRF method, because of its sensitivity to the silicon component, can determine the concentration of overfinish separately from the concentration of a lubricating spin finish.
[0118] The following examples are presented to provide a more complete understanding of the invention. The specific techniques, conditions, materials, proportions and reported data set forth to illustrate the principles of the invention are exemplary and should not be construed as limiting the scope of the invention.
EXAMPLES
Comparative Example 1
[0119] A 250 filament polyethylene terephthalate (PET) yarn was drawn on a draw panel as shown in FIG. 3. A spin finish was applied to the yarn using a rotating ceramic kiss roll of 5.5 inch (14 cm) diameter partially immersed in a pan of spin finish. The spin finish kiss roll was located at the entrance to the draw panel at the position labeled ( 71 ) in FIG. 3. The finish roller speed was 13 RPM.
[0120] A package of yarn was collected under these conditions and then rewound with a yarn sample taken for determination of FOY approximately every 500 meters. The average of seventeen determinations of FOY was 0.354 wt. %
[0121] A PET yarn of 200 filaments was drawn in the same manner as described above. Fourteen FOY determinations approximately every 500 meters along the yarn averaged 0.386 wt. %.
Comparative Example 2 and Examples 1 and 2
[0122] An experiment was performed to compare overfinish application on a draw panel at a yarn speed of about 5400 m/min by the following means:
[0123] a) In Comparative Example 2, a prior art applicator similar to that described in U.S. Pat. No. 4,268,550.
[0124] b) In Example 1, an “immersion applicator” of the invention (FIG. 1) having a single liquid fed chamber having a length of 3.95 inches (10.03 cm) in the direction of yarn travel;
[0125] c) In Example 2, a “slotted applicator” of the invention (FIG. 2)
[0126] The yarn in each case was a 300-filament PET. Approximately 0.386 wt. % spin finish was applied by a kiss roll applicator (at position 71 in FIGS. 3 and 4) to each yarn at speed of about 2800 meters per minute at the entrance to the draw panel.
[0127] Overfinish was applied to the yarns by each of the devices listed above. The overfinish composition was similar to those described in U.S. Pat. No. 4,617,236 having a room temperature viscosity of 4.8 centistokes and a density of 0.98 g/cm 3 . The speed of the yarn as it passed the overfinish applicator was about 5400 meters per minute in each case. The yarn denier at each overfinish applicator was about 1000 denier.
Comparative Example 2
[0128] The prior art finish applicator was located after the draw panel and before the winder in the position labeled 75 in FIG. 3. A very high degree of finish spray to the surrounding area was generated at the finish applicator. The total finish on yarn (FOY) averaged 0.465 wt. %. The overfinish picked up from the prior art applicator at 5400 m/min was therefore only about 0.465−0.386=0.079 wt. %.
[0129] It should be noted that the magnitude of the spraying with prior art applicator prevented its placement in the last draw stage. The finish spray created with this device would build up on the draw rolls and eventually cause yarn defects or breakage. It should also be noted that with placement of the prior art finish applicator after the last draw stage, the yarn going to the winder was wet with uncured overfinish. Pooling of the wet overfinish where yarns were in contact on the wound package produced further non-uniformity in finish coverage.
Example 1 and Example 2
[0130] A finish applicator of the invention was place in the location labeled 77 in FIG. 4 between the heated roll sets in the final draw stage. The distance from the roll labeled 65 to the entrance of an inventive finish applicator was 32 inches (0.813 meters).
[0131] The cross-sectional area of the yarn entry openings (FIG. 1, yarn entry opening ( 5 )), and the area of the constricted passages (FIG. 1, constricted yarn passage ( 6 )) of the “immersion applicator” were 0.0335 cm 2 . No dimension of the yarn entry openings was greater than 5.5 times the effective diameter of the yarn. In the “slotted applicator” the cross-sectional area of the first restriction (FIG. 2, first restriction ( 30 )) in the channel was 0.0116 cm 2 . The cross-sectional areas of the subsequent restrictions in the channel were 0.0503 cm 2 or about 4.3 times the cross-sectional area of the first restriction.
[0132] The percent of the air boundary layer cross-section that was blocked by each of the inventive finish applicators was at least 98%. Yarn-finish contact pressures in each of the inventive finish applicators estimated from finite element numerical modeling were greater than 40 psi (276 kPa).
[0133] Finish was supplied to each of the inventive finish applicators from a reservoir by means of positive displacement gear pump with a variable speed drive. The finish feed rate to the applicators was varied and is shown in Table II. Excess finish was disengaged from the yarn within an applicator, drained, and sent to a reservoir for recycling.
[0134] The overfinish and the FOY (spin finish plus overfinish) applied to the yarns is listed in Table II. Little, if any finish spray to the environment was generated at any finish level.
TABLE II Overfinish Overfinish, wt. % FOY, % Feed Example 1 Example 2 Example 1 Example 2 Rate, “immersion” “slotted “immersion” “slotted ml/min applicator applicator” applicator applicator” 22 0.17 — 0.56 — 130 1.03 0.084 1.42 0.47 380 2.95 — 3.34 — 670 5.20 2.93 5.59 3.32
[0135] Examples 1 and 2 of the invention demonstrate that at a yarn speed of 5400 m/min, an inventive active finish applicator can provide finish application of about 5.2% and levels of FOY up to about 5.6 wt. %. Comparison of the FOY data for Examples 1 and 2 with Comparative Example 2 demonstrate that at a yarn speed of 5400 m/min, the inventive active finish applicators can provide significantly higher levels of FOY compared to the prior art kiss roll, and without generating spray to the environment. It is expected that finish levels of 6 wt. % or more may be applied by the methods and devices of the invention at speeds greater than 5000 m/min, and possibly greater than 8000 m/min or greater than 9000 m/min.
[0136] In contrast to Comparative Example 2 therefore, the inventive finish applicators were readily placed in the last draw stage. The yarn products after passing over the last heated roll set were dry. This is a substantial advantage of the inventive method, and a novel feature of the yarns so produced.
[0137] The data also demonstrate that the finish application by the inventive applicators can be controlled by the finish feed rate.
Example 3
[0138] A 250 filament, 1000 denier PET yarn was overfinished at 5400 m/min using an “immersion applicator” similar to that described in Example 1 but having two liquid fed chambers whose total length in the direction of yarn travel was 1.5 inches (3.81 cm). The cross-sectional area of the yarn entry openings (FIG. 1, yarn entry opening ( 5 )), and the area of the constricted passages (FIG. 1, constricted passages ( 6 )) of the “immersion applicator” were 0.0335 cm 2 . No dimension of the yarn entry openings was greater than 5.5 times the effective diameter of the yarn. The percent of the air boundary layer cross-section that was blocked from entry into the finish applicator was at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling was greater than 40 psi (276 kPa).
[0139] Approximately 0.386 wt. % spin finish was applied by a kiss roll applicator at a speed of about 2800 meters per minute at the entrance to the draw panel. The placement of the “immersion applicator” between heated godets was as described in Example 1. The overfinish feed rate to the applicator was about 250 ml/min. The overfinish composition was similar to one described in U.S. Pat. No. 4,617,236 having a room temperature viscosity of 4.8 centistokes and a density of 0.98 g/cm 3 .
[0140] The yarn was dry as it left the last heated godet. A package of yarn was collected and then rewound with a yarn sample taken for determination of FOY approximately every 500 meters. The results of the determinations are shown in Table III below.
TABLE III Rewind package number FOY, wt. % 1 1.48 2 1.40 3 1.26 4 1.31 5 1.50 6 1.34 7 1.36 8 1.24 9 1.33 10 1.17 11 1.36 12 1.21 13 1.09 14 1.30 15 1.29 16 1.36 17 1.26 Average 1.31 COV, % 7.9
[0141] The overfinish applied, by difference between the FOY and the spin finish, was about 1.31 wt. %−0.386 wt. %=0.92 wt. %.
[0142] The data of Example 3 demonstrate that yarn with about 0.9 wt. % overfinish and more than 1 wt. % FOY and can be prepared with a uniformity (COV) of less than 10% using a finish applicator and method of the invention.
Example 4
[0143] A 250 filament, 1000 denier PET yarn is overfinished at 3000 m/min using an “immersion applicator” and overfinish as described in Example 3. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 99%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 10 psi (68.9 kPa).
[0144] Approximately 0.4 wt. % spin finish is applied by a kiss roll applicator at a speed of about 1550 meters per minute at the entrance to the draw panel. The placement of the “immersion applicator” between heated godets and the procedure are as described in Example 3. The finish feed rate to the applicator is about 250 ml/min.
[0145] Overfinish applied to the yarn is about 0.7 wt. % with a COV of about 8%. FOY is about 1.1 wt. %. The yarn is dry as it leaves the last heated godet.
Example 5
[0146] A 250 filament, 1000 denier PET yarn was overfinished at 5400 m/min using an “immersion applicator” and overfinish as described in Example 3. The placement of the “immersion applicator” between heated godets and the procedure were as described in Example 3. The percent of the air boundary layer cross-section that was blocked from entry into the finish applicator was at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling was greater than 40 psi (276 kPa).
[0147] Approximately 0.40 wt. % spin finish was applied by a kiss roll applicator at a speed of about 2800 meters per minute at the entrance to the draw panel. The finish feed rate to the applicator was about 165 ml/min. The overfinish composition was the same as in Example 3.
[0148] The yarn was dry as it left the last heated godet. A package of yarn was collected and then rewound with two yarn samples (labeled “A” and “B”) taken at the same point for duplicate determinations of FOY approximately every 500 meters. The results of the determinations are shown in Table IV below.
TABLE IV FOY, % Rewind package number “A” Sample “B” Sample 1 — 0.87 2 — 0.90 3 0.93 0.85 4 1.07 1.03 5 1.12 1.02 6 0.96 0.94 7 1.07 1.00 8 0.97 1.01 9 0.97 0.98 10 0.89 0.94 11 0.97 0.93 12 0.95 0.98 13 1.07 0.94 14 0.99 0.96 15 0.91 0.94 16 1.01 1.06 17 0.82 0.98 Average 0.98 0.96 COV 8.1% 5.0%
[0149] An analysis of variance of the data of Table IV shows the standard error of measurement of FOY between any two samples at the same position was 0.079% FOY. The variation of FOY along a yarn overfinished by a device of the invention was about the same as the error in measurement.
[0150] The overfinish applied, by difference between the FOY and the spin finish, was about 0.97 wt. %−0.40 wt. %=0.57 wt. %.
Example 6
[0151] A 300 filament, 1000 denier PET yarn was overfinished at 5300 m/min using an “immersion applicator” and overfinish as described in Example 3. The placement of the “immersion applicator” between heated godets and the procedure were as described in Example 3. The percent of the air boundary layer cross-section that was blocked from entry into the overfinish applicator was at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling was greater than 40 psi (276 kPa).
[0152] Approximately 0.38 wt. % spin finish was applied by a kiss roll applicator at a speed of about 2700 meters per minute at the entrance to the draw panel.
[0153] The overfinish feed rate to the “immersion applicator” was varied with the resulting finish application shown in Table V. The yarn was dry as it left the last heated godet.
TABLE V Overfinish Feed Rate, Overfinish, ml/min wt % FOY, wt. % 0 0 0.38 84 0.27 0.65 96 0.38 0.77 96 0.28 0.67 96 0.40 0.79 108 0.31 0.69 120 0.32 0.71 120 0.40 0.79 120 0.43 0.81 132 0.48 0.87 144 0.65 1.04 144 0.52 0.91 144 0.52 0.91
[0154] The data of Example 6 illustrate the response of the overfinish application rate to the overfinish feed rate in the range of about 0.2 wt. % to about 0.7 wt. % overfinish.
Example 7
[0155] Approximately 0.39 wt. % spin finish is applied to a 250 filament, 1920 denier PET at about 4000 m/min. The yarn is overfinished between heated godets at about 8,100 m/min using an “immersion applicator ” as described in Example 3. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 60 psi (414 kPa). The placement of the overfinish applicator and the procedure are as described in Example 3. The finish feed rate to the applicator is about 370 ml/min.
[0156] Overfinish applied to the yarn is about 0.51 wt. % with a COV of about 9%. FOY is about 0.9 wt. %. The yarn is dry as it leaves the last heated godet.
Example 8
[0157] Approximately 0.4 wt. % spin finish is applied to a 250 filament, 1920 denier PET yarn at 5200 m/min using the “immersion applicator” and overfinish as described in Example 3. The yarn enters the applicator at a distance of 1.5 meters from the last driven roll. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 40 psi (276 kPa). Spin finish feed to the applicator is about 100 ml/min.
[0158] The yarn is overfinished between heated godets at 10,000 m/min using an “immersion applicator” as described in Example 3. The percent of the air boundary layer cross-section that is blocked from entry into the finish applicator is at least 98%. Yarn-finish contact pressure estimated from finite element numerical modeling is greater than 75 psi (517 kPa). The placement of the overfinish applicator and the procedure are as described in Example 3. The finish feed rate to the applicator is about 500 ml/min.
[0159] Overfinish applied to the yarn is about 0.5 wt. % with a COV of about 9%. FOY is about 0.9 wt. %. The yarn is dry as it leaves the last heated godet. | Methods and devices are provided to actively apply finish to one or more yarns in motion at speeds greater than about 3000 m/min, to achieve a finish application of 0.2 wt. % or more, and with a coefficient of variation of finish concentration of 10% or less. The devices are compact, portable and readily installed at a variety of positions on a fiber processing line. The devices of the invention contain the finish so that contamination of the surrounding areas is prevented.
The devices may be used to provide an overfinish to a moving yarn between heated godet rolls. The so-provided heating may be used to dry the yarn and to promote curing reactions in the finish and between the yarn and finish compounds.
The invention also includes the finished yarn products so produced. A yarn with increased finish uniformity is provided with an overfinish actively applied and dried on the draw bench before the first winding operation. The yarn products of the invention may be used in textile and leisure fiber applications, and in industrial fiber applications, such as in tires. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to devices for the oral or nasal inhalation of finely divided materials, such as medicinal agents and drugs.
Certain disease of the respiratory tract are known to respond to treatment by the direct application of medicinal agents. As many such agents are most readily available as a finely divided material, e.g., in dry powdered form, their delivery is most conveniently accomplished by inhaling the finely divided material through the nose or mouth. This results in better utilization of the medicinal agent in that it is deposited exactly at the site desired and where its action may be required; hence, very minute doses of the therapeutic agent are often equally as efficacious as larger doses administered by other means, with a consequent marked reduction in the incidence of undesired side effects. Alternately, the therapeutic agent in this form may be used for treatment of diseases other than those of the respiratory system. When the drug is deposited on the very large surface areas of the respiratory tract, it may be very rapidly absorbed into the blood stream; hence, this method of application may take the place of administration by injection, tablet, or other conventional means.
A variety of inhalation devices for the delivery of finely divided materials are known in the art. For example, U.S. Pat. No. 4,240,418 discloses inhalation devices wherein a container of finely divided material is positioned so that the material from the container can pass by gravity to a delivery area of the device from which it is dispensed. Accordingly, these devices suffer the disadvantage that the use must maintain the device in a particular position so that the finely divided material can pass by gravity to the collecting plate and is not dislodged therefrom prior to dispensing. It appears that such devices also require a large dispensing passage to prevent interference with the free fall of a relatively large load of the finely divided material.
Other known inhalation devices incorporate a deflector (U.S. Pat. No. 4,098,273) or a hollow tube (U.S. Pat. No. 3,938,516) to divert air flow into a chamber to dislodge the finely divided material, thereby requiring a substantial flow of air to disperse the finely divided material. Inhalation sufficient to create such a substantial flow of air is difficult for some users, e.g., asthmatics. Furthermore, it is believed that such devices deliver somewhat imprecise doses due to the inevitable variations in residue of finely divided material left behind in the container after dispensing.
Some known inhalation devices use members which vibrate to dispense the finely divided material, thus increasing the complexity and bulk of the device. For example, the devices of U.S. Pat. No. 3,948,264, utilize batteries to activate vibrators. Other devices incorporate breath activated vibratable members to disperse the finely divided materials. See, e.g., U.S. Pat. Nos. 3,888,253 and 4,995,385 which include a member which vibrates in the airflow to dispense the finely divided material. Still other known devices use a breath activated propeller device to spin the container of finely divided material, thereby casting the material out by centrifugal force, e.g., U.S. Pat. No. 3,507,277. A relatively high velocity of air flow is required to activate such devices, again a problem for breath impaired users.
Moisture in most powders tends to cause agglomeration and clumping thereby inhibiting the breakup and dispersion of the finely divided medication, an essential step in effective dispensing of the material. However, the manner in which many known devices operate renders hermetic sealing of the container of finely divided material impossible. In still other known devices, the containers for finely divided materials are gelatin capsules which are susceptible to atmospheric moisture.
In some known inhalation devices, e.g., conventional aerosol bronchodilators, drug delivery is achieved by the sometimes difficult coordination of digital force with voluntary inhalation.
New and more potent drugs which can be used in increasingly small quantities are being developed on an ongoing basis. In most instances, known inhalation devices for finely divided materials are not capable of delivering such small quantities without the addition of a significant amount of filler. It is highly desirable to minimize the use of such fillers, e.g., in order to reduce the likelihood of side effects.
It can be seen that presently known devices for the delivery of finely divided materials suffer disadvantages which include imprecise delivery, inability to deliver directly from a hermetically sealed container, high breath demands upon the user, limited portability due to bulk, and complexity of design. Thus, alternative inhalation devices are being sought.
SUMMARY OF THE INVENTION
Devices of the present invention utilize air flow through a container of finely divided material, the container having one section open to the atmosphere and another open to the interior of the device, to dispense the finely divided material. As air if drawn through the container and the device by oral or nasal inhalation of the user, increased air velocity causes decreased pressure within the device. This results in a pressure differential between the section of the container open to the atmosphere and the section open to the body member. The resultant flow of air from outside atmospheric pressure to inside partial vacuum picks up the finely divided material carrying it into the device to mix with the internal flow of air. The passage of air through the container of finely divided material, and the device virtually purges the material from both the container and the device, thereby carrying it along with the user's inspired breath to the lungs or nasal passages.
The inhalation devices of the present invention overcome many of the disadvantages associated with known devices. One important advantage resides in their ability to accurately and repeatedly dispense the finely divided material. Because it is air flow through the finely divided material that causes dispensing, the air flow through the container typically causes virtually all of the finely divided material to be evacuated. Another advantage of devices in accordance with the present invention is that loads of finely divided material as low as about 0.1 mg can be dispensed. This is also an important advantage because by dispensing small doses of finely divided materials, such as pharmaceuticals, the use of fillers, such as lactose, is minimized.
Yet another major advantage of inhalation devices in accordance with the present invention is the total protection of the finely divided material up to the moment of use. Each individual dose is hermetically sealed, in some cases removably hermetically sealed, to assure as long a shelf life as possible and freedom from contamination.
Furthermore, the present inhalation devices require little or no coordination on the part of the user, since inhalation of breath causes the device to function. In one embodiment, the user need only press down on a conveniently located button to perforate the container of finely divided material to ready the device for use. The finely divided material remains in the container until activated by patient inhalation which can occur within any reasonable time period after the container seal is broken. Moreover, a relatively low velocity of air flow through the body member, as measured by a standard flow meter, is adequate to achieve full dispensing, generally even for a child.
The inhalation devices of the present invention have the further advantage of great simplicity which renders them capable of being made in a small size for inconspicuous portability, further enhancing the desirability for use as a personal dispenser. One preferred inhalation device of the present invention is pen-like in design to render it easy to use inconspicuously, as well as to provide other important advantages.
The devices disclosed herein are adapted for receiving from a single to multiple containers of finely divided material. In one preferred embodiment, the device is adapted to receive a circular disk containing multiple containers of finely divided material. Not only does this embodiment provide a convenience for the user, it also provides an economy in production filling.
One inhalation device in accordance with the present invention comprises (i) a body member having an air passageway therethrough, one end of the body member being adapted for insertion into the mouth or nose of the user; (ii) a holder connected to the body member for receiving at least one removably sealed container of finely divided material; and (iii) at least one piercer for piercing the removably sealed container while the sealed container is in the holder, the piercer extending from the body member and into the holder and having a passageway therethrough open to the body member and the holder. A removably sealed container is placed in the holder thereby causing the piercer to pierce the sealed container. The removable seal is then removed and air drawn through the unsealed nd pierced container, the piercer, and the body member cooperate to cause finely divided material disposed in the container to be dispensed therefrom.
In another similar embodiment of the present invention, the piercer extends from the body member through the holder for a distance greater than the dimension of the sealed container to be pierced, thus, providing devices for the oral or nasal inhalation of finely divided materials from a sealed container which need not be provided with a removable seal. In such embodiments, the dimensions of the piercer are such that when the sealed container is placed in the holder thereby causing the piercer to pierce through the sealed container therein, the finely divided material is transferred from the container to the air passageway of the piercer as it passes through the container. Subsequently, air drawn through the piercer and the air passageway of the body member cooperate to cause the finely divided material disposed in the piercer to be dispersed therefrom.
The present invention provides yet another inhalation device for dispensing finely divided materials from a sealed container which is not provided with a removable seal. Such devices typically include at least two piercers and comprise: (i) a body member having an air passage therethrough, one end of the body member being adapted for insertion into the mouth or nose of the user; (ii) a holder for receiving at least one sealed container of finely divided material, the holder being connected to the body member; (iii) at least one first piercer for piercing the sealed container while in the holder, the first piercer extending into the interior of the holder and having an air passageway therethrough open to the body member and the holder; (iv) at least one second piercer for piercing the sealed container while in the holder, the second piercer extending into the holder and having a air passageway therethrough, open to the interior and exterior of the holder; and (v) engaging means for causing the first and second piercer, while the sealed container is in the holder, to pierce the sealed container.
These devices operate so that when the sealed container is positioned in the holder and the engaging means causes the first and second piercers to pierce the sealed container to create an air passageway therethrough, air drawn through the first piercer, the pierced container, the second piercer, and the passageway of the body member cooperate to cause finely divided material disposed in the pierced container to be dispensed therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an perspective view of one embodiment of a device in accordance with the present invention.
FIG. 2 is an perspective view of another embodiment of a device according to the present invention.
FIG. 3A is a section on line 3A--3A of the device shown in FIG. 1, showing a cross-section of a container of finely divided material disposed therein, wherein the removable seal has been removed.
FIG. 3B is an end view of the device shown in FIG. 1.
FIG. 3C is a plan view of the device shown in FIG. 1.
FIG. 4 is cross-sectional view of yet another embodiment of a device of the present invention, similar to that shown in FIG. 3.
FIG. 5 is an enlarged cross-sectional view of the removably sealed container of finely divided material shown in FIG. 3A wherein the removable seal is intact.
FIG. 6A is a cross-sectional view of the device shown in FIG. 2 taken along line 6A--6A of FIG. 2A.
FIG. 6B is an end view of the device shown in FIG. 2 showing the inhalation end.
FIG. 6C is an end view of the device shown in FIG. 2 showing the air intake end.
FIG. 6D is a plan view of the device shown in FIG. 2.
FIG. 7A is a plan view of a disk provided with multiple sealed containers containing finely divided materials for use in the present invention.
FIG. 7B is a side view of the disk shown in FIG. 7A.
FIG. 7C is a bottom view of the disk shown in FIG. 7A.
FIG. 8 is a cross-sectional view of another device in accordance with the present invention, showing a cross-sectional view of a tapered container.
FIG. 9A-9D are cross-sectional views of yet other devices in accordance with the present invention.
FIG. 10 is a graph showing total excretion of free H 3 -cortisol for a 24 hour period after administration nasally in accordance with the present invention as compared with excretion of free H 3 cortisol after conventional oral administration.
FIG. 11 is a graph showing excretion of free H 3 -cortisol over a 24 hour period after administration nasally in accordance with the present invention as compared with excretion of free H 3 cortisol after conventional oral administration.
DETAILED DESCRIPTION OF THE INVENTION
Although the inhalation devices of the present invention are primarily illustrated by means of devices which have been adapted for oral inhalation, it will be appreciated by those skilled in the art that such devices may also be adapted for nasal inhalation of finely divided materials.
Referring now to FIGS. 1 and 3 there is shown one embodiment of an inhalation device of the present invention for the oral inhalation of finely divided materials from a removably sealed container. The device shown comprises a body member 20 having an air passageway 22 therethrough, the air passageway comprising a venturi. One end 24 of the body member 20 is adapted for insertion into the mouth of the user. The other end 27 is an air intake end and may optionally be provided with a screen (not shown) to filter inhaled air. A holder 40, comprising an open receptacle for receiving at least one removably sealed container 60 of finely divided material 64, is connected to body member 20. At least one piercer 26 (shown in FIG. 3A) for piercing the removably sealed container 60, while the sealed container 60 is in the holder 40, extends from the body member 20 and into the holder 40. The piercer 26 has a passageway therethrough open to the body member 20 and the holder 40.
The container 60 is dimensioned to extend above the holder 40 while present therein so that the user can access the removable seal 62 and can grasp and remove the container 60 after use. An enlarged cross-sectional view of a removably sealed container is shown in FIG. 5. In use, the removably sealed container 60 is placed in the holder 40 thereby causing the piercer 26 to pierce the sealed container 60 and to hold the tab of sealing material 66 created thereby (See, e.g., FIG. 5) against the container 40. The removable container seal 62 is then removed, thereby creating an opening to the atmosphere.
The device shown in FIG. 4 is similar to that shown in FIG. 3. However, it is adapted for use in conjunction with a sealed container which is not provided with a removable seal. The piercer 26 in this device extends from the body member 20 through the holder 40 for a distance greater than the dimension of the sealed container 60 to be pierced. When the sealed container 60, is placed in the holder 40 as shown in FIG. 4, thereby causing the piercer 26 to pierce through the sealed container 60, the finely divided material 64 is transferred from the container 60 to the air passageway of the piercer 26 from which it is dispensed upon inhalation by the user.
In use, the mouthpiece 24 of the inhalation devices of the present invention is placed inside the lips of the user to minimize impingement of the finely divided material on the mouth. A quick intake of breath causes air to flow through the air intake end 27 and into air passageway 22 of body member 20 to create a partial vacuum, thereby causing the finely divided material 64 to be dispensed from (i) the pierced and unsealed container 60 in the embodiment showing in FIGS. 1, 3, and 9; and (ii) from the air passageway of the piercer 26 in the embodiment shown in FIG. 4.
Another preferred device in accordance with the present invention, shown in FIGS. 2 and 6, comprises a body member 20 having an air passageway 22 therethrough, and a holder 40. One end 24 of the body member 20 is adapted for insertion into the mouth of the user. The other end 27, the air intake end, of body member 20 is provided with a screen 28 to minimize inhalation of undesired materials, e.g., dust, which may be present in the air. A first piercer 26 for piercing the sealed container 60 while in the holder 40, extends into the interior of the holder 40 and has a passageway therethrough open to the body member 20 and the holder 40.
In the embodiment shown in FIGS. 2 and 6, the holder 40 is adapted to receive a disk 70 provided with multiple containers 60 as shown in FIG. 7. The holder 40 comprises a receptacle 42 fixed to the body member 20 and a cover 44 movably attached to receptacle 42 by hinge means 46. The disk 70 while in the holder 40 is rotatably, centrally disposed on a pin (not shown) which is mounted therein.
The disk 70 is provided with a conventional locking means so that during rotation, the disk is locked in position each time a container of finely divided material is disposed adjacent piercer 26, 52, thereby locating each single dose container 60 for dispensation. Disks of a given diameter can contain different numbers of single doses depending upon the requirements of the particular drug in use. Thus, one inhalation device in accordance with the present invention can have many different drug applications.
A preferred multiple cavity disk 70 is about 0.75 to 1.25 inches in diameter, about 0.250 to 0.312 inches deep and is provided with individual sealed containers, similar to those shown in FIG. 5. The disk 70 is typically made of conventional molded plastics, such as, polypropylene, polyethylene, acetal, ABS and so forth. However, other conventional materials known to those skilled in the art may also be used. Although disk 70 can be rotated mechanically after use, for simplicity the preferred method is hand rotation. It will be apparent to those skilled in the art that the disk 70 could be replaced with multiple container strips, either rigid or in flexible rolls, e.g., as in a cartridge belt for an automatic weapon, and so forth.
The cover 44 is provided with perforations 45 to provide an opening to the atmosphere through which air is drawn upon inhalation by the user when the pierced container 60 is in the device. The cover is also provided with a section 48 having a first leaf spring 50. Section 48 is movably mounted in the cover 44, flanges 49 providing stops to maintain section 48 in cover 44, when cover 44 is raised to insert a disk 70 of sealed containers 60.
A second piercer 52 mounted in cover section 48 extends into the interior of the holder 40 and has a passageway therethrough open at both ends to the holder 40. The second piercer 52 is positioned relative to the first piercer 26 so that they are capable of cooperating to pierce the sealed container 60 when the sealed container 60 is in receptacle 42 and rotated into dispersing position adjacent piercers 26, 50.
Receptacle 42 is provided with a second leaf spring 51 disposed between body member 20 and disk 70, when the disk 70 is in holder 40. The movable cover section 48 cooperates with leaf springs 50, 51 to provide the engaging means for causing the first and second piercers 26, 52 to pierce the sealed container 60 while in the holder 40 when movable cover section 48 is pressed towards container 60 by the user.
To operate the device shown in FIGS. 2 and 6, the movable cover section 48 is depressed by the user so that piercers 26 and 52 pierce the seals 61 (shown in FIG. 5) of the container 60 of finely divided material 64, thereby creating an air passage. The air passage is blocked only by the finely divided material 64, because the tab of pierced seal 66 is held against the side of holder 40 by piercer 26 (See FIG. 5). The movable cover section 48 is held in a depressed position until after inhalation by the user so that the piercers 52, 26 will remain in contact with the container 60 of finely divided material 64. The passage of air through the perforation in seal 62, needle 52, container 60, needle 26, and air passageway 22, virtually purges the finely divided material 64 from the container 60, carrying it along with the patients inspired breath into the lungs.
In preferred embodiments of the present invention, the air passageway 22 of the body member 20 comprises a venturi or a tube, wherein the first piercer 26 is disposed at or adjacent the smallest diameter of the venturi or the midpoint of the tube. A venturi is a particularly preferred configuration for the air passageway 22 of the body member as shown, e.g., in FIGS. 3A, 4, 6A and 8.
In one particularly preferred embodiment of the present invention, the body member 20 has a major diameter at each end ("B" in FIG. 6A) of about 0.3 to 0.8 inches with, in the case of embodiments wherein the air passageway 22 composes a venturi, a minor diameter ("A" in FIG. 6A) at the venturi's point of restriction 23 of about 0.2 to 0.5 inches. These dimensions are based upon end 24 of body member 20 being adapted for insertion into the nose or mouth of the user, as well as providing a minor diameter adequately large to allow an uninhibited intake of breath. The inner diameter ("D" in FIG. 6A) of holder 40 is dimensioned to receive disk 70 and may be from about 0.5 to 1.5 inches when A and B have the dimensions set forth above. It is understood that the circumstances of use will dictate the dimensions without altering the intent of the device. For example, one might wish the unit to resemble a pocketable pen as shown in FIG. 8 to achieve an enhanced degree of portability.
The relative dimensions of the containers of finely divided material for use in the devices of the present invention and the piercer(s) of such devices are selected to provide accurate delivery of the finely divided material. The dimensions of the piercer 26 which open to body member 20, as well as the end or ends of the container 60 pierced thereby, are selected to minimize entrapment of the finely divide material 64 adjacent piercer 26. Finely divided material below the orifice of the needle 26 is unlikely to evacuate, yet the needle 26 must project high enough to hold tab 66 (shown in FIG. 5) in a vertical position. If tab 66 is not held parallel to the sides of the container, it may be drawn down by the vacuum created upon inhalation to seal off piercer 26, thereby upsetting dosage accuracy.
In some preferred embodiments of the present invention, the diameter of the cylindrical container is stepped down at the end disposed adjacent piercer 26 while in the device, to minimize entrapment of the finely divided material. See, e.g., stepped down section 69 in FIG. 5. The step is preferably equal in length to the outside diameter of piercer 26 (i.e., about the size of tab 66 in the vertical position). The dimensions of piercer 52 are not as important since the tab created by piercer 52 is not positioned so that it will interfere with dispensing of the finely divided material. However, piercer 52 must be sufficiently large to permit unobstructed flow of air.
The inhalation devices of the present invention shown in the figures embody a piercer 26 which comprises a needle, preferably sharpened at the piercing end to about a 30° to 45° angle. The rim of the needle opposite the apex of the needle point is typically blunted to avoid cutting a piece of the seal 61 of container 60 free. As shown in FIG. 5, this leaves a tab 66 of the seal "hinged" to the container 60 thereby preventing ingestion.
In a preferred embodiment the needle 26 has an inner diameter of about 0.01 to 0.15 inches and an outer diameter of about 0.03 to 0.170 inches. Such inside diameters afford adequate flow of finely divided material while still retaining it in the container 40 until the moment of discharge. However, diameters outside the preferred ranges may be useful, depending in part upon the fluidity of the finely divided material. For example, a highly fluid finely divided material would call for a smaller diameter needle 26 than less fluid material in order to hold the powder inside the container 40 until evacuated by the inhalation of the user.
In preferred embodiments of the present invention, other than those similar to the embodiment shown in FIG. 4, the needle 26 extends into the container 60 for approximately one needle diameter length, plus the length of the sharpened angle, or sufficiently far to hold tab 66 in a position generally parallel to the side of the needle 26 and adjacent the inner wall of the container 40, thereby leaving a clear passage for air flow. This enables tab 66 to remain attached to the container 40 and to be bent to a position as shown in FIG. 5.
In embodiments wherein the needle 26 preferably has an inner diameter of about 0.01 to 0.15 inches and an outer diameter of about 0.03 to 0.170 inches, section 69 of the container has an inner diameter of about 0.035 to 0.180 inches, and section 68 has a diameter of about 0.045 to about 0.190 inches. In a particularly preferred embodiments piercer 26 has an inner diameter of about 0.045 inches and an outer diameter of about 0.062 inches and the section 68 of container 60 has an inner diameter of about 0.070 inches and section 69 has an inner diameter of about 0.080 inches.
In embodiments of the present invention which include a second piercer 52, such as those shown in FIGS. 2, 6 and 8, the second piercer 52 is also preferably sharpened at the piercing end to about a 30° to 45° angle and the rim opposite the apex of the point is typically blunted. The inner diameter of piercer 52 is typically about 10 to 15% greater than the inner diameter of piercer 26.
In the embodiment shown in FIGS. 2 and 6, leaf springs 50 and 51 are preferably stainless steel and are about 0.005 to 0.015 inches, more preferably about 0.010 to 0.012 inches. Molded plastic springs can also be used but the extra thickness of such springs may be undesirable.
The configuration and dimensions of containers for use in the inhalation devices of the present invention are adapted to the particular device. For example, in embodiments wherein the piercer 26 is a needle, the container is preferably cylindrical. In some embodiments, the diameter of the container 60 is constant throughout, e.g., as shown in FIG. 4. In other embodiments, the container is provided with a first section 68 and a second section 69, narrower in diameter than section 68, as shown in, e.g., FIG. 5. In yet other embodiments of the present invention, e.g., as shown in FIG. 8, section 68 of container 60 tapers outwardly. This taper allows a greater volume of finely divided material to be loaded within a given depth. For proper evacuation of the container 60, the taper should not exceed an angle of about 10° to 15°.
In the embodiments shown in the figures, other than embodiments similar to the embodiment shown in FIG. 4, the inner diameter of section 68 of the container 60 is about 10 to 15% larger than the outer diameter of needle 26. In embodiments similar to that shown in FIG. 4, because the finely divided material is transferred to the needle as it pierces the container, the inner diameter of the container is only about 10 to 15% larger than the outer diameter of needle 26 to minimize any residue of finely divided material which may be left behind in the container.
The amount and fluidity of the finely divided material to be delivered will in large part determine the dimensions of the inhalation devices of the present invention. The devices of the present invention are capable of delivering amounts of finely divided material ranging from about 0.1 to 25 milligrams.
The dimensions of containers of the finely divided material for use in the present invention are also adapted for the particle size and amount of such material to be dispensed and, preferably, are large enough to provide an empty space 65 above the surface of the finely divided material. See, e.g., FIG. 5. This space 65 allows the finely divided material 64 to remain loose, avoiding agglomeration in storage and compaction from pressure as the needle 26 penetrates the container 60. In preferred embodiments, the container 60 is about half filled with finely divided material 64.
The particle size of the finely divided material to be delivered also influences the dimensions of the devices of the present invention. The desired particle size is determined, in part, by the mode of delivery, i.e., orally or nasally. Generally in oral administration, the intent is to get the greatest possible portion of the dose of finely divided material into the lungs and to avoid impingement on the lining of the buccal cavity. Whereas for nasal administration, it is desirable to have the major portion of the powder dose deposited on the nasal mucosa and the minimum amount carried to the lungs. A finer particle size and greater flow of air through the device of the present invention is used in oral delivery as compared with nasal delivery to accomplish the desired end. It is believed that the minimum air flow that would discharge the powder fully would also minimize the amount of powder carried to the lungs for nasal applications.
Containers for use in the present invention are sealed at one or both ends with a conventional piercable material, such as a plastic or metal film using methods known to those skilled in the art. See. e.g., film 61 in FIG. 5. In such embodiments, the thickness of the film is about 0.002 to 0.004 inches. The desired characteristics for such sealing materials are high tensile strength to avoid tearing during perforation and resistance to the passage of moisture. In a preferred embodiment, a polyester film having heat activating adhesive on one side is used to seal the containers. Although polyester is preferred, other films known in the art, such as aluminum foil, may also be employed. In one preferred embodiment of the present invention wherein the container is removably sealed, the removable seal comprises a hermetic foil seal which is provided with an integral tab for ease of manual removal.
In the manufacture of embodiments of the present invention wherein multiple containers 60 are disposed in disk 70, the disk 70 is typically first sealed on one side with a piercable sealing material. The finely divided material 64 to be dispensed is then added to the multiple containers 60 disposed in disk 70 and the containers 60 are then hermetically sealed by sealing the other side of disk 70 either with a removable seal or with piercable sealing material.
The devices and containers of the present invention are made from conventional materials and by conventional techniques known to those of ordinary skill in the art. To ensure simple manufacture of such devices and containers, it is advantageous to use a readily processable plastic where suitable.
It will be apparent to the skilled artisan in light of the teachings of the present invention that configurations of body member 20, holder 40, piercer 26 and/or and piercers 26, 52 other than those shown may be utilized without departing from the spirit and scope of the invention.
For example, holder 40 may be connected to the body member 20 at various angles as illustrated in FIG. 9: FIG. 9A showing a 45° angle, FIGS. 9B and 9C a 90° angle, and FIG. 9D a 30° angle. In yet another embodiment shown in FIG. 8, body member 20, hold 40, and piercers 26 and 52 are arranged in parallel, i.e., at 0° angle. Furthermore, the embodiment shown in FIG. 8 is pocketable and less conspicuous in use, being somewhat pen-like in appearance.
In use, the cover 44 of the embodiment shown in FIG. 8 is removed, the sealed container 60 is inserted in the holder 40, and the bottom seal of container 60 is pierced. The cover 44 is replaced and pressed home to pierce the top seal. After removing the dust cap 54, the user places the mouthpiece 24 in the mouth and inhales. In preferred embodiments, the dimensions are as follows: overall length, about 3 to 6 inches; diameter, about 0.25 to 0.75 inches; length of body member 20, about 2 to 4 inches; length of cover 44, about 1.5 to 2.5 inches; length of piercer 26, about 1 to 1.75 inches; and length of piercer 52, about 0.375 to 0.75 inches. In one such preferred embodiment for oral inhalation the breath required for actuation of the device was only about 25 liters per minute. The dimensions of this device were as follows: overall length of about 3.375 inches; an inside diameter of about 0.32 inches at the widest section and 0.25 inches at the narrowest section of the venturi; body member 20 length of about 2.25 inches; holder 40 length of about 0.375 inches; piercer 26 length of about 1.1 inches; and piercer 52 length of about 0.5 inches.
In the adaptations of the embodiment shown in FIG. 8 for nasal inhalation, the internal diameter is reduced to restrict the air flow for delivery. For example, the narrowest section of the venturi can be reduced to about 0.187 inches in diameter to restrict the air flow. Furthermore, end 24 of the body member 20 is adapted to fit the human nose, and in some such embodiments, is bent upward at a 30° angle for comfort in use. Other than diameter, the basic dimensions are similar to those given above.
As is amply illustrated by the various embodiments in accordance with the present invention described herein, by following the teachings of the present invention one of ordinary skill in the art can vary the disclosed devices in structure by utilizing ordinary skill in the art to meet the demands of a particular finely divided material, particular user and so forth.
In order to illustrate the delivery advantages of the inhalation devices of the present invention, administration of cortisol tritiated (H 3 -cortisol) using an inhalation device similar to that shown in FIGS. 1 and 3A was compared with conventional oral administration of H 3 -cortisol by testing the urine of recipients of the H 3 -cortisol for its presence.
Free, unmetabolized H 3 -cortisol present in the urine reflects the amount of H 3 -cortisol in circulation. By free cortisol is meant cortisol which has not been altered by the liver. It is known that when cortisol is ingested, a good portion is inactivated or metabolized in the liver.
FIG. 10 shows that more free H 3 -cortisol was excreted in a 24 hour period in the urine when the H 3 cortisol was administered via an inhalation device of the present invention as compared with ingestion. FIG. 11 shows that inhaled cortisol is more directly available for excretion in the urine at an earlier time than is ingested cortisol. These results give very powerful indirect evidence that the inhaled cortisol was not just swallowed but reached the alveolar epithelium and, thus, entered systemic circulation in a manner almost equivalent to delivery of H 3 -cortisol intravenously. In contrast, the ingested cortisol was metabolized rapidly by the liver, because it was absorbed by the gut into the portal circulation.
A device similar to that shown in FIGS. 1 and 3A was tested to determine its delivery accuracy.
A container similar to that shown in FIGS. 3A and 5 was filled with about 3.24 mg of finely divided material and placed in the holder 40 of a device similar to that shown in FIGS. 1 and 3A. It was not necessary to provide the container with a removeable seal 62 because the finely divided material was dispensed immediately after being placed in the container. The method of discharge was by hand vacuum pump with a volume approximately equal to the human lung. A constant stroke was used in dispensing to minimize variation. Immediately after dispensing, the container was removed from the device and weighed again, and the residue of finely divided material determined. This process was repeated thirty-five times. The container was virtually purged with each delivery, and the residue remaining was very constant and very small. Thus, very accurate dose delivery was achieved by the use of a device of the present invention.
This invention will be further understood with reference to the following examples which are purely exemplary in nature and are not meant to limit the scope of the invention.
EXAMPLE
Example 1: Administration of Tritiated Cortisol
A device similar to that shown in FIGS. 1 and 3A was used in this Example.
H 3 -cortisol for inhalation and for oral ingestion was prepared as follows: 100 mg of cortisol was weighed in a clean crucible. 200 mμ of H 3 -cortisol dissolved in ethanol was added to the powder, and thereafter, the ethanol was evaporated in a desiccator and the sample mixed well. The mixture of unlabelled and H 3 -cortisol was ground with a stainless steel spoon shaped spatula. 5 mg of this mixture was weighed on glassene paper and then placed in a vial containing 0.5 ml of water and 5.0 ml of pico-fluor. Approximately 6,523,223 counts per minute/5 mg was prepared, giving a specific activity for H 3 -cortisol of 1,279,063 counts/minute/mg.
10 mg of the H 3 -cortisol was administered to one subject by use of an inhalation device of the present invention and to another subject orally.
The paper and tools used for weighing, as well the inhalation device were washed with ethanol and the amounts of H 3 -cortisol found were then appropriately subtracted from the counts obtained from dose inhaled and ingested.
Excretion of free, unmetabolized cortisol as tritium was counted after extraction from the urine into dichloromethane, which was dried down and counted. The measurement of free H 3 -cortisol was carried out via conventional radioimmunoassay procedures after preliminary purification by thin layer chromatography.
FIG. 10 demonstrates that of the total counts per minute excreted, for a 24 hour period the percent as free H 3 -cortisol was approximately 25% for the inhaled dose and less than 5% for the ingested dose.
FIG. 11 shows counts per minute of free H 3 -cortisol excreted over a 24 hour period for both oral ingestion and inhalation of the same dose. It can be seen that there was an early rise in counts per minute of free H 3 -cortisol after inhalation which is not observed in the urine of an individual after oral ingestion of the labeled cortisol.
These results indicate that the inhaled H 3 -cortisol reached the alveolar epithelium and the systematic circulation, whereas the ingested cortisol was metabolized rapidly because it was absorbed by the gut into the portal circulation.
It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof that will be suggested to persons skilled in the art are to be included in the spirit and purview of this application and the scope of the approved claims. | The present invention provides devices for the oral or nasal inhalation of finely divided materials such as medicinal agents and drugs. | 0 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/006,409, filed Dec. 6, 2004, which is a continuation of U.S. application Ser. No. 10/418,509, filed Apr. 16, 2003, now U.S. Pat. No. 6,945,903, which is a continuation of U.S. application Ser. No. 10/141,652, filed May 7, 2002, now U.S. Pat. No. 6,551,210, which is a continuation of U.S. application Ser. No. 09/695,757, filed Oct. 24, 2000, now U.S. Pat. No. 6,419,608, which issued Jul. 16, 2002. Each of the above identified applications is incorporated by reference in its entirety.
[0002] The U.S. application Ser. No. 10/418,509 is also a continuation-in-part of U.S. application Ser. No. 10/016,116, filed on Oct. 30, 2001, now U.S. Pat. No. 6,676,559, which is a continuation of U.S. application Ser. No. 09/823,620, filed Mar. 30, 2001, now U.S. Pat. No. 6,322,475, which is a continuation of U.S. application Ser. No. 09/133,284, filed Aug. 12, 1998, now U.S. Pat. No. 6,241,636, which in turn claims priority to U.S. provisional application No. 60/062,860, filed on Oct. 16, 1997; U.S. provisional application No. 60/056,045, filed on Sep. 2, 1997; U.S. provisional application No. 60/062,620, filed on Oct. 22, 1997 and U.S. provisional application No. 60/070,044 filed on Dec. 30, 1997.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The field of the invention relates to transmissions. More particularly the invention relates to continuously variable transmissions.
[0005] 2. Description of the Related Art
[0006] In order to provide an infinitely variable transmission, various traction roller transmissions in which power is transmitted through traction rollers supported in a housing between torque input and output discs have been developed. In such transmissions, the traction rollers are mounted on support structures which, when pivoted, cause the engagement of traction rollers with the torque discs in circles of varying diameters depending on the desired transmission ratio.
[0007] However, the success of these traditional solutions has been limited. For example, in U.S. Pat. No. 5,236,403 to Schievelbusch, a driving hub for a vehicle with a variable adjustable transmission ratio is disclosed. Schievelbusch teaches the use of two iris plates, one on each side of the traction rollers, to tilt the axis of rotation of each of the rollers. However, the use of iris plates can be very complicated due to the large number of parts which are required to adjust the iris plates during shifting the transmission. Another difficulty with this transmission is that it has a guide ring which is configured to be predominantly stationary in relation to each of the rollers. Since the guide ring is stationary, shifting the axis of rotation of each of the traction rollers is difficult. Yet another limitation of this design is that it requires the use of two half axles, one on each side of the rollers, to provide a gap in the middle of the two half axles. The gap is necessary because the rollers are shifted with rotating motion instead of sliding linear motion. The use of two axles is not desirable and requires a complex fastening system to prevent the axles from bending when the transmission is accidentally bumped, is as often the case when a transmission is employed in a vehicle. Yet another limitation of this design is that it does not provide for an automatic transmission.
[0008] Therefore, there is a need for a continuously variable transmission with a simpler shifting method, a single axle, and a support ring having a substantially uniform outer surface. Additionally, there is a need for an automatic traction roller transmission that is configured to shift automatically. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission.
SUMMARY OF THE INVENTION
[0009] The present invention includes a transmission for use in rotationally or linearly powered machines and vehicles. For example the present transmission may be used in machines such as drill presses, turbines, and food processing equipment, and vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft.
[0010] In one embodiment of the invention, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is centrally located within each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, at least one platform for actuating axial movement of the support member and for actuating a shift in the axis of rotation of the power adjusters, wherein the platform provides a convex surface, at least one stationary support that is non-rotatable about the axis of rotation that is defined by the support member, wherein the at least one stationary support provides a concave surface, and a plurality of spindle supports, wherein each of the spindle supports are slidingly engaged with the convex surface of the platform and the concave surface of the stationary support, and wherein each of the spindle supports adjusts the axes of rotation of the power adjusters in response to the axial movement of the platform.
[0011] In another embodiment, the transmission comprises a rotatable driving member; three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is respectively central to the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, a rotatable driving member for rotating each of the power adjusters, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a coiled spring for biasing the rotatable driving member against the power adjusters, at least one lock pawl ratchet, wherein the lock pawl ratchet is rigidly attached to the rotatable driving member, wherein the at least one lock pawl is operably attached to the coiled spring, and at least one lock pawl for locking the lock pawl ratchet in response to the rotatable driving member becoming disengaged from the power adjusters.
[0012] In still another embodiment, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis that is respectively central to each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a screw that is coaxially and rigidly attached to the rotatable driving member or the bearing disc, and a nut that, if the screw is attached to the rotatable driving member, is coaxially and rigidly attached to the bearing disc, or if the screw is rigidly attached to the bearing disc, coaxially and rigidly attached to the rotatable driving member, wherein the inclined ramps of the bearing disc have a higher lead than the screw.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a cutaway side view of the transmission of the present invention.
[0014] FIG. 2 is a partial perspective view of the transmission of FIG. 1 .
[0015] FIG. 3 is a perspective view of two stationary supports of the transmission of FIG. 1 .
[0016] FIG. 4 is a partial end, cross-sectional view of the transmission of FIG. 1 .
[0017] FIG. 5 is a perspective view of a drive disc, bearing cage, screw, and ramp bearings of the transmission of FIG. 1 .
[0018] FIG. 6 is a perspective view of a ratchet and pawl subsystem of the transmission of FIG. 1 that is used to engage and disengage the transmission.
[0019] FIG. 7 is partial perspective view of the transmission of FIG. 1 , wherein, among other things, a rotatable drive disc has been removed.
[0020] FIG. 8 is a partial perspective view of the transmission of FIG. 1 , wherein, among other things, the hub shell has been removed.
[0021] FIG. 9 is a partial perspective view of the transmission of FIG. 1 , wherein the shifting is done automatically.
[0022] FIG. 10 is a perspective view of the shifting handlegrip that is mechanically coupled to the transmission of FIG. 1 .
[0023] FIG. 11 is an end view of a thrust bearing, of the transmission shown in FIG. 1 , which is used for automatic shifting of the transmission.
[0024] FIG. 12 is an end view of the weight design of the transmission shown in FIG. 1 .
[0025] FIG. 13 is a perspective view of an alternate embodiment of the transmission bolted to a flat surface.
[0026] FIG. 14 is a cutaway side view of the transmission shown in FIG. 13 .
[0027] FIG. 15 is a schematic end view of the transmission in FIG. 1 showing the cable routing across a spacer extension of the automatic portion of the transmission.
[0028] FIG. 16 is a schematic end view of the cable routing of the transmission shown in FIG. 13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways as defined and covered by the claims. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout. Furthermore, embodiments of the invention may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the inventions herein described.
[0030] The present invention includes a continuously variable transmission that may be employed in connection with any type of machine that is in need of a transmission. For example, the transmission may be used in (i) a motorized vehicle such as an automobile, motorcycle, or watercraft, (ii) a non-motorized vehicle such as a bicycle, tricycle, scooter, exercise equipment or (iii) industrial equipment, such as a drill press, power generating equipment, or textile mill.
[0031] Referring to FIGS. 1 and 2 , a continuously variable transmission 100 is disclosed. The transmission 100 is shrouded in a hub shell 40 covered by a hub cap 67 . At the heart of the transmission 100 are three or more power adjusters 1 a, 1 b, 1 c which are spherical in shape and are circumferentially spaced equally around the centerline or axis of rotation of the transmission 100 . As seen more clearly in FIG. 2 , spindles 3 a, 3 b, 3 c are inserted through the center of the power adjusters 1 a, 1 b, 1 c to define an axis of rotation for the power adjusters 1 a, 1 b, 1 c. In FIG. 1 , the power adjuster's axis of rotation is shown in the horizontal direction. Spindle supports 2 a - f are attached perpendicular to and at the exposed ends of the spindles 3 a, 3 b, 3 c. In one embodiment, each of the spindles supports have a bore to receive one end of one of the spindles 3 a, 3 b, 3 c. The spindles 3 a, 3 b, 3 c also have spindle rollers 4 a - f coaxially and slidingly positioned over the exposed ends of the spindles 3 a, 3 b, 3 c outside of the spindle supports 2 a - f.
[0032] As the rotational axis of the power adjusters 1 a, 1 b, 1 c is changed by tilting the spindles 3 a, 3 b, 3 c, each spindle roller 4 a - f follows in a groove 6 a - f cut into a stationary support 5 a, 5 b. Referring to FIGS. 1 and 3 , the stationary supports 5 a, 5 b are generally in the form of parallel discs with an axis of rotation along the centerline of the transmission 100 . The grooves 6 a - f extend from the outer circumference of the stationary supports 5 a, 5 b towards the centerline of the transmission 100 . While the sides of the grooves 6 a - f are substantially parallel, the bottom surface of the grooves 6 a - f forms a decreasing radius as it runs towards the centerline of the transmission 100 . As the transmission 100 is shifted to a lower or higher gear by changing the rotational axes of the power adjusters 1 a, 1 b, 1 c, each pair of spindle rollers 4 a - f, located on a single spindle 3 a, 3 b, 3 c, moves in opposite directions along their corresponding grooves 6 a - f.
[0033] Referring to FIGS. 1 and 3 , a centerline hole 7 a, 7 b in the stationary supports 5 a, 5 b allows the insertion of a hollow shaft 10 through both stationary supports 5 a, 5 b. Referring to FIG. 4 , in an embodiment of the invention, one or more of the stationary support holes 7 a, 7 b may have a non-cylindrical shape 14 , which fits over a corresponding non-cylindrical shape 15 along the hollow shaft 10 to prevent any relative rotation between the stationary supports 5 a, 5 b and the hollow shaft 10 . If the rigidity of the stationary supports 5 a, 5 b is insufficient, additional structure may be used to minimize any relative rotational movement or flexing of the stationary supports 5 a, 5 b. This type of movement by the stationary supports 5 a, 5 b may cause binding of the spindle rollers 4 a - f as they move along the grooves 6 a - f.
[0034] As shown in FIGS. 4 and 7 , the additional structure may take the form of spacers 8 a, 8 b, 8 c attached between the stationary supports 5 a, 5 b. The spacers 8 a, 8 b, 8 c add rigidity between the stationary supports 5 a, 5 b and, in one embodiment, are located near the outer circumference of the stationary supports 5 a, 5 b. In one embodiment, the stationary supports 5 a, 5 b are connected to the spacers 8 a, 8 b, 8 c by bolts or other fastener devices 45 a - f inserted through holes 46 a - f in the stationary supports 5 a, 5 b.
[0035] Referring back to FIGS. 1 and 3 , the stationary support 5 a is fixedly attached to a stationary support sleeve 42 , which coaxially encloses the hollow shaft 10 and extends through the wall of the hub shell 40 . The end of the stationary support sleeve 42 that extends through the hub shell 40 attaches to the frame support and preferentially has a non-cylindrical shape to enhance subsequent attachment of a torque lever 43 . As shown more clearly in FIG. 7 , the torque lever 43 is placed over the non-cylindrical shaped end of the stationary support sleeve 42 , and is held in place by a torque nut 44 . The torque lever 43 at its other end is rigidly attached to a strong, non-moving part, such as a frame (not shown). A stationary support bearing 48 supports the hub shell 40 and permits the hub shell 40 to rotate relative to the stationary support sleeve 42 .
[0036] Referring back to FIGS. 1 and 2 , shifting is manually activated by axially sliding a rod 11 positioned in the hollow shaft 10 . One or more pins 12 are inserted through one or more transverse holes in the rod 11 and further extend through one or more longitudinal slots 16 (not shown) in the hollow shaft 10 . The slots 16 in the hollow shaft 10 allow for axial movement of the pin 12 and rod 11 assembly in the hollow shaft 10 . As the rod 11 slides axially in the hollow shaft 10 , the ends of the transverse pins 12 extend into and couple with a coaxial sleeve 19 . The sleeve 19 is fixedly attached at each end to a substantially planar platform 13 a , 13 b forming a trough around the circumference of the sleeve 19 .
[0037] As seen more clearly in FIG. 4 , the planar platforms 13 a, 13 b each contact and push multiple wheels 21 a - f. The wheels 21 a - f fit into slots in the spindle supports 2 a - f and are held in place by wheel axles 22 a - f . The wheel axles 22 a - f are supported at their ends by the spindle supports 2 a - f and allow rotational movement of the wheels 21 a - f.
[0038] Referring back to FIGS. 1 and 2 , the substantially planar platforms 13 a, 13 b transition into a convex surface at their outer perimeter (farthest from the hollow shaft 10 ). This region allows slack to be taken up when the spindle supports 2 a - f and power adjusters 1 a, 1 b, 1 c are tilted as the transmission 100 is shifted. A cylindrical support member 18 is located in the trough formed between the planar platforms 13 a, 13 b and sleeve 19 and thus moves in concert with the planar platforms 13 a, 13 b and sleeve 19 . The support member 18 rides on contact bearings 17 a, 17 b located at the intersection of the planar platforms 13 a, 13 b and sleeve 19 to allow the support member 18 to freely rotate about the axis of the transmission 100 . Thus, the bearings 17 a, 17 b, support member 18 , and sleeve 19 all slide axially with the planar platforms 13 a, 13 b when the transmission 100 is shifted.
[0039] Now referring to FIGS. 3 and 4 , stationary support rollers 30 a - 1 are attached in pairs to each spindle leg 2 a - f through a roller pin 31 a - f and held in place by roller clips 32 a - 1 . The roller pins 31 a - f allow the stationary support rollers 30 a - 1 to rotate freely about the roller pins 31 a - f. The stationary support rollers 30 a - 1 roll on a concave radius in the stationary support 5 a, 5 b along a substantially parallel path with the grooves 6 a - f. As the spindle rollers 4 a - f move back and forth inside the grooves 6 a - f, the stationary support rollers 30 a - 1 do not allow the ends of the spindles 3 a, 3 b, 3 c nor the spindle rollers 4 a - f to contact the bottom surface of the grooves 6 a - f, to maintain the position of the spindles 3 a, 3 b, 3 c, and to minimize any frictional losses.
[0040] FIG. 4 shows the stationary support rollers 30 a - 1 , the roller pins, 31 a - f, and roller clips 32 a - 1 , as seen through the stationary support 5 a, for ease of viewing. For clarity, i.e., too many numbers in FIG. 1 , the stationary support rollers 30 a - 1 , the roller pins, 31 a - f, and roller clips 32 a - 1 , are not numbered in FIG. 1 .
[0041] Referring to FIGS. 1 and 5 , a concave drive disc 34 , located adjacent to the stationary support 5 b, partially encapsulates but does not contact the stationary support 5 b. The drive disc 34 is rigidly attached through its center to a screw 35 . The screw 35 is coaxial to and forms a sleeve around the hollow shaft 10 adjacent to the stationary support 5 b and faces a driving member 69 . The drive disc 34 is rotatively coupled to the power adjusters 1 a, 1 b, 1 c along a circumferential bearing surface on the lip of the drive disc 34 . A nut 37 is threaded over the screw 35 and is rigidly attached around its circumference to a bearing disc 60 . One face of the nut 37 is further attached to the driving member 69 . Also rigidly attached to the bearing disc 60 surface are a plurality of ramps 61 which face the drive disc 34 . For each ramp 61 there is one ramp bearing 62 held in position by a bearing cage 63 . The ramp bearings 62 contact both the ramps 61 and the drive disc 34 . A spring 65 is attached at one end to the bearing cage 63 and at its other end to the drive disc 34 , or the bearing disc 60 in an alternate embodiment, to bias the ramp bearings 62 up the ramps 61 . The bearing disc 60 , on the side opposite the ramps 61 and at approximately the same circumference contacts a hub cap bearing 66 . The hub cap bearing 66 contacts both the hub cap 67 and the bearing disc 60 to allow their relative motion. The hub cap 67 is threaded or pressed into the hub shell 40 and secured with an internal ring 68 . A sprocket or pulley 38 is rigidly attached to the rotating driving member 69 and is held in place externally by a cone bearing 70 secured by a cone nut 71 and internally by a driver bearing 72 which contacts both the driving member 69 and the hub cap 67 .
[0042] In operation, an input rotation from the sprocket or pulley 38 , which is fixedly attached to the driver 69 , rotates the bearing disc 60 and the plurality of ramps 61 causing the ramp bearings 62 to roll up the ramps 61 and press the drive disc 34 against the power adjusters 1 a, 1 b, 1 c. Simultaneously, the nut 37 , which has a smaller lead than the ramps 61 , rotates to cause the screw 35 and nut 37 to bind. This feature imparts rotation of the drive disc 34 against the power adjusters 1 a, 1 b, 1 c. The power adjusters 1 a, 1 b, 1 c, when rotating, contact and rotate the hub shell 40 .
[0043] When the transmission 100 is coasting, the sprocket or pulley 38 stops rotating but the hub shell 40 and the power adjusters 1 a, 1 b, 1 c, continue to rotate. This causes the drive disc 34 to rotate so that the screw 35 winds into the nut 37 until the drive disc 34 no longer contacts the power adjusters 1 a, 1 b, 1 c.
[0044] Referring to FIGS. 1, 6 , and 7 , a coiled spring 80 , coaxial with the transmission 100 , is located between and attached by pins or other fasteners (not shown) to both the bearing disc 60 and drive disc 34 at the ends of the coiled spring 80 . During operation of the transmission 100 , the coiled spring 80 ensures contact between the power adjusters 1 a, 1 b, 1 c and the drive disc 34 . A pawl carrier 83 fits in the coiled spring 80 with its middle coil attached to the pawl carrier 83 by a pin or standard fastener (not shown). Because the pawl carrier 83 is attached to the middle coil of the coiled spring 80 , it rotates at half the speed of the drive disc 34 when the bearing disc 60 is not rotating. This allows one or more lock pawls 81 a , 81 b , 81 c , which are attached to the pawl carrier 83 by one or more pins 84 a, 84 b, 84 c, to engage a drive disc ratchet 82 , which is coaxial with and rigidly attached to the drive disc 34 . The one or more lock pawls 84 a, 84 b, 84 c are preferably spaced asymmetrically around the drive disc ratchet 82 . Once engaged, the loaded coiled spring 80 is prevented from forcing the drive disc 34 against the power adjusters 1 a, 1 b, 1 c. Thus, with the drive disc 34 not making contact against the power adjusters 1 a, 1 b, 1 c, the transmission 100 is in neutral and the ease of shifting is increased. The transmission 100 can also be shifted while in operation.
[0045] When operation of the transmission 100 is resumed by turning the sprocket or pulley 38 , one or more release pawls 85 a, 85 b, 85 c, each attached to one of the lock pawls 81 a, 81 b, 81 c by a pawl pin 88 a, 88 b, 88 c, make contact with an opposing bearing disc ratchet 87 . The bearing disc ratchet 87 is coaxial with and rigidly attached to the bearing disc 60 . The bearing disc ratchet 87 actuates the release pawls 85 a, 85 b, 85 c because the release pawls 85 a, 85 b, 85 c are connected to the pawl carrier 83 via the lock pawls 81 a, 81 b, 81 c. In operation, the release pawls 85 a, 85 b, 85 c rotate at half the speed of the bearing disc 60 , since the drive disc 34 is not rotating, and disengage the lock pawls 81 a, 81 b, 81 c from the drive disc ratchet 82 allowing the coiled spring 80 to wind the drive disc 34 against the power adjusters 1 a, 1 b, 1 c. One or more pawl tensioners (not shown), one for each release pawl 85 a, 85 b, 85 c, ensures that the lock pawls 81 a, 81 b, 81 c are pressed against the drive disc ratchet 82 and that the release pawls 85 a, 85 b, 85 c are pressed against the bearing disc ratchet 87 . The pawl tensioners are attached at one end to the pawl carrier 83 and make contact at the other end to the release pawls 85 a, 85 b, 85 c. An assembly hole 93 (not shown) through the hub cap 67 , the bearing disc 60 , and the drive disc 34 , allows an assembly pin (not shown) to be inserted into the loaded coiled spring 80 during assembly of the transmission 100 . The assembly pin prevents the coiled spring 80 from losing its tension and is removed after transmission 100 assembly is complete.
[0046] Referring to FIGS. 1, 11 , 12 , and 15 , automatic shifting of the transmission 100 , is accomplished by means of spindle cables 602 , 604 , 606 which are attached at one end to a non-moving component of the transmission 100 , such as the hollow shaft 10 or the stationary support 5 a. The spindle cables 602 , 604 , 606 then travel around spindle pulleys 630 , 632 , 634 , which are coaxially positioned over the spindles 3 a, 3 b, 3 c. The spindle cables 602 , 604 , 606 further travel around spacer pulleys 636 , 638 , 640 , 644 , 646 , 648 which are attached to a spacer extension 642 which may be rigidly attached to the spacers 8 a, 8 b, 8 c. As more clearly shown in FIGS. 11 and 12 , the other ends of the spindle cables 602 , 604 , 606 are attached to a plurality of holes 620 , 622 , 624 in a non-rotating annular bearing race 816 . A plurality of weight cables 532 , 534 , 536 are attached at one end to a plurality of holes 610 , 612 , 614 in a rotating annular bearing race 806 . An annular bearing 808 , positioned between the rotating annular bearing race 806 and the non-rotating annular bearing race 816 , allows their relative movement.
[0047] Referring to FIG. 15 , the transmission 100 is shown with the cable routing for automatic shifting.
[0048] As shown in FIGS. 1, 9 , 11 , and 12 , the weight cables 532 , 534 , 536 then travel around the hub shell pulleys 654 , 656 , 658 , through holes in the hub shell 40 , and into hollow spokes 504 , 506 , 508 (best seen in FIG. 12 ) where they attach to weights 526 , 528 , 530 . The weights 526 , 528 , 530 are attached to and receive support from weight assisters 516 , 518 , 520 which attach to a wheel 514 or other rotating object at there opposite end. As the wheel 514 increases its speed of rotation, the weights 526 , 528 , 530 are pulled radially away from the hub shell 40 , pulling the rotating annular bearing race 806 and the non-rotating annular bearing race 816 axially toward the hub cap 67 . The non-rotating annular bearing race 816 pulls the spindle cables 602 , 604 , 606 , which pulls the spindle pulleys 630 , 632 , 634 closer to the hollow shaft 10 and results in the shifting of the transmission 100 into a higher gear. When rotation of the wheel 514 slows, one or more tension members 9 positioned inside the hollow shaft 10 and held in place by a shaft cap 92 , push the spindle pulleys 630 , 632 , 634 farther from the hollow shaft 10 and results in the shifting of the transmission 100 into a lower gear.
[0049] Alternatively, or in conjunction with the tension member 9 , multiple tension members (not shown) may be attached to the spindles 3 a, 3 b, 3 c opposite the spindle pulleys 630 , 632 , 634 .
[0050] Still referring to FIG. 1 , the transmission 100 can also be manually shifted to override the automatic shifting mechanism or to use in place of the automatic shifting mechanism. A rotatable shifter 50 has internal threads that thread onto external threads of a shifter screw 52 which is attached over the hollow shaft 10 . The shifter 50 has a cap 53 with a hole that fits over the rod 11 that is inserted into the hollow shaft 10 . The rod 11 is threaded where it protrudes from the hollow shaft 10 so that nuts 54 , 55 may be threaded onto the rod 11 . The nuts 54 , 55 are positioned on both sides of the cap 53 . A shifter lever 56 is rigidly attached to the shifter 50 and provides a moment arm for the rod 11 . The shifter cable 51 is attached to the shifter lever 56 through lever slots 57 a, 57 b, 57 c. The multiple lever slots 57 a, 57 b, 57 c provide for variations in speed and ease of shifting.
[0051] Now referring to FIGS. 1 and 10 , the shifter cable 51 is routed to and coaxially wraps around a handlegrip 300 . When the handlegrip 300 is rotated in a first direction, the shifter 50 winds or unwinds axially over the hollow shaft 10 and pushes or pulls the rod 11 into or out of the hollow shaft 10 . When the handlegrip 300 is rotated in a second direction, a shifter spring 58 , coaxially positioned over the shifter 50 , returns the shifter 50 to its original position. The ends of the shifter spring 58 are attached to the shifter 50 and to a non-moving component, such as a frame (not shown).
[0052] As seen more clearly in FIG. 10 , the handlegrip 300 is positioned over a handlebar (not shown) or other rigid component. The handlegrip 300 includes a rotating grip 302 , which consists of a cable attachment 304 that provides for attachment of the shifter cable 51 and a groove 306 that allows the shifter cable 51 to wrap around the rotating grip 302 . A flange 308 is also provided to preclude a user from interfering with the routing of the shifter cable 51 . Grip ratchet teeth 310 are located on the rotating grip 302 at its interface with a rotating clamp 314 . The grip ratchet teeth 310 lock onto an opposing set of clamp ratchet teeth 312 when the rotating grip 302 is rotated in a first direction. The clamp ratchet teeth 312 form a ring and are attached to the rotating clamp 314 which rotates with the rotating grip 302 when the grip ratchet teeth 310 and the clamp ratchet teeth 312 are locked. The force required to rotate the rotating clamp 314 can be adjusted with a set screw 316 or other fastener. When the rotating grip 302 , is rotated in a second direction, the grip ratchet teeth 310 , and the clamp ratchet teeth 312 disengage. Referring back to FIG. 1 , the tension of the shifter spring 58 increases when the rotating grip 302 is rotated in the second direction. A non-rotating clamp 318 and a non-rotating grip 320 prevent excessive axial movement of the handlegrip 300 assembly.
[0053] Referring to FIGS. 13 and 14 , another embodiment of the transmission 900 , is disclosed. For purposes of simplicity, only the differences between the transmission 100 and the transmission 900 are discussed.
[0054] Replacing the rotating hub shell 40 are a stationary case 901 and housing 902 , which are joined with one or more set screws 903 , 904 , 905 . The set screws 903 , 904 , 905 may be removed to allow access for repairs to the transmission 900 . Both the case 901 and housing 902 have coplanar flanges 906 , 907 with a plurality of bolt holes 908 , 910 , 912 , 914 for insertion of a plurality of bolts 918 , 920 , 922 , 924 to fixedly mount the transmission 900 to a non-moving component, such as a frame (not shown).
[0055] The spacer extension 930 is compressed between the stationary case 901 and housing 902 with the set screws 903 , 904 , 905 and extend towards and are rigidly attached to the spacers 8 a, 8 b, 8 c. The spacer extension 930 prevents rotation of the stationary supports 5 a, 5 b. The stationary support 5 a does not have the stationary support sleeve 42 as in the transmission 100 . The stationary supports 5 a, 5 b hold the hollow shaft 10 in a fixed position. The hollow shaft 10 terminates at one end at the stationary support 5 a and at its other end at the screw 35 . An output drive disc 942 is added and is supported against the case 901 by a case bearing 944 . The output drive disc 942 is attached to an output drive component, such as a drive shaft, gear, sprocket, or pulley (not shown). Similarly, the driving member 69 is attached to the input drive component, such as a motor, gear, sprocket, or pulley.
[0056] Referring to FIG. 16 , shifting of the transmission 900 is accomplished with a single cable 946 that wraps around each of the spindle pulleys 630 , 632 , 634 . At one end, the single cable 946 is attached to a non-moving component of the transmission 900 , such as the hollow shaft 10 or the stationary support 5 a. After traveling around each of the spindle pulleys 630 , 632 , 634 and the spacer pulleys 636 , 644 , the single cable 946 exits the transmission 900 through a hole in the housing 902 . Alternatively a rod (not shown) attached to one or more of the spindles 3 a, 3 b, 3 c, may be used to shift the transmission 900 in place of the single cable 946 .
[0057] The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof. | A continuously variable transmission is disclosed for use in rotationally or linearly powered machines and vehicles. The single axle transmission provides a simple manual shifting method for the user. An additional embodiment is disclosed which shifts automatically dependent upon the rotational speed of the wheel. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission. The disclosed transmission may be used in vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft. | 1 |
[0001] This application claims benefit under 35 U.S.C §119(e) of provisional application No. 60/591,104, filed on Jul. 27, 2004 and provisional application No. 60/634,102 filed on Dec. 8, 2004, the contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to wireless communication systems and more particularly to long training sequences of minimum peak-to-average power ratio which may be used by legacy systems.
[0004] 2. Description of the Related Art
[0005] Each wireless communication device participating in wireless communications includes a built-in radio transceiver (i.e., receiver and transmitter) or is coupled to an associated radio transceiver. As is known to those skilled in the art, the transmitter typically includes a data modulation stage, one or more intermediate frequency stages, and a power amplifier. The data modulation stage converts raw data into baseband signals in accordance with a particular wireless communication standard. The intermediate frequency stages mix the baseband signals with one or more local oscillations to produce RF signals. The power amplifier amplifies the RF signals prior to transmission via an antenna.
[0006] The receiver is typically coupled to the antenna and includes a low noise amplifier, one or more intermediate frequency stages, a filtering stage, and a data recovery stage. The low noise amplifier receives, via the antenna, inbound RF signals and amplifies the inbound RF signals. The intermediate frequency stages mix the amplified RF signals with one or more local oscillations to convert the amplified RF signal into baseband signals or intermediate frequency (IF) signals. The filtering stage filters the baseband signals or the IF signals to attenuate unwanted out of band signals to produce filtered signals. The data recovery stage recovers raw data from the filtered signals in accordance with a particular wireless communication standard.
[0007] Different wireless devices in a wireless communication system may be compliant with different standards or different variations of the same standard. For example, 802.11a an extension of the 802.11 standard, provides up to 54 Mbps in the 5 GHz band. 802.11b, another extension of the 802.11 standard, provides 11 Mbps transmission (with a fallback to 5.5, 2 and 1 Mbps) in the 2.4 GHz band. 802.11g, another extension of the 802.11 standard, provides 20+ Mbps in the 2.4 GHz band. 802.11n, a new extension of 802.11, is being developed to address, among other thins, higher throughput and compatibility issues. An 802.11a compliant communications device may reside in the same WLAN as a device that is compliant with another 802.11 standard. When devices that are compliant with multiple versions of the 802.11 standard are in the same WLAN, the devices that are compliant with older versions are considered to be legacy devices. To ensure backward compatibility with legacy devices, specific mechanisms must be employed to insure that the legacy devices know when a device that is compliant with a newer version of the standard is using a wireless channel to avoid a collision. New implementations of wireless communication protocol enable higher speed throughput, while also enabling legacy devices which might be only compliant with 802.11a or 802.11g to communicate in systems which are operating at higher speeds.
[0008] Devices implementing both the 802.11a and 802.11g standards use an orthogonal frequency division multiplexing (OFDM) encoding scheme. OFDM is a frequency division multiplexing modulation technique for transmitting large amounts of digital data over a radio wave. OFDM works by spreading a single data stream over a band of sub-carriers, each of which is transmitted in parallel. In 802.11a and 802.11g compliant devices, only 52 of the 64 active sub-carriers are used. Four of the active sub-carriers are pilot sub-carriers that the system uses as a reference to disregard frequency or phase shifts of the signal during transmission. The remaining 48 sub-carriers provide separate wireless pathways for sending information in a parallel fashion. The 52 sub-carriers are modulated using binary or quadrature phase shift keying (BPSK/QPSK), 16 Quadrature Amplitude Modulation (QAM), or 64 QAM. Therefore, 802.11a and 802.11g compliant devices use sub-carriers − 26 to + 26 , with the 0-index sub-carrier set to 0 and 0-index sub-carrier being the carrier frequency. As such, only part of the 20 Mhz bandwidth supported by 802.11a and 802.11g is use.
[0009] In 802.11a/802.11g, each data packet starts with a preamble which includes a short training sequence followed by a long training sequence. The short and long training sequences are used for synchronization between the sender and the receiver. The long training sequence of 802.11a and 802.11g is defined such that each of sub-carriers − 26 to + 26 has one BPSK consellation point, either +1 or −1.
[0010] There exists a need to create a long training sequence of minimum peak-to-average ratio that uses more sub-carriers without interfering with adjacent channels. The inventive long trains sequence with a minimum peak-to-average power ratio should be usable by legacy devices in order to estimate channel impulse response and to estimate carrier frequency offset between a transmitter and a receiver.
SUMMARY OF THE INVENTION
[0011] According to one aspect of the invention, there is provided a network device for generating an expanded long training sequence with a minimal peak-to-average ratio. The network device includes a signal generating circuit for generating the expanded long training sequence. The network device also includes an Inverse Fourier Transform for processing the expanded long training sequence from the signal generating circuit and producing an optimal expanded long training sequence with a minimal peak-to-average ratio. The expanded long training sequence and the optimal expanded long training sequence are stored on more than 52 sub-carriers.
[0012] According to another aspect of the invention, there is provided a network device for generating an expanded long training sequence with a minimal peak-to-average ratio. The network device includes a signal generating circuit for generating the expanded long training sequence. The network device also includes an Inverse Fourier Transform for processing the expanded long training sequence from the signal generating circuit and producing an optimal expanded long training sequence with a minimal peak-to-average ratio. The expanded long training sequence and the optimal expanded long training sequence are stored on more than 56 sub-carriers.
[0013] According to another aspect of the invention, there is provided a a net-work device for generating an expanded long training sequence with a minimal peak-to-average ratio. The network device includes a signal generating circuit for generating the expanded long training sequence. The network device also includes an Inverse Fourier Transform for processing the expanded long training sequence from the signal generating circuit and producing an optimal expanded long training sequence with a minimal peak-to-average ratio. The expanded long training sequence and the optimal expanded long training sequence are stored on more than 63 sub-carriers.
[0014] According to another aspect of the invention, there is provided a method for generating an expanded long training sequence with a minimal peak-to-average ratio. The method includes the steps of generating the expanded long training sequence and producing an optimal expanded long training sequence with a minimal peak-to-average ratio. The method also includes the step of storing the expanded long training sequence and the optimal expanded long training sequence on more than 52 sub-carriers
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention that together with the description serve to explain the principles of the invention, wherein:
[0016] FIG. 1 illustrates a communication system that includes a plurality of base stations, a plurality of wireless communication devices and a network hardware component;
[0017] FIG. 2 illustrates a schematic block diagram of a processor that is configured to generate an expanded long training sequence;
[0018] FIG. 3 is a schematic block diagram of a processor that is configured to process an expanded long training sequence;
[0019] FIG. 4 illustrates the long training sequence that is used in 56 active sub-carriers; and
[0020] FIG. 5 illustrates the long training sequence that is used in 63 active sub-carriers.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Reference will now be made to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0022] FIG. 1 illustrates a communication system 10 that includes a plurality of base stations and/or access points 12 - 16 , a plurality of wireless communication devices 18 - 32 and a network hardware component 34 . Wireless communication devices 18 - 32 may be laptop computers 18 and 26 , personal digital assistant hosts 20 and 30 , personal computer 24 and 32 and/or cellular telephone 22 and 28 . Base stations or access points 12 - 16 are operably coupled to network hardware 34 via local area network connections 36 , 38 and 40 . Network hardware 34 , for example a router, a switch, a bridge, a modem, or a system controller, provides a wide area network connection for communication system 10 . Each of base stations or access points 12 - 16 has an associated antenna or antenna array to communicate with the wireless communication devices in its area. Typically, the wireless communication devices register with a particular base station or access point 12 - 14 to receive services from communication system 10 . Each wireless communication device includes a built-in radio or is coupled to an associated radio. The radio includes at least one radio frequency (RF) transmitter and at least one RF receiver.
[0023] The present invention provides an expanded long training sequence of minimum peak-to-average power ratio and thereby decreases power back-off. The inventive expanded long training sequence may be used by 802.11a or 802.11g devices for estimating the channel impulse response and by a receiver for estimating the carrier frequency offset between the transmitter clock and receiver clock. The inventive expanded long training sequence is usable by 802.11a or 802.11g systems only if the values at sub-carriers − 26 to + 26 are identical to those of the current long training sequence used in 802.11a and 802.11g systems. As such, the invention utilized the same +1 or −1 binary phase shift key (BPSK) encoding for each new sub-carrier and the long training sequence of 802.11a or 802.11g systems is maintained in the present invention.
[0024] In a first embodiment of the invention, the expanded long training sequence is implemented in 56 active sub-carriers including sub-carriers − 28 to + 28 . In another embodiment, an expanded long training sequence is implemented using 63 active sub-carriers, i.e., all of the active sub-carriers (− 32 to + 31 ) except the 0-index sub-carrier which is set to 0. In both embodiments of the invention, orthogonality is not affected, since a 64-point orthogonal transform is used to generate the time-domain sequence. Additionally, the output of an autocorrelator for computing the carrier frequency offset is not affected by the extra sub-carriers.
[0025] FIG. 2 illustrates a schematic block diagram of a processor that is configured to generate an expanded long training sequence. Processor 200 includes a symbol mapper 202 , a frequency domain window 204 , a signal generating circuit 205 , an inverse fast Fourier transform (IFFT) module 206 , a serial to parallel module 208 , a digital transmit filter and/or time domain window module 210 , and digital to analog converters (D/A) 212 . For an expanded long training sequence, symbol mapper 202 generates symbols from the coded bits for each of the 64 subcarriers of an OFDM sequence. Frequency domain window 204 applies a weighting factor on each subcarrier. Signal generating circuit 205 generates the expanded long training sequence and if 56 active sub-carriers are being used, signal generating circuit generates the expanded long training sequence and stores the expanded long training sequence in sub-carriers − 28 to + 28 . If 63 active sub-carriers are being used, signal generating circuit generates the expanded long training sequence and stores the expanded long training sequence in sub-carriers − 32 to + 32 i.e., all of the active sub-carriers (− 32 to + 31 ) except the 0-index sub-carrier which is set to 0. The inventive long training sequence is inputted into an Inverse Fourier Transform 206 . The invention uses the same +1 or −1 BPSK encoding for each new sub-carrier. Inverse Fourier Transform 206 may be an inverse Fast Fourier Transform (IFFT) or Inverse Discrete Fourier Transform (IFDT). Inverse Fourier Transform 206 processes the long training sequence from signal generating circuit 205 and thereafter produces an optimal expanded long training sequence with a minimal peak-to-average power ratio. The optimal expanded long training sequence may be used in either 56 active sub-carriers or 63 active subscribers. Serial to parallel module 208 converts the serial time domain signals into parallel time domain signals that are subsequently filtered and converted to analog signals via the D/A.
[0026] FIG. 3 is a schematic block diagram of a processor that is configured to process an expanded long training sequence. Processor 300 includes a symbol demapper 302 , a frequency domain window 304 , a fast Fourier transform (FFT) module 306 , a parallel to serial module 308 , a digital receiver filter and/or time domain window module 310 , and analog to digital converters (A/D) 312 . A/D converters 312 convert the sequence into digital signals that are filtered via digital receiver filter 310 . Parallel to serial module 308 converts the digital time domain signals into a plurality of serial time domain signals. FFT module 306 converts the serial time domain signals into frequency domain signals. Frequency domain window 304 applies a weighting factor on each frequency domain signal. Symbol demapper 302 generates the coded bits from each of the 64 subcarriers of an OFDM sequence received from the frequency domain window.
[0027] FIG. 4 illustrates the long training sequence with a minimum peak-to-average power ratio that is used in 56 active sub-carriers. Out of the 16 possibilities for the four new sub-carrier positions, the sequence illustrated in FIG. 4 has the minimum peak-to-average power ratio, i.e., a peak-to-average power ratio of 3.6 dB.
[0028] FIG. 5 illustrates the long training sequence with a minimum peak-to-average power ratio that is used in 63 active sub-carriers. Out of the 2048 possibilities for the eleven new sub-carrier positions, the sequence illustrated in FIG. 5 has the minimum peak-to-average power ratio, i.e., a peak-to-average power ratio of 3.6 dB.
[0029] It should be appreciated by one skilled in art, that the present invention may be utilized in any device that implements the OFDM encoding scheme. The foregoing description has been directed to specific embodiments of this invention. It will be apparent, however, that other variations and modifications may be made to the described embodiments, with the attainment of some or all of their advantages. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention. | A network device for generating an expanded long training sequence with a minimal peak-to-average ratio. The network device includes a signal generating circuit for generating the expanded long training sequence. The network device also includes an Inverse Fourier Transform for processing the expanded long training sequence from the signal generating circuit and producing an optimal expanded long training sequence with a minimal peak-to-average ratio. The expanded long training sequence and the optimal expanded long training sequence are stored on more than 52 sub-carriers. | 7 |
TECHNICAL FIELD
This invention relates to automotive vehicle doors reinforced with an anti-intrusion beam or panel.
BACKGROUND OF THE INVENTION
Current automotive-type vehicle doors generally comprise an assembly of parts including an inner panel, an outer panel, a door intrusion beam and an assortment of brackets and reinforcements which make up the structure of the door, window glass and associated lift mechanism, mountings and fasteners to facilitate manufacture and assembly, and mounting hinges, a latch, and a door handle for opening and closing the door. The intrusion beam may comprise a sub-assembly of a tube and/or one or more stamped steel components. However, a reinforcing panel supporting a lower portion of the outer panel has also been proposed.
SUMMARY OF THE INVENTION
The present invention provides an improved reinforced vehicle door assembly or structure. This structure includes a novel reinforcement panel which supports a major portion of the outer panel surface below the window sill, providing intrusion protection over this lower panel area. The reinforcement panel includes front and rear sidewalls overlapping and assembled with front and rear edge portions of the inner panel to provide stiffening of these hinge mounting and latch containing side portions.
Preferably, the reinforcement panel includes a number of longitudinal flutes with intermediate peripheral surfaces that are bonded to the outer panel and/or to an optional support panel to form hollow load-bearing sections. For light weight, the door panels are preferably made of alloys of aluminum although alloys of other materials, such as steel and magnesium, and metal matrix composites and various polymer materials, including reinforced polymer composites, may be used if desired. In a preferred embodiment, the reinforcement panel is made by superplastic forming from a suitable aluminum alloy or other superplastically formable material capable of providing the complex shapes required for the selected panel configuration. Other suitable means of forming the reinforcement panel may be used if desired.
In general, the present invention can consolidate the functions of many of the pieces that make up a conventional intrusion beam sub-assembly plus that of other associated parts and replace them with a single reinforcement panel. The panel preferably has a large longitudinally-extending peripheral surface with several flutes extending the entire length or a pan of the length. Preferably, at least portions of the peripheral surface conform to contiguous portions of the contour of the door outer panel. Reinforcement panel thickness, material strength and cross-section of the flutes can be tailored to match the impact energy that must be absorbed in a lateral impact to the vehicle. Optionally, vertical or other flute arrangements or other patterns may be provided if desired.
In addition, this one-piece panel will include, if desired, laterally extending vertical side walls which can also be designed with flutes, if necessary, to impart section stiffness and/or strength to the reinforcement panel. The panel can also be designed to include laterally extending horizontal walls at the top and/or bottom, each with or without flutes. Thus, the reinforcement panel can be made in the shape of a one-piece tray with flutes of the desired shape, size and pattern or layout on the large peripheral portion of the tray as well as along its walls, if preferred.
The reinforcement panel can be placed and fastened inside a door inner panel of conventional or other design, as is the intrusion beam assembly in a current door. This can be done in such a manner that the longitudinal flutes in the reinforcement panel are essentially parallel to the large flat section of the inner panel and the lateral vertical walls in the reinforcement panel mate very closely with the laterally extending vertical side portions of the door inner panel. If the reinforcement panel has upper and/or lower walls, then these are preferably designed to mate with and be joined to their counterparts on the inner panel. Thus, the two panels will form a very effective closed box-section structure of required strength and stiffness.
This new two-piece sub-assembly is then joined with the door outer panel such that the peripheral surface(s) of the reinforcement panel abuts contiguous portions of the outer panel. Preferably, the peaks on the flutes which abut the outer panel are bonded adhesively or in some other suitable way to the inside surface of the outer panel. Thus, the outer panel forms with the reinforcement panel a series of closed-section beams to increase the strength and stiffness of the door assembly as well as serve to stabilize the reinforcement panel. Alternatively (or in addition), rather than bond to the outer panel, a similar series of closed-section strengthening and stiffening beams can be formed by bonding adhesively or otherwise the inwardly protruding portions or valleys of the flutes on the reinforcement panel to an optional support panel which may be made to conform to the inside shape of the reinforcement panel.
The reinforcement panel of this invention may be too complex to be made in one piece by conventional stamping, roll-forming or extrusion processes with either steel or aluminum. In such cases, a different process is suggested for fabricating the reinforcement panel. This is the known process of superplastic forming.
When certain alloy compositions of steel or aluminum are suitably processed (such as with a very fine grain microstructure), they exhibit superplastic behavior at certain elevated temperatures. When deformed at these temperatures, the ductility (or elongation before yield or failure) of these materials exceeds several hundred percent. Such high levels of ductility can enable fabrication of very complex structures in a single sheet of material. A reinforcement panel of the design discussed above can be fabricated in one piece using such techniques. Such panel then can cooperate structurally with an adjacent conforming panel to form a strong but light weight door.
In addition to various steels and aluminum alloys, other structural materials such as zinc, brass, magnesium, titanium and their alloys have also been reported to exhibit superplastic behavior. Furthermore, certain polymers and reinforced polymer composites have the required ductility to make this panel. These materials and other metal matrix composites could also be used to make the reinforcement panel of this invention, if desired.
In a test of this invention, a steel tool was built having an internal die cavity shaped to the desired contour of the reinforcement panel. Aluminum alloy 5083, which exhibits superplastic behavior at around 510° C., was selected for making the panel. The tool was heated and maintained at the desired temperature. A sheet of 5083 aluminum of the proper size was placed in the tool, and air or nitrogen gas at a maximum pressure of 300 psi was applied to deform the sheet into the female cavity. After about 30 minutes, the flat sheet of aluminum was found to have stretched fully into the tool cavity, accurately replicating the contours of the die surface and thus producing the reinforcement panel of the desired shape.
This one-piece reinforcement panel was used instead of the ten pieces it replaced to build a door according to the invention. All other pieces used to build this door were of existing conventional design. The door was subjected to standard door tests, which it successfully passed. In addition, the reinforcement panel provided effective intrusion protection over the entire lower surface of the door.
These and other features and advantages of the invention will be more fully understood from the following description of a specific embodiment of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 it a pictorial view, partially in phantom, illustrating the assembly of a reinforced vehicle door according to the invention;
FIG. 2 is a vertical cross-sectional view through the door assembly of FIG. 1;
FIG. 3 is an exploded pictorial view illustrating the major components of the door assembly of FIGS. 1 and 2; and
FIG. 4 is a view similar to FIG. 2 showing an alternative embodiment of reinforced door according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, numeral 10 generally indicates a vehicle door formed according to the invention to be stiffened or reinforced against impact on its outer surface while requiring fewer parts and less complicated assembly. Door 10 includes an outer panel 12, a reinforcement panel 14, an inner panel 16 and an inner cover 18 as well as a hinge plate 20 joined together into an assembly. In the cross-sectional view of FIG. 2, the window glass 22 is also shown. Not shown in the drawings are the hinges, door latch, door handle and window lift mechanism which would need to be added to provide an operational door. However, these non-illustrated elements do not form part of the present invention and are omitted for clarity.
The outer panel 12, formed of a single sheet of material, has a generally smooth exterior, slightly contoured in accordance with the exterior styling of the associated vehicle. It includes an upper edge 24 forming in part an outer window sill, a bottom edge 26, and front and rear edges 28, 30, each including material for assembly with the inner panel.
The inner panel 16 includes vertically and laterally extending front and rear side portions 32, 34, respectively, longitudinally connected by a bottom portion 36. A window sill support member 38 interconnects the upper ends of the front and rear side portions. Outer edges of the front and rear side portions and the bottom portion are adapted for connection with the corresponding parts of the outer panel 12. In addition, the bottom portion includes structural support members for the window lift mechanism, not shown. Panel 16 is suitably stamped and trimmed from a single sheet of material.
The inner cover 18 is adapted to attach to the inner panel to cover the open center where the window lift mechanism and door latch mechanisms are located. Cover 18 is removable in order to allow access to these mechanisms for service.
The reinforcement panel 14, like the outer panel, is formed from a single sheet. However, its configuration in the illustrated embodiment is considerably more complex such that it is preferably manufactured by a known, but relatively new, method called superplastic sheet forming. This method requires the use of materials which have superplastic forming qualities including very high ductility at forming temperature which may be around 500° C. for aluminum and 100020 C. for stainless steel. Such superplastically formable alloys usually have to be processed to have very fine grained metallurgical microstructures which provide such increased ductility. Thus, a sheet of such material can be formed into a complex shape without tearing or other failure.
The reinforcement panel 14 is configured with an outer periphery 40 that as shown comprises a plurality of longitudinal surfaces (all 40) which approximate or conform to the shape of the inner side of the outer panel 12. This outer periphery 40 (with its plurality of surfaces) extends from near the bottom edge 26 of the outer panel to adjacent to the upper window sill edge 24 and longitudinally along the length of the outer panel over the distance between the front and rear side portions 32, 34 of the inner panel. The outer periphery of the reinforcement panel is provided with (or interrupted with) a plurality of, in this case seven, longitudinally extending flutes 42. These are, optionally, each about three centimeters wide, have a bell-shaped cross section and extend the full length of the reinforcement panel, except for one which stops short of an opening 44 for the door handle.
At the front and rear edges of the reinforcement panel are vertical inwardly extending front and rear side walls 46, 48, respectively. These side walls extend within and are fixed such as by welding to the corresponding front and rear side portions 32, 34, respectively, of the inner panel. Four laterally extending flutes 50 are provided in the front side wall for stiffening its structure, and two laterally extending flutes 52 are provided in the rear side wall for the same purpose.
The hinge plate 20 is fixed to the inner side of the front side wall 46 and contains openings 54 for receiving hinge connection fasteners as well as a central opening 56 aligned with corresponding openings in the front side wall 46 and front edge 28 of the reinforcement panel and inner panel, respectively, for the passage of necessary wiring. The front and rear side walls 46, 48 of the reinforcement panel add to the structural stiffness of the front and rear door outer panel side portions 32, 34 and provide a stiff box-like support for the reinforcement panel outer portion. If, as shown, the reinforcement panel is not provided with an optional lower wall, lateral strips 58 may be added for assisting in assembly of the panel to the bottom portion of the inner panel.
Preferably, in assembly, portions of the outer periphery 40 of the reinforcement panel between the flutes 42 are positioned in abutting relation to contiguous portions of the outer panel and are preferably fixed thereto, such as by bonding. In similar manner, the peripheral edges of the outer panel may also be bonded to the reinforcement panel. The bonded portions of the outer panel and reinforcement panel join with the flutes to form load-bearing box sections, i.e., or hollow load-bearing sections, which add to the stiffness of the outer panel-reinforcement panel assembly and improve the strength of the door assembly against intrusion.
FIG. 4 shows an alternative embodiment of door 10' containing a separate support panel 60. Panel 60 conforms to the inside of the reinforcement panel 14 and is preferably bonded to the adjacent surfaces of the valleys (or inner portions) of the flutes 42 to form stiffness- and strength-enhancing closed box sections. The arrangement is particularly desirable where bonding between the outer panel and the reinforcement panel is not desired as the box section structure is provided by assembly of the support and reinforcement panels.
For weight reduction, it is presently preferred that the reinforcement panel, as well as the inner and outer panels, be made from a suitable aluminum alloy material. However, other materials may also be used within the scope of the present invention. For example, polymer materials, fiber-polymer composites, and metals such as steel may be utilized in any of the panels if desired. The inner cover is sometimes formed from a plastic or plastic/fiber composite material suitable for vehicle interior use.
Thus, the subject invention provides a tough, durable, impact-resistant vehicle door structure from a minimal number of structurally cooperating formed sheet members. Furthermore, because of the reduced number of pieces, the weight of the door can be reduced and manufacture and assembly of the door is enhanced.
While the invention has been described by reference to certain embodiments, numerous other changes could be made within the spirit and scope of the inventive concepts described. Thus, the invention should not be limited to the disclosed embodiments but should have the full scope permitted by the language of the following claims. | A vehicle door is reinforced by an integral reinforcement panel that is fixed to and reinforces side portions of an inner door panel. The reinforcement panel has an outer periphery adjacent and preferably abutting the outer door panel and includes stiffening flutes. Preferably, abutting portions of the outer panel and the stiffening panel are bonded together to form reinforcing box sections. Alternatively, a support panel may abut inner surfaces of the reinforcement panel and is preferably bonded to valley portions of the stiffening flutes to form the reinforcing box sections. The reinforcement panel may replace an anti-intrusion beam and other components of a conventional vehicle door. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of and claims priority to U.S. application Ser. No. 11/775,516, filed Jul. 10, 2007, which is a continuation application of U.S. application Ser. No. 11/429,461, filed May 4, 2006, now abandoned, which is a continuation application of U.S. application Ser. No. 10/851,757, filed on May 21, 2004, now abandoned, which is a continuation application of U.S. application Ser. No. 10/421,102, filed Apr. 23, 2003, now abandoned, which is a continuation application of U.S. application Ser. No. 10/099,774, filed Mar. 15, 2002, now abandoned, which is a continuation application of U.S. application Ser. No. 09/606,458, filed Jun. 29, 2000, now abandoned, which is a continuation application of U.S. application Ser. No. 09/205,135, filed Dec. 3, 1998, now abandoned, which is a continuation application of U.S. application Ser. No. 08/919,292, filed Aug. 28, 1997, now abandoned, which is a continuation application of U.S. application Ser. No. 08/703,470, filed Aug. 27, 1996, now abandoned, which claims priority to U.S. application Ser. No. 08/627,723, filed Apr. 2, 1996, now issued U.S. Pat. No. 5,693,094, which claims priority from U.S. application Ser. No. 08/437,656, filed May 9, 1995, now issued U.S. Pat. No. 5,549,670. The disclosure of the prior applications is considered part of (and are incorporated by reference in) the disclosure of this application.
BACKGROUND
[0002] This invention relates to intraocular lenses and in particular to intraocular lenses (IOL's) which reduce secondary opacification.
[0003] An intraocular lens is commonly used to replace the natural lens of the human eye when warranted by medical conditions. It is common practice to implant an IOL in a region of the eye known as the capsular bag or posterior capsule.
[0004] One problem that is experienced with many IOL's following their implantation is that cells from the eye, particularly lens epithelial cells from the capsular bag, lend to grow on the capsular bag in front of and/or in back of the optical portion of the IOL. This tends to block the optical portion of the IOL and to impair vision.
[0005] A common treatment for this condition is to use a laser to destroy the cells and a central region of the capsular bag. Although this treatment is effective, the laser is expensive and is not available throughout the world. There is also cost associated with the laser treatment as well as some patient inconvenience and risk of complications, Finally, the laser treatment may affect the performance of some IOL's.
[0006] Davenport U.S. Pat. No. 4,743,254 discloses an IOL which includes glare reducing sections on the opposite sides of an optic. These glare reducing sections are fully or partially opaque and their surfaces are not smooth. It has been observed that cell migration across the glare reducing sections appears to be reduced. A similar result has been observed in a plate IOL in which a plate, which is used as a haptic for fixing the IOL in the eye, surrounds the optic. Specifically cell migration across the plate, which has a somewhat textured surface, appears to be reduced.
[0007] Kelman U.S. Pat. No. 4,808,181 discloses an IOL including a lens assembly having an anterior surface formation and a posterior surface formation. At least a portion of the posterior surface formation constitutes a planar contact region adapted to seat against the posterior capsule of the eye to permanently anchor the lens assembly. The contact region is provided with a roughened surface area defined by a series of ordered narrow linear depressions extending transverse of the plane of the contact region. This patent teaches that these ordered narrow linear depressions accelerate adhesion and enhance anchoring of the tissue of the posterior capsule to the lens assembly. This patent is not concerned with secondary opacification and provides no solution to this problem.
SUMMARY
[0008] This invention provides an IOL which is believed to solve the secondary opacification problem discussed above. With this invention, an optical portion, which is adapted to be placed in the capsular bag of an eye, directs light toward the retina of the eye, and a cell barrier portion circumscribes the optical portion. With this construction, the optical portion serves the normal function of directing and focusing light at or near the retina. The cell barrier portion inhibits cell growth from the eye, for example, from the capsular bag, in front of and/or in back of (behind) the optical portion. The optical portion and the cell barrier portion may be considered as being portions of the optic.
[0009] The cell barrier portion of the optic circumscribes the optical portion so as to not leave any path available for the migration of cells in front of or in back of the optical portion. The cell barrier portion is constructed so as to be incapable of or ineffective in focusing light on the retina. The cell barrier portion is preferably partially or wholly opaque to eliminate light scattering.
[0010] At least one fixation member, preferably an elongated fixation member, is coupled to, and preferably extends outwardly from, the optic for use in fixing the optic in the eye. Viewed from a different perspective, a structure other than the cell barrier portion is employed for fixing the optic in the eye. Such structure may include one or more fixation members of various different configurations coupled to the optic. The fixation members may be separate members attached to the optic or members which are integral with the optic, and they may comprise elongated filaments or one or more wider plate or plate-like members.
[0011] The cell barrier portion may be of any construction which performs the function of inhibiting cell growth from the eye in front of or in back of the optical portion. In this regard, the cell barrier portion may include an irregularly configured structure or surface feature, such as an irregularly roughened or textured surface region and/or one or more annular grooves which are at least partially defined by irregular surfaces.
[0012] As used herein, the terms “irregular” or “irregularly” refer to a thing, for example, an irregularly roughened surface region, or series of things, for example, irregular surfaces, which do not have a consistent order, pattern or configuration. In one embodiment, these terms refer to a thing or series of things which are substantially unordered or which have a pattern or configuration with a significant or substantial degree of randomness, or even substantially complete randomness. In one embodiment, the irregularity in accordance with the present invention is sufficient to result in the irregularly configured structure, present in an otherwise optically clear cell barrier portion to be at least about 50% opaque (that is frosty or hazy), more preferably at least about 80% opaque and still more preferably substantially completely opaque.
[0013] The irregularly configured structure or surface feature of the cell barrier portion preferably has a radial dimension of no more than about 2 mm, more preferably no more than about 0.75 mm and still more preferably no more that about 0.25 mm. If the cell barrier portion includes an annular groove, the groove preferably has a maximum width and a maximum depth each no greater than about 0.02 mm. In one preferred construction, the cell barrier portion includes at least about 20 annular grooves.
[0014] The optic has anterior and posterior faces. The irregularly configured structure, for example, surface roughening or texturing and/or grooves, may be provided on any surface or surfaces along which the cells may migrate and completely circumscribes the optical portion. Preferably, the irregularly configured structure is provided at least on the posterior face and/or anterior face of the optic in the cell barrier portion.
[0015] The irregularly configured structure or surface feature can be included in/on the cell barrier portion using any suitable technique or methodology. Of course, it is important that this structure or surface feature be sufficiently irregular to achieve the desired inhibition of cell migration or cell growth so that the risk of secondary opacification is reduced. The technique or methodology chosen to include this structure or surface feature should take this basic criterion into account. This structure or surface feature can be formed during the initial formation, for example, the molding, of the cell barrier portion or optic, or can be included after the cell barrier portion or optic is produced, for example, using a laser, lathe, other mechanical implement and the like. In one particularly useful embodiment, a lathe is employed to form a spiral array of annular grooves defined by irregular surfaces in the cell barrier portion. Cell barrier portions may be processed in a manner similar to the glare reducing sections of Davenport U.S. Pat. No. 4,743,254 to yield fully or partially opaque structures the surfaces of which are irregular and not smooth. The disclosure of this patent is incorporated in its entirety herein by reference.
[0016] The cell barrier portion may be integral with the optical portion, or may be a separate member coupled to the optical portion. Also, the fixation member or members may be integral with the cell barrier portion and/or the optical portion, or may be a separate element or elements, e.g., filament or filaments, coupled to the optical portion or the cell barrier portion.
[0017] The invention, together with additional features and advantages thereof may best be understood by reference to the following description taken in connection with the accompanying illustrative drawings.
DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a plan view of one form of IOL constructed in accordance with the teachings of this invention.
[0019] FIG. 1A is an elevational view of the IOL shown in FIG. 1 .
[0020] FIG. 2 is an enlarged fragmentary view of the region generally bounded by the are 2 in FIG. 1 and showing a more detailed view of the cell barrier portion of the IOL.
[0021] FIG. 3 is an enlarged fragmentary sectional view taken generally along 3-3 of FIG. 2 .
[0022] FIG. 4 is an enlarged fragmentary sectional view taken generally along line 3 - 3 of FIG. 2 and showing the growth of cells from the capsular bag of the eye on only a portion of the cell barrier region.
[0023] FIG. 5 is a plan view of a second form of IOL constructed in accordance with the teachings of this invention.
[0024] FIG. 6 is an enlarged fragmentary sectional view taken generally along line 6 - 6 of FIG. 5 .
[0025] FIG. 7 is a plan view with portions broken away of a third from of IOL constructed in accordance with the teachings of this invention.
[0026] FIG. 8 is an enlarged fragmentary sectional view taken generally along line 8 - 8 and illustrating another construction of the cell barrier portion.
DETAILED DESCRIPTION
[0027] FIGS. 1 and 1A show an IOL 11 which generally comprises an optic 13 and fixation members 15 and 17 . In this embodiment, the optic 13 may be considered as including an optical portion 19 for focusing light on or near the retina of the eye and a cell barrier portion 21 circumscribing the optical portion and being incapable of focusing light on the retina. Optical axis 22 passes through the center of optic 13 in a direction generally transverse to the plane of the optic.
[0028] In this embodiment, the optic 13 is circular in plan and biconvex; however, this is purely illustrative as other configurations and shapes may be employed. The optic 13 may be constructed of any of the commonly employed materials commonly used for rigid optics, such as polymethylmethacrylate (PMMA), or commonly used for resiliently deformable optics, such as silicone polymeric materials, acrylic polymeric materials, hydrogel-forming polymeric materials, mixtures thereof and the like.
[0029] The fixation members 15 and 17 in this embodiment are generally C-shaped and are integral with the optic 13 . However, this is purely illustrative as the fixation members 15 and 17 may be of other configurations and/or may be separate members affixed to the optic in any of a variety of conventional ways.
[0030] The optic 13 has an anterior face 23 , a posterior face 25 and a peripheral edge 27 . In this embodiment, the faces 23 and 25 are convex and the peripheral edge 27 is cylindrical, but as indicated above, these shapes are shown only by way of example.
[0031] The optic 13 is designed to be placed in the capsular bag. The diameter of the optic 13 may be conventional, and as such, may be about 6 mm or less. The optical portion 19 performs the normal function of the optic of an IOL, i.e. to appropriately focus light at or near the retina. The optical portion 19 may be monofocal or multifocal.
[0032] In this embodiment, the cell barrier portion 21 is integral with the optical portion 19 . The cell barrier portion 21 is incapable of focusing light on the retina of the eye and includes an irregularly configured structure or surface feature effective to inhibit, and preferably substantially prevent, cell growth radially inwardly across the cell barrier portion. In the embodiment of FIGS. 1-6 , the cell barrier portion 21 includes a concentric array of annular grooves 29 each of which is at least partially defined by irregular surfaces. Similar arrays of the grooves 29 are in either the anterior face 23 or the posterior face 25 , or both. Although various different arrangements can be employed, in this embodiment the grooves 29 are concentric and substantially equally spaced apart.
[0033] Without wishing to limit the invention to any particular theory of operation, it is believed that grooves 29 , acts to disrupt or otherwise interfere with the process of eye cell, for example, lens epithelial cell, migration or growth so that the cumulative effect of this irregular structure is to significantly reduce, or even eliminate, the migration or growth of cells in front of or in back of the optical portion 19 after IOL 11 is implanted in the eye. FIG. 4 illustrates that eye cells 30 from the capsular bag 32 do migrate or grow to some extent onto and cover a portion of the cell barrier portion 21 . This limited cell migration is advantageous in at least assisting or facilitating the effective fixation of IOL 11 in the eye. Thus, the present invention preferably provides for such advantageous limited eye lens epithelial cell migration or growth while preventing excessive cell migration or growth in front of or in back of the optical portion 19 , as shown in FIG. 4 .
[0034] Another way of viewing the degree of irregularity of the irregularly configured structure, for example, grooves 29 , on cell barrier portion 21 is opacity. The grooves 29 are sufficiently irregular so that the cell barrier portion 21 is substantially completely opaque to the transmission of light. When viewed by the naked eye, cell barrier portion 21 is a white or frosty band on the otherwise optically clear optic 13 .
[0035] Preferably, the radial dimension of the cell barrier portion 21 is no greater than about 2 mm, and more preferably no greater than 0.25 mm.
[0036] In the embodiment shown in FIGS. 1 to 4 , the number of grooves 29 is about 50 to about 100. In order to obtain an advantageous degree of cell migration inhibition, it is preferred that the number of grooves included in cell barrier portion 2 be at least about 20, although fewer grooves can provide some useful benefits.
[0037] The grooves 29 are located wherever it is desired to inhibit cell migration. In the present embodiment, the grooves 29 are placed on both the anterior face 23 and the posterior face 25 so that the cell barrier portion 21 is on both faces of the optic 13 . However, the cell barrier portion can be eliminated from a particular face if it is determined that cell migration in front of that face is not likely to occur.
[0038] The IOL 11 can be implanted in the capsular bag of the eye in accordance with conventional techniques. When so implanted, the cell barrier portion 21 defines a radially relatively narrow annular barrier for inhibiting cell growth radially inwardly in front of or in back of the optical portion 19 where the cells could cause secondary opacification.
[0039] The present invention is applicable to IOLs including a hard or rigid optic, such as the optics made from PMMA, and those which include a foldable or deformable optic, such as optics comprising silicone polymeric materials, other acrylic polymeric materials, hydrogel-forming polymeric materials, such as polyhydro-xyethylmethacrylate (poly HEM A), and the like. Such foldable/deformable optics are particularly advantageous since they can be inserted into the eye through a small incision. The fixation members 15 and 17 , are flexible and strandlike or filaments so that they can be easily inserted into the eye. The fixation members 15 and 17 can be formed integrally with the optic 13 or can be separately coupled to the optic.
[0040] FIGS. 5 and 6 show an IOL 11 a which is identical to the IOL 11 in all respects not shown or described herein. Portions of the IOL 11 a corresponding to portions of the IOL 11 are designated by corresponding reference numerals followed by the letter a.
[0041] The only difference between the IOL's 11 and 11 a is that in the IOL 11 a the grooves 29 are replaced with an irregularly roughened or textured surface 31 . The cell barrier portion 21 a , in particular the roughened or textured surface 31 , is sufficiently irregular as to be at least partially, and preferably substantially completely, opaque to the > transmission of light. This not only provides cell migration inhibition, but also avoids glare from the interaction of light with the cell barrier portion 21 a . The textured surface 31 may be textured or roughened in any of a variety of ways including machining as with a lathe, chemical etching, abrading or the like. If the optic 13 a is molded, as for example when it is constructed of silicone polymeric material or other soft foldable material, the texturing or roughening of the textured surface 31 may be imparted by the mold.
[0042] The degree of irregularity of the roughening of the surface 31 should be sufficient to enable the textured surface to perform the inhibition of cell migration function.
[0043] FIGS. 7 and 8 show an IOL 11 b which is identical to the IOL 11 in all respects not shown or described herein. Portions of the IOL 11 b corresponding to portions of the IOL 11 are designated by corresponding reference numerals follows by the letter b.
[0044] There are two primary differences between the IOL's 11 b and 11 . First, in the IOL 11 b , the fixation members 15 b and 17 b are separate strands or filaments which are attached to the optic 13 b in an suitable conventional manner. Secondly, the cell barrier portion 21 b is in the form of a separate member coupled to the optical portion 19 b.
[0045] In this embodiment, the cell barrier 21 b includes spaced legs 33 joined by a web 35 . The legs 33 engage the faces 23 b and 25 b , respectively, and the web 35 confronts and engages the peripheral edge 27 b . The cell barrier portion 21 b is annular and extends completely around the optical portion 19 b and is mounted on the optical portion in a manner similar to a tire. The cell barrier portion 21 b may have a radial width of up to about 2 mm or about 1 mm, for example, about 0.25 mm.
[0046] While this invention has been described with respect to various specific examples and embodiments, it is to be understood that the invention is not limited thereto and that it can be variously practiced within the scope of the following claims. | An IOL implantable in an eye comprising an optic having an optical portion for directing light toward the retina of the eye and a cell barrier portion for inhibiting cell growth from the eye in front of or in back of the optical portion. The cell barrier portion circumscribes the optical portion, is incapable of focusing light on the retina and includes an irregularly configured structure, for example, irregular grooves. At least one elongated fixation member is coupled to the optic for use in fixing the optic in the eye. | 0 |
BACKGROUND OF THE INVENTION
The present invention is directed generally to molds for use in injection molding machines and to related apparatus used in conjunction with the molds to process articles produced in the molds. The invention pertains to the operation of elements for causing relative movement of some portions of the molds with respect to other portions, particularly in conjunction with the motion of the related molded article processing apparatus. The present invention is more particularly related to such apparatus for use in three portion molds consisting essentially of a mold cavity assembly, a mold core assembly and an intermediate assembly including space surface defining elements that cooperate with the mold core and cavity assemblies to define the space in which articles are molded of plastic, the apparatus regulating the movement of the space surface defining elements during movement of the intermediate assembly relative to the other portions of the mold and relative to the related molded article processing apparatus. The invention has particular utility in a molding operation in which the related molded article processing apparatus comprises a molded article receiver unit designed to enter into an interval or opening between the mold cavity assembly and the other mold assemblies subsequent to formation of the molded article. Of particular interest is the controlled positioning and/or timing of release of the molded article from the intermediate assembly into the molded article receiver unit.
Brun, Jr., et al., U.S. Pat. No. 5,531,588 discloses an adjustable cam track for a mold having a mold cavity assembly, a mold core assembly that is movable relative to the mold cavity assembly, and a stripper assembly movably interposed between the mold core and cavity assemblies. The stripper assembly has at least one pair of space defining surfaces that together with the mold cavity and core assemblies, defines at least one space for receiving plastic material injected therein to form at least one molded article. The mold core assembly and the stripper assembly can be moved away as a coupled pair from the mold cavity assembly to remove the at least one molded article from the mold cavity assembly. The mold core assembly and the stripper assembly are then separated to remove the at least one molded article from the mold core assembly. The adjustable cam track of Brun, Jr., et al., includes a guide fixed to the stripper assembly. A cam follower is coupled to the space defining surfaces of the stripper assembly platen and is engaged in the adjustable cam track so that movement of the cam follower causes movement of each pair of space defining surfaces relative to each other to release the molded article from the molding machine. The adjustable a cam track also includes a cam insert that is adjustably positionable with respect to the guide to adjust the point of release of the molded article. The cam insert includes a first toothed rack, and a second toothed rack removably fixed to the guide and engaging the first toothed rack to fix the position of the cam insert relative to the guide only at certain preselected locations.
The previously described adjustable cam track of Brun, Jr., et al., has been used in the manufacture of parisons for containers at rates that required special handling of the parisons upon their removal from the mold core assembly. This special handling was accomplished with a molded article receiver assembly that was movable into the interval between the mold cavity assembly and the mold core assembly when the mold was in an open position such as that disclosed in Delfer III, U.S. Pat. No. 4,721,452. Ideally, the position of the molded article receiver assembly was such that movement of the stripper assembly relative to the mold core assembly inserted the parisons into the molded article receiver assembly. This was followed immediately by the release of the parisons by the pair of space defining surfaces, which only occurred when the parisons were properly located in the molded article receiver assembly. However, as a practical matter, even slight misalignment between the mold core assembly and the molded article receiver assembly caused one or more of the parisons to be significantly damaged as they were inserted into the molded article receiver assembly. Furthermore, since release of the parisons was related only to the relative position of the stripper assembly relative to the mold core assembly, is was also necessary to accurately position the molded article receiver assembly and coordinate the timing of such positioning so that as little damage as possible occurred. While substantial efforts were focused on insuring the proper alignment between the mold core assembly and the molded article receiver assembly during the movement of the stripper assembly, this did not always accomplish the desired end.
In co-pending U.S. application Ser. No. 09/726,743, filed Nov. 30, 2000 and assigned to the same assignee, an adjustable cam track is disclosed that includes a guide coupled to a mold core assembly, the guide defining a first portion of the adjustable cam track. A cam follower is engaged in the cam track and is coupled to the space defining surfaces carried by the stripper assembly for causing relative movement of each pair of space defining surfaces as the stripper assembly moves relative to the mold core assembly. The cam follower is engaged in the first portion of the cam track when the mold portions are in the closed position. The first portion of the cam track also includes a ramp to an intermediate portion defining the prerelease position of each pair of space defining surfaces so that the molded article is loosely retained by the space defining surfaces. This loose retention accommodates for any small amount of misalignment between the molded article receiver assembly during the transfer of the molded articles from the stripper assembly to the molded article receiver assembly. The adjustable cam track of the co-pending application also includes a cam insert defining a second portion of the adjustable cam track. The path defined by the cam insert is generally a matter of choice of design except that it defines the point of release of the molded article from the space defining surfaces. The cam insert is adjustably positionable with respect to the guide to adjust the point of release with respect to the ramp defining the onset of prerelease, thereby permitting the adaptation of the cam track to molded articles of a variety of sizes. However this adjustment of position of the cam insert is one made to generally coordinate the position of the release, but is not responsive to the timing of the achievement of the specified position by the molded article receiver apparatus.
It is therefore desirable that each pair of space defining surfaces of the stripper assembly be allowed to separate slightly, but not entirely, from the molded articles so that the molded articles are only loosely retained in a prerelease position. This prerelease position allows some play in the position of the molded articles relative to the stripper assembly thus permitting some variation in position of the molded article receiver assembly at the time of introduction of the molded articles. Due to the variation in length of the molded articles, it is also desirable to modify or adjust the position of product release from the stripper assembly in relation to the position of onset of the prerelease position. It is also desirable for the product release from the stripper assembly to occur in response to an indication of the attainment of a specified position by the molded article receiver assembly.
SUMMARY OF THE INVENTION
Accordingly, an article molding assembly of the present invention includes a mold and a release mechanism for releasing molded articles from the mold. The mold includes a first mold portion, a second mold portion that is movable with respect to the first mold portion, and a third mold portion. The third mold portion is movably interposed between the first and second portions and has at least one pair of space defining surfaces which, together with the first and second mold portions, defines in a closed position at least one space for receiving plastic material injected therein to form one or more molded articles. The second and the third mold portions are movable away from the first mold portion to permit removal of the molded articles from the first mold portion. The second mold portion is also movable away from the third mold portion to remove the molded articles from the second mold portion. The release mechanism operates to release the molded articles from the third mold portion. In an embodiment of particular interest, the first mold portion is a mold cavity plate including a plurality of cavities and the second mold portion is a mold core plate supporting a like plurality of cores adapted to inserted into the cavities when the mold is in a closed position. The third mold portion is a stripper plate that supports a like plurality of sets of engaging elements such as thread splits. The thread splits or other similar elements function, in conjunction with the core and cavity portions of the mold, to define the spaces into which plastic can be injected to form the articles having a desired configuration. The release mechanism acts to release the molded articles from the thread splits or similar article engaging elements, generally into a cooling mechanism that will complete the cooling cycle needed for the formation of the molded articles, thereby shortening the residence time of the molded articles in the mold subsequent to injection.
The release mechanism of the present invention includes a guide coupled to the second mold portion. The guide controls the relative position of the sets of space defining surfaces that, together with a first and second mold portions, define in the closed position the space for receiving injected plastic material to form the molded articles. The guide generally includes a first portion having a closed end and including a pair of inner sides confronting each other to define a cam track. The inner sides in the first portion are spaced sufficiently from each other to accommodate a cam follower that is closely received between the inner sides when the mold portions are in the closed position. The first portion can also include a ramp leading to an intermediate portion. The intermediate portion functions to define a pre-release position for the pairs of space defining surfaces so that the molded articles are loosely retained by the space defining surfaces. In a preferred embodiment, one of the inner sides in the intermediate portion is inclined away from the other inner side thus expanding the space that can be occupied by the cam follower toward a second portion. The second portion includes an open end so that the cam follower can move outside the space between the inner sides of the cam track. Further, the inclined away inner surface is adapted to contact the cam follower as the third mold portion moves from the full release position toward the second mold portion. The cam follower then travels along the inclined away inner surface to return the space defining surfaces to a closed position.
As has already been indicated, a cam follower that is coupled to the sets of space defining surfaces of the third mold portion is engaged in the cam track when the second and third mold portions are within a pre-selected distance of each other. The cam follower interacts with the inner surfaces of the cam track to cause relative movement of the sets of space defining surfaces. The cam follower is generally closely engaged in the first portion of the cam track when the mold portions are in the closed position. The cam follower can be less closely engaged in the intermediate portion defining the pre-release position of the sets of space defining surfaces. The cam follower can be completely outside the cam track defined by the confronting inner surfaces at the point of full release of the molded articles.
The release is achieved by a power operator, such as a fluid operated cylinder, solenoid, or other similar device carried by the third mold portion and coupled to the space defining surfaces. The power operator is responsive to a signal to move the sets of space defining surfaces from the pre-release position to a full release position. In the preferred embodiment the signal is supplied by a molded article receiver in sufficiently close proximity to the third mold portion that the molded articles are transferred from the third mold portion to the molded article receiver at such time as the articles are released by the sets of space defining surfaces.
In a particularly desirable embodiment, the molded article receiver includes at least one corresponding receiver tube alignable with each set of space defining surfaces for receiving the molded article, and at least one sensor for detecting any deposition of a molded articles into a receiver tube, the sensor being coupled to a signal source for sending said signal to said power operator. In this embodiment the receiver tube can include an open forward end configured to receive a molded article and a closed rearward end having a surface contact element movably situated with respect to the forward end and configured to conform to a portion of the surface of the molded article. A vacuum duct couples to the closed rearward end of the receiver tube to a source of vacuum for assisting in the retention of a molded article within the receiver tube. An air cylinder is coupled to the surface contact element, and a pressure duct couples each air cylinder to a source of air pressure for controlling the position of the surface contact element with respect to the forward end of the receiver tube.
In the usual operation of an injection molding machine, molded articles are formed in a mold having a first mold portion, a second mold portion movable with respect to the first mold portion. In molding machines of particular interest to the present invention, a third mold portion is movably interposed between the first and second portions that has at least one pair of space defining surfaces for each space defined between the first and second mold portions for receiving plastic material to form molded articles. The second and the third mold portions generally are movable relative to the first mold portion to permit removal of the molded articles from the first mold portion. The second mold portion is movable relative to the third mold portion to permit removal of the molded articles from the second mold portion. When the second and third mold portions have moved as a unit sufficient distance to remove the molded articles from contact with the first mold portion and provide a gap between the first and second mold portions, a molded article receiver moves into proximity with the third mold portion. The present invention is directed toward removing the molded articles from the third mold portion and introducing the molded articles into the receiver for further treatment, generally cooling, without damaging the newly molded articles.
The release of the molded articles from the third mold portion into the molded article receiver is accomplished by providing a guide coupled to the second mold portion that forms a cam track. A cam follower is coupled to the pairs of space defining surfaces of the third mold portion, the cam follower engaging the cam track at least when the second and third mold portions are in a closed position as well as when second and third mold portions are within a pre-selected distance of each other. While the cam track and follower are engaged, the cam follower interacts with the cam track to cause relative movement of each pair of space defining surfaces. As the third mold moves toward the molded article receiver, the cam follower moves to a portion of the cam track including a ramp defining a pre-release position of each pair of space defining surfaces mounted to the third mold portion so that the molded articles are loosely retained by the space defining surfaces. In this loosely retained position, the articles can be inserted into appropriate receivers, such a receiving tubes, despite some amount of misalignment between the receivers and the molded articles. This has the advantage of reducing the amount of damage suffered by the newly molded articles and prevents any machine lock-up due to minor misalignment between the molded article receiver and the articles being held by the third portion of the mold. Additional insertion of the molded article into the molded article receiver is achieved by movement of the third mold portion even further away from the second mold portion, to a point where the cam is no longer captured in the cam track and no longer controls the position of the pairs of space defining surfaces.
Once the molded articles are at least partially received in the receiver elements or tubes of the molded article receiver through movement of the third mold portion away from the second mold portion, a signal is provided to a power operator carried by the third mold portion and coupled to the space defining surfaces. The signal causes the power operator to move each pair of space defining surfaces from the pre-release position toward a full release position for releasing the molded articles from the third mold portion into the molded article receiver. The signal can be provided by a proximity detector situated on the third mold portion that senses, for example, the position of the third mold portion in relation to either the second mold portion or preferably the molded article receiver. A signal can also be provided by a sensor situated on the molded article receiver that senses, for example, the position of the third mold portion or preferably any deposit of molded articles into a receiver tube of the molded article receiver. In any case, the sensor is generally coupled to a signal generator capable of sending a signal to the power operator situated on the third mold portion. Desirably, the signal causing the power operator to move the space defining surfaces on the third mold portion is generated before the molded articles are fully deposited into the receiver elements or tube of the molded article receiver. This has the advantage of preventing damage to the portion of the molded article being held by the space defining surfaces that might occur if completed positioning is required prior to release due to “bottoming out” of the molded article within the article receiver element or tube.
Further avoidance of damage caused by “bottoming out” can be achieved by providing within each receiver tube an open forward end configured to receive a molded article and a closed rearward end including a surface contact element movably situated with respect to the forward end. The surface contact element is configured to conform to a portion of the surface of the molded article, and to be easily moved away from the forward end by contact with a molded article as it is deposited within the tube. To assist in this rearward movement, the closed rearward end of the receiver tube is coupled to a source of vacuum. There is also an air cylinder coupled to the movable surface contact element, the air cylinder being provided with sufficient air pressure to bias the surface contact element toward the open forward end of the receiver tube. The vacuum coupled to the closed rearward end of the receiver tube is generally insufficient to overcome the bias provided to the surface contact element by the air pressure within the air cylinder when no molded article is present within the receiver tube. However, when a molded article is located within the receiver tube, the vacuum becomes enhanced and assists in locating a molded article within the receiver tube in contact with the surface contact element. This vacuum action had the advantage of centering the molded article within the receiving tube so that the spacing of the cooling tubes now controls the spacing of the molded articles, even though the article spacing may have varied from that dimension due to the loose holding arrangement between the molded articles and the pairs of space defining surfaces prior to insertion of the molded articles into the receiving tubes.
In a particularly desirable embodiment, the signal, which causes operation of the power operator on the third mold portion releasing the molded articles from the space defining surfaces, is provided said signal from the molded article receiver to said power operator to cause movement of each pair of space defining surfaces from the pre-release position to a full release position only after the molded article is in contact with the surface contact element. This ensures that the molded articles are suitably positioned to allow the vacuum to overcome the bias provided by the air pressure within the air cylinders so that the surface contact element and molded article are displaced toward the receiver tube closed end thus uncoupling the molded article from the third mold portion, usually causing a displacement of the molded article away from the plane generally defined by the third mold portion. The release of the molded articles from the space defining surfaces under operation of the vacuum is sufficiently gentle that the surfaces of the molded articles held by the space defining surfaces are not damaged during the release process.
After the molded articles are safely situated in the molded article receiver, the molded article receiver is withdrawn from the gap between the first and second mold portions. After a suitable lapse of time and after the molded article receiver is moved to a suitable location, the air cylinder is provided with sufficient air pressure to displace the surface contact element toward the open end with sufficient speed to eject the molded article from the receiver tube for further processing. Generally, subsequent to the release of the molded articles from the pairs of space defining surfaces, and at the same time that the molded article receiver is removed from the gap between the first and second mold portions, the third mold portion is moved back toward the second mold portion so that the cam follower re-enters the cam track. The cam track is provided with an inclined surface adapted to contact the cam follower as the third mold portion moves from the full release position toward the second mold portion. This contact between the cam follower and inclined surface of the cam track returns the space defining surfaces to a closed position. This operation has the advantage of ensuring the repeatability of the positioning of the space defining surfaces without requiring very highly calibrated power operators coupling the space defining surfaces to the third mold portion.
Other features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following description of the illustrated preferred embodiment shown in the accompanying figures showing the best mode of the present invention as understood by the inventors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of an injection molding machine including an article molding assembly of the present invention.
FIG. 2 is a front elevation view of a third mold portion including the power operators of the present invention partially broken away to show certain features and operation through phantom depiction.
FIG. 3 is a detail view of one side of the third mold portion, cam follower and power operator shown in FIG. 2 .
FIG. 4 is a side elevation view of a guide including a cam track of the present invention.
FIG. 5 is a partial sectional view of a molded article receiver of the present invention showing a surface contact element and molded article.
FIGS. 6A-D are four views of a surface contact element suitable for use in tube of a molded article receiver shown in FIG. 5
DESCRIPTION OF PREFERRED EMBODIMENTS
An injection molding machine 10 is shown in FIG. 1 to include an extruder 13 coupled to a fixed platen 9 and a movable platen 8 coupled to a clamping mechanism 7 including hydraulic cylinder 16 . Tie rods 15 tie the fixed platen 9 to the clamping mechanism 7 and the movable platen 8 reciprocates on tie rods 15 relative to the fixed platen 9 in a cycle determined by a suitable control system 6 in a well known manner. A first mold portion 11 , which contains a plurality of cavities, is coupled to the fixed platen 9 . A second mold portion 12 , which includes a like plurality of cores 14 , the number of cores corresponding to the number of cavities, is coupled to the movable platen 8 . A third mold portion 18 is situated between the first and second mold portions 11 and 12 , and includes a plurality of pairs of space defining surfaces that surround each of the cores 14 . The mold portions 11 , 12 and 18 are shown in FIG. 1 in an “open” position. The second and third mold portions 12 and 18 are movable with the movable platen 8 in the direction A into engagement with the first mold portion 11 in a “closed” position to form a plurality of spaces for receiving molten plastic from the extruder 13 to form a plurality of plastic articles 21 by injection molding in the conventional manner. The number of articles 21 formed in an injection molding cycle will depend on the number of cavities and cores included in the mold portions 11 and 12 .
Subsequent to the formation of the plastic articles 21 by the injection of molten plastic, the mold portions 12 and 18 move away from mold portion 11 and toward the illustrated “open” position together as a unit with the formed plastic articles 21 on cores 14 . Retention of the plastic articles can be aided by shrinkage of the articles onto cores 14 . When in the “open” position, an interval or gap 17 is created between the cavity mold portion 11 and the cores 14 that permits the insertion in the direction B of an article carrier plate 20 of a molded article retrieval apparatus 22 . The article carrier plate 20 is moved into and out of the gap 17 between the mold portions 11 and 18 by a trolley system 19 that is coupled to the fixed platen 9 . The article carrier plate 20 can be provided with one or more sets of receivers for receiving the molded plastic articles 21 , each set of receivers being equal to the number of cores 14 on mold portion 12 . Removal of the plastic articles 21 from cores 14 onto the article carrier plate 20 is accomplished by the movement of the third mold portion 18 in the direction C toward the interposed article carrier plate 20 . During such movement, the pairs of space defining surfaces, which surround each of the cores 14 and engaging each of the molded articles, strips the molded articles from the cores and into the waiting receivers of the article carrier plate 20 . To enhance the reliability of successful placement of the molded articles into the receivers of the article carrier plate 20 with the least likelihood of damage, the spacing of the pairs of space defining surfaces are controlled by a release mechanism of the present invention described below.
FIG. 2 shows a face 24 of the third mold portion 18 that confronts the first mold portion 11 . A plurality of pairs of space defining surfaces 22 a and 22 b , commonly known in the trade as “thread splits”, are mounted to the face 24 . The thread splits 22 a and 22 b cooperate with the cores 14 of the second mold portion 12 and the cavities of the first mold portion 11 to complete the definition of the spaces that receive the plastic from the injection extruder 13 to form the molded articles 21 . The space defining surfaces 22 a and 22 b hold the articles 21 as they are stripped from the cores 14 . Each half 22 a and 22 b of each of the thread splits is mounted to separate slides 25 and 26 , respectively, by clamps 23 . The slides 25 and 26 reciprocate laterally within channels defined by brackets 27 and 28 that are fixed to face 24 of the third mold portion 18 . While FIG. 2 shows nine such sets of thread splits, it will be appreciated that the number of sets is a matter of choice of design and depends directly on the number of cores 14 on the first mold portion 12 .
The slides 25 are secured together by tie members 29 while slides 26 are tied together by tie members 30 such that the lateral movement of all slides 25 or 26 is uniform and coordinated. The movement of all slides 25 is not directly coupled to the movement of all slides 26 . A plurality of actuating rods 31 are fixed to the laterally outermost slides 25 and 26 . The actuating rods 31 extend outward through blocks 33 that are coupled to the sides of third mold portion 18 . The actuating rods 31 are coupled to movable actuating beams 40 a and 40 b located on either side of the third mold portion 18 . Any lateral movement of slides 25 and tie members 29 is caused by corresponding movement of the actuating rods 31 and actuating beam 40 a . Likewise, any lateral movement of slides 26 and tie members 30 is caused by corresponding movement of the actuating rods 31 and actuating beam 40 b.
The actuating beams 40 can be moved by two independent means. A first means for moving the beams is a cam follower 41 fixed to each end of each beam 40 . The cam followers 41 can be rollers or slides that are designed for interaction with a cam track 42 that is fixed to the second mold portion 12 . A second means for moving the beams is a power operator 44 that is coupled between each beam 40 and block 33 fixed to the third mold portion 18 . The power operator 44 can be any suitable mechanism that is capable of causing reciprocal motion of one of the beams 40 relative to the third mold portion 18 , for example, a pneumatic or other fluid actuated cylinder and piston, a solenoid including a throw member, or a motorized pinion gear coupled to a rack. Other suitable power operators will be apparent to those skilled in the art.
FIG. 3 illustrates a particularly preferred embodiment of the release mechanism of the present invention. Any dimensional changes between FIGS. 2 and 3 are merely to provide clarity of structure and operation, and neither Figure should be considered a scale drawing. Each of the actuating rods 31 are shown in FIG. 3 to be formed by a bolt 45 extending through beam 40 and block 33 , the bolt 45 being secured to one of the outermost slides (either 25 or 26 depending on which side of the mold is being considered). Each bolt 45 is surrounded by a sleeve 46 that abuts the slide 25 , 26 . The sleeve 46 is movable relative to beam 40 and block 33 . A compression spring 47 biases the sleeve 46 toward the slide 25 , 26 . The block 33 also includes a plurality of stops 48 held in recesses in the inside surface of the block by fasteners 49 so that a portion protrudes inward beyond the inner surface 50 of block 33 . A plurality of shock absorbers 51 are also located in block 33 having movable plungers 52 that protrude toward the adjacent surface 53 of slides 25 , 26 . The shock absorbers 51 are threaded or otherwise secured into recesses in block 33 , and have a rearward extension including an adjustment screw 54 for adjusting the resistance applied by the shock absorber. A sensor 55 senses the arrival of the slides 25 , 26 in substantial contact with block 33 . The sensor 55 can be any sort of electromechanical switch that is coupled to a suitable cable 56 leading to the control 6 for the molding machine 10 or other suitable control mechanism.
Any movement of the beam 40 away from block 33 results in a corresponding movement of the slides 25 or 26 to which the beam 40 is attached through actuating rods 31 . As the slide 25 or 26 approaches block 33 , it is initially slowed in its travel by contact with the plungers 52 of shock absorbers 51 and then stopped by the protruding stops 48 . Any movement of the beam 40 back toward block 30 applies a force through compression spring 47 and sleeve 46 against surface 53 of beam 25 , 26 . In the absence of any resistance, the applied force is sufficient to cause a corresponding movement of the adjacent beam 25 , 26 as well as the related beams connected thereto through slides 29 or 30 as shown in FIG. 2 . In the event of some resistance (usually due to an incompletely released molded article or other mechanical obstruction) the travel provided by the sliding sleeve 46 and compression spring 47 allows the beam 40 to return toward the illustrated position without a corresponding movement of the slides 25 , 26 , thereby protecting the slides and related structures from physical damage.
As indicated earlier, a first means for moving the beams is a cam follower 41 fixed to each end of each beam 40 . The cam followers 41 can be rollers or slides that are designed for interaction with a cam track 42 that is fixed to the second mold portion 12 . In the context of the present invention, a preferred cam track 42 is shown in FIG. 4 . It will be appreciated that the cam tracks 42 on opposite ends of the same beam 40 must be mirror images of each other and similarly situated with respect to the beam 40 if stress and torque on the beam 40 are to be minimized. It will also be appreciated that the illustrated cam track 42 shown in FIG. 4 would necessarily be suitably reproduced in mirror image to correctly interact with the opposite ends of the beam 40 . The following discussion of the structure of the cam track 42 and the movement of the beam in association therewith reflects this mirror image construction of the two cam tracks located at opposite ends of the beam 40 . The cam follower 41 is shown in FIG. 4 to consist of a roller 62 mounted on a spindle 63 that projects from and is secured to the end of the beam 40 . The cam follower 41 is shown in four different locations indicating different positions that the cam follower 41 is likely to occupy during movement of the beam 40 in accordance with this invention.
The cam track 42 comprises essentially a shaped groove 60 in a suitably dimensioned block 61 that includes a first portion 64 that receives the cam follower 41 when the mold portions 11 , 12 and 18 are in the closed position. This location is designated in FIG. 4 by the cam follower 41 at position A. The cam track 42 includes a ramp portion 65 between the first portion 64 and a second portion 66 . As the second and third mold portions move apart from each other, the cam follower 41 moves from position A to position B traversing the ramp portion 65 , which causes the beam 40 to move slightly away from block 33 , and correspondingly causes the space defining surfaces 22 a and 22 b to separate only by a distance sufficient to permit the molded articles 21 to be loosely held but not released by the space defining surfaces. The second portion 66 of the cam track 41 is structured so that the cam follower 41 can move, to the right as shown in FIG. 4, through position C completely outside the end of the cam track 41 . This freedom of movement allows the third mold portion to travel toward the molded article receiver 22 by what ever distance is required to safely deposit the molded articles into the tubes 20 of the article receiver 22 .
Once the molded articles are delivered to the article receiver 22 , a sensor of the relative position of the third mold portion 18 and the article receiver 22 causes the power operator 44 coupled to the beam 40 to actuate thus causing movement of the beam 40 and the cam followers 41 coupled thereto to move in direction Y as shown in FIG. 4, thereby releasing the molded articles 21 from the space defining surfaces 22 a , 22 b . The third mold portion is then caused to move back toward the second mold portion until the cam followers 41 reenter the cam track 42 . When the second and third mold portions 12 and 18 are within a pre-selected distance of each other, the cam follower 41 comes into position D and engages the cam track. As the second and third mold portions 12 and 18 come closer together, the cam follower 41 interacting with a surface 67 of the cam track 42 causes relative movement of each pair of space defining surfaces 22 a , 22 b back toward each other until the cam follower 41 re-enters the first portion 64 of the cam track. This closing motion of the third mold portion 18 toward the second 12 provides sufficient space for the molded article receiver 22 to exit the gap 17 . The mold portions 11 , 12 , and 18 then return to the fully closed position to permit the subsequent injection of plastic to from another set of molded articles.
A detailed look at a preferred molded article receiver 22 is given by FIG. 5 . The molded article receiver 22 comprises a support plate 70 to which a plurality of tube-like molded article article receiver tubes 20 are attached. The support plate 70 is preferably made of a lightweight material such as 6061-T6 aluminum, or an engineering plastic such a ACETRON GP™, manufactured by Polymer Corporation, Reading, Pa., so that the molded article receiver as a whole has as low inertia as possible. Each of the individual article receiver tubes 20 has a sleeve 71 fixed to the frame 70 by base mounting 72 . A sleeve insert 73 is received within the sleeve 71 and base mounting 72 . A space between the sleeve 71 and the sleeve insert 73 defines a channel 74 for receiving liquid that has been thermally adjusted to a temperature selected to thermally modify or treat the molded articles 21 . The channel 74 includes both an inlet 75 and an outlet 76 that are coupled to liquid supply channel 77 and liquid drain channel 78 , respectively, which are located in frame 70 . An inner surface 79 of each sleeve insert 73 has a distal portion 80 that is configured to generally reflect or match an exterior surface portion of the molded articles 21 . A proximal portion 81 of each sleeve insert 73 is generally cylindrical and dimensioned to receive a movable surface contact element 82 for reciprocal movement within the generally cylindrical portion 81 . The sleeve inserts 73 and the contact elements 82 are preferable made of highly thermally conductive material to maximize the thermal transfer between any molded article 21 received within the sleeve insert 73 and the liquid located in channel 74 .
In addition to liquid channels 77 and 78 , the frame 70 also includes a vacuum duct 83 , which is coupled to a vacuum source, not shown, and to the interior of sleeve insert 73 by way of a channel 84 . The channel 84 also provides a pathway for a stem 85 coupling the contact element 82 to an air or gas spring 86 . A distal surface 87 of the contact element 82 is generally configured to reflect or match a portion of an exterior surface 90 of the molded articles 21 . The contact element 82 also includes a plurality of openings 88 through which, in the absence of a molded article 21 , air is drawn into the vacuum duct 83 through a space 89 , located between the contact element 82 and the bottom of the sleeve insert 73 , and channel 84 . As the molded article 21 contacts the distal surface 87 of the contact element 82 , the matching shape of the distal surface 87 and the molded article 21 restricts the flow of air through the openings 88 . The restricted air flow causes the vacuum in duct 83 to harden. The hardening of the vacuum in duct 83 can be sensed by a vacuum/pressure sensor, schematically shown as sensor 91 . The restricted air flow caused by the contact of the molded articles 21 and distal surfaces 87 also causes a pressure differential between the inside of the molded article 21 and space 89 below the contact element 82 that biases the contact element 82 to the right against the pressure exerted by the air or gas spring 86 .
The fluid pressure supplied to the gas or air spring 86 can be controlled by valve 106 coupled between a source of gas or air pressure 105 and all or some portion of the air springs 86 . The valve can be, in turn, coupled to the control system 6 of the injection molding machine 10 or to other independent controls for the apparatus 22 . In the absence of any molded article 21 , or with the molded article 21 spaced from the distal surface 87 of the contact element 82 , the fluid pressure supplied to the spring 86 exerts sufficient force to maintain the contact element 82 in an extended position as shown in the lower portion of FIG. 5 . When the fluid pressure to springs 86 is reduced, the pressure differential developed across the molded article 21 and contact element 82 is sufficient to move the contact element 82 and molded article 21 to the right, as shown in the top of FIG. 5 . However, this movement can only happen if the molded articles 21 are not restrained by the space defining surfaces 22 a , and 22 b . It will be appreciated that the contact between the distal surfaces 87 of the contact elements 82 and the surfaces 90 of all of the molded articles 21 generally occurs nearly simultaneously, or over such a short period of time, so that the change in pressure sensed by vacuum sensor 91 occurs over a similarly short period of time. This change in pressure can be used to trigger power operator 44 to move the beam 40 , and the coupled slides 25 or 26 relative to the third mold portion 18 so as to fully release the molded articles 21 from the space defining surfaces 22 a , 22 b . With the molded articles 21 fully released, the motion between the top and bottom of FIG. 5 quickly follows, thus transferring the molded articles 21 from the space defining surface 22 a , 22 b of the third mold portion 18 to the molded article receiver 22 . The change in pressure sensed by vacuum sensor 91 can also be used to restrict the flow of air or other gas through valve 106 to the air springs 86 , thus ensuring retention of the molded articles 21 within the sleeve inserts 73 . This coordination of the restriction of pressure through valve 106 and the opening of the space defining surfaces 22 a , 22 b can also be done with a coordinated timing circuit and the system control 6 , or in other equivalent manners as will be apparent to those skilled in the art.
Once the molded articles 21 have been retained in the molded article retrieval apparatus 22 for sufficient time to achieve the desired thermal modification, the molded articles 21 can be released. This is achieved by reducing or eliminating the vacuum being supplied to vacuum duct 83 coupled with the supply of air or other gas to gas springs 86 in sufficient amount to rapidly move the contact elements 82 to the left as shown in FIG. 5, thereby ejecting the molded articles 21 from the article receiver 22 . If desired, each gas spring 86 can be monitored to make sure that the desired motion has taken place, and that no motion takes place when the vacuum is reapplied to vacuum duct 83 , thus signifying that to molded article 21 has been retained by the article receiver 22 .
A particularly desirable surface contact element 82 is shown in FIGS. 6A through 6D. FIG. 6A is a front elevation view of the distal surface 87 of the contact element shown in FIG. 5 . FIG. 6B is a sectional view of a contact element 82 taken along line B—B of FIG. 6A, and is similar to the sectional view shown in FIG. 5 . FIG. 6C is a section view of the same contact element 82 taken along line C—C of FIG. 6 A. FIG. 6D is a back elevation view of the contact element 82 . From these four views, it will be seen that the contact element has a generally concave distal surface 87 , the curvature of which is dictated by the shape of the corresponding molded articles 21 with which the contact element is to be employed. The contact element 82 has an outer cylindrical surface 92 that is substantially identical in dimension to the interior dimension of the proximal portion 81 of sleeve insert 73 , so that a smooth linear motion of the contact element 82 within the sleeve insert 73 can be obtained. The cylindrical surface 92 extends from the distal surface 87 to a first proximal surface 93 , which is ring-like and contains two sets of openings 94 and 95 . A step 96 is provided in a central portion of proximal surface 93 , which contacts a rear surface of sleeve insert 73 when the contact element 82 is in the rearward position shown in the upper portion of FIG. 5. A stem connection 97 projects rearwardly from the step 96 and includes a threaded opening 98 for coupling with stem 85 of gas spring 86 . The openings 94 are inwardly inclined as shown in FIG. 6B to intercept axial channel 99 which extends forward to an enlarged portion 101 intercepting an axial portion of distal surface 87 . The openings 95 extending longitudinally through the contact element 82 from the proximal surface 93 to a location adjacent to distal surface 87 , where short openings 100 provide peripheral access to the distal surface 87 . The enlarged portion 101 of the axial channel 99 is preferably faceted to accept a suitable tool to facilitate engagement between the threaded opening 98 for coupling with stem 85 of gas spring 86 . An inner portion of axial channel 99 is threaded to permit insertion of a plug to help maintain a vacuum when a selected portion of the apparatus is not being used.
While the present invention has been described in detail with reference to the accompanying drawings showing a preferred embodiment of the invention, variations and modifications exist within the scope and spirit of the invention as described and as defined in the following claims. | A release mechanism operating to release molded articles from a third mold portion includes a guide coupled to the second mold portion forming a cam track. A cam follower coupled to the surfaces of the third mold portion, which are holding the molded articles, is engaged in the cam track when the second and third mold portions are within a pre-selected distance of each other. The cam follower interacts with the cam track to cause some initial movement of the surfaces holding the molded articles to a pre-release position for the holding surfaces so that the molded articles are loosely retained by the holding surfaces. A power operator, carried by the third mold portion and coupled to the article holding surfaces, is responsive to a signal to move the article holding surfaces from the pre-release position to a full release position when a molded article receiver is suitably positioned to receive the molded articles. The molded article receiver includes receiver tubes for receiving the molded articles. The receiver tubes have an open forward end configured to receive a molded article, a closed rearward end including a surface contact element movably situated with respect to the forward end. The surface contact element is configured to conform to a portion of the surface of the molded article. A vacuum duct couples the closed rearward end to a source of vacuum for assisting in the retention of the molded articles within the receiver tubes. An air cylinder is coupled to each surface contact element, and a pressure duct couples to each air cylinder to a source of air pressure for controlling the position of the surface contact element with respect to the forward end of the receiving tube. | 8 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/851,155, filed on Mar. 4, 2013.
FIELD OF THE INVENTION
[0002] The invention provides for the automatic cleaning of an entire toilet bowel using an electrically powered motor that simultaneously spins flexible, but rigid, circular brushes that are substantially the same length as the height of the bowl in both vertical and horizontal directions.
BACKGROUND OF THE INVENTION
[0003] Cleaning the toilet is one of the less pleasant chores facing many homeowners. Doing a thorough job can require a certain amount of time, elbow grease, and effort. At present, there are a variety of products designed to treat the water handled by such fixtures. Although these can help reduce the frequency at which the interior of their bowls must be cleaned, their effect is limited against heavy deposits. When the washing machine was first introduced at the turn of the century, homemakers not only became more productive, they also became free of the most difficult and arduous household chore of that time. They became freer to pursue their own educations and careers, and therefore in a sense, society benefited as a whole. Today the most difficult and arduous household chore is CLEANING THE TOILET. Additionally, the number of bathrooms per household has increased over the years, especially in the ever larger mansions being built today with the number of bathrooms doubling and tripling per unit. It is not only arduous and smelly to clean the ever increasing number of toilet bowls in the world, but it is also degrading to one's soul. Mankind can do better.
[0004] Over the years, many attempts have been made to automate the toilet, some using programmable key pads and electrically controlled functions and features, while others used auto-release chemicals such as antiseptics. The first “automatic flushing toilet system” was invented by Masakazu Matsunaga of Asaka, Japan (U.S. Pat. No. 4,134,163, issued Jan. 16, 1979, hereinafter, “Matsunaga”). Matsunaga disclosed “an automatic flushing system for flushing a plurality of toilet bowls with water, which is provided with a solenoid-controlled valve and a detecting device. So long as the detecting appliance detects no toilet user, the solenoid-controlled valve is opened every time a predetermined time lapses, thereby to flush all the toilet bowls. If only one toilet user is detected, the solenoid-controlled valve is opened thereafter upon lapse of a reference time shorter than the predetermined time, thereby to flush the toilet bowls. If two or more toilet users are detected, the solenoid-controlled valve is opened thereafter upon lapse of a time shorter than the reference time, the time being shorter by a predetermined length for each additional toilet user detected.” Martin J. Layerty, Jr. of Earlysville, Va. (U.S. Pat. No. 4,793,588, issued Dec. 27, 1988, hereinafter, “Layerty”) is the earliest reference to a fully automatic flush toilet with a sensor. Layerty disclosed an “invention [that] relates to flush valves in which an external operating handle is eliminated. An electronic sensor, solenoid valve and a solenoid contained within a single unit to operate a flush valve are provided which is either built into the flush valve or can be retrofitted to a conventional flush valve with an external operating handle. The solenoid valve can also be controlled by external means separate and apart from the infra-red sensor mechanism.” Layerty controlled his “sensor operated flush valve” by the magnetization of a coil. Actuation of the coil for a pre-set period of time is caused by a timer which is started by a signal coming from the infrared sensor implanted in small round holes in a cap. The infrared sensor could sense if the toilet had been used and sent a signal after a preset period of time so as to electrify the coil. On May 3, 1994, U.S. Pat. No. 5,307,524 was issued to Bennie N. Veal (hereinafter, “Veal”) which included an “automatic toilet seat device which will cause a toilet seat to be either raised or lowered” under the control of a micro-processor controlled first switch that activates an electric motor to raise the toilet seat and “a float switch associated with a tank of the toilet” which activates the motor to lower the toilet seat after the toilet has been flushed. Further, U.S. Pat. No. 4,183,105 was issued to Leo K. Womack on Jan. 15, 1980 that introduced the automatic infusion into a toilet bowl of chemicals “admixed with water” to “clean, disinfect, and deodorize” the bowl.
[0005] With all the sophisticated automation and advanced technical features of the prior art toilet bowl cleaning systems, one must ask, “what is that manual toilet bowl cleaning brush doing next to almost every toilet in almost every home?” The world is well aware of the automatic flushing toilets like Matsunaga and Layerty, which employed automatic sensors that sense humans and/or toilet bowl debris alike to automatically flush toilets in conjunction with timers, etc. It is also well known in the art that electric motors under the control of micro-processors can be used to raise and lower toilet seats either before or after flushing, etc. (Veal). Furthermore, automatic infusion into toilet bowls with chemicals is also well known. (Womack) So with all this automation, why do humans continue to use brushes manually controlled by humans to actually wash in inner rim and vertical wall of toilet bowls, worldwide?
[0006] A need now exists to eliminate the manual toilet bowl cleaning brush and to replace it with an improved, low maintenance, apparatus and method for the automatic cleaning of an entire toilet bowel using an electrically powered motor that simultaneously spins flexible, but rigid, circular brushes that are substantially the same length as the height of the bowl in both vertical and horizontal directions; not only around the bowl, but also along the height of the bowl, with special attention on the two parts of the bowl that collect the most calcium, lime, rust and debris: at the “water line” and “under the rim”. Many times, the longer one waits to clean a toilet bowl, the more likely an anti-calcium, lime and/or rust (hereinafter just “rust”) chemicals will be required to soak the water line and under the rim first, for a few minutes, before cleaning the bowl rigorously with a brush. Otherwise, even the use of manual brushes can be ineffective. Therefore, the automatic introduction of anti-rust chemicals for timed soaking before cleaning is also needed to achieve full automation of the task of cleaning a toilet bowl.
SUMMARY OF THE INVENTION
[0007] This invention can be implemented using a modified toilet design, or a new toilet seat design. Either implementation would differ from conventional units through the incorporation of a set of motor-driven brushes that could automatically clean the interior of the bowl, can optionally be microprocessor-controlled. The simplest use of the invention would require an individual to merely add a suitable rust cleaner to the bowl. Wait a few minutes, and then activate the system. Once it finished, the brushes would automatically stop and retract back into their stowed positions.
[0008] One embodiment of the invention provides for the automatic cleaning of an entire toilet bowel using an electrically powered motor that simultaneously spins flexible, but rigid, circular brushes that are substantially the same length as the height of the bowl in both vertical and horizontal directions, not only around the bowl, but also along the height of the bowl, with special attention to the two parts of the bowl that collect the most rust and debris: at the “water line” and “under the rim”. Many times, the longer one waits to clean a toilet, the more likely an anti-rust chemical will be required to soak the water line and under the rim for a few minutes prior to brushing. Further, before one administers the chemicals, the toilet should be flushed to eliminate any residual debris. Automatically flushing the toilet, and the release of anti-rust chemicals just prior to cleaning, waiting for several minutes, and then controlling both backward and forward spinning of a motor with its' shaft turning a brush rotation mechanism, requires a programmable microprocessor to truly operate automatically. There are fundamentally several embodiments of the invention that vary from the simplest embodiment where a microprocessor is not required, and where pre-flushing and/or introduction of chemicals into the bowl may be done manually, to a more advanced embodiment that may require the user to press an appropriate button to perform any particular brushing cycle in a forward or backward direction for the time duration desired, for example. Further, one can contemplate many alternative advanced embodiments optionally incorporating use of a hot water source, for example; or placing the rotation means within the toilet seat itself, rather than built into the rim of the bowl. Other contemplated embodiments may capitalize on new technologies such as “wireless power” between a programmable display device situated on top of the toilet lid that controls electric motors and valves, wirelessly. One embodiment of the invention contemplates a wireless power source at an AC outlet in a bathroom, and a wireless receiver located under or behind the toilet bowl, including a wireless keypad fixidly attached to the lid of the tank, that wirelessly controls a motor to automatically flush the toilet; a wireless mechanism to automatically release anti-rust chemicals on one schedule and optionally release anti-septic chemicals on another schedule; and another motor, powered wirelessly or not, that turns and rotates cleaning brushes that circumnavigates the toilet bowl.
[0009] One embodiment is a modified residential, tank-style toilet. As with conventional units, it would be produced of vitreous china and would utilize a two-piece, separate tank and bowl configuration. It would differ from the prior art by the incorporation of a self-cleaning system in the form of a pair of rotating brushes. These would be mounted on tracks on the upper inside edge of the bowl and would be able to move around the bowl when actuated. The unit would be linked to a micro-processor control and display that could also retract the units when not in use.
[0010] The invention must meet with the specifications set forth by the National Standard Plumbing Code (NSPC) and a variety of local building codes, and could require a password to operate for safety. In addition, since it would involve electrical wiring and circuitry, it is likely that approval would have to be obtained from Underwriters Laboratories (UL). UL approval involves the testing of prototype and/or production units primarily as relates to fire safety.
[0011] As with conventional fixtures of this nature, one embodiment could be produced of cast, glazed, and fired vitreous china, or of cast iron or stainless steal for increased strength, particularly around the rim holding the brush rotation mechanism. In order to provide the clearance for the tracks and space for the unit's control system, recesses may have to be cast into the bowl and tank. The ball cock, trip lever, flapper valve, overflow tube, and related items could all be standard components. Any type of flushing apparatus is contemplated, whether it be gravity based or water pressure based. The cleaning system could employ replaceable polyester or nylon bristle-based, twisted stainless steel wire brushes that could be mounted in arbors on the output shafts of a pair of small, electrically operated motors or on wheels or ball bearings that rotate the brushes. The tracks, guides, ball bearings, and brush mounting elements could be made of cast and machined stainless steel. The latter could be equipped with small rollers. They could potentially employ a rubber tire, belt or chain-based drive system linked to additional motors at the rear end of the bowl. Limit switches and related hardware could be standard items. The unit could employ standard integrated circuit chips, resistors, push-button elements, and related components for its control circuit. These could be contained within a sealed plastic housing.
[0012] The many objects and advantages of the present invention will become apparent to those skilled in the art when the following description of the invention and its various embodiments are reviewed in accompaniment with the attached drawings wherein like reference numerals refer to like components throughout. The previously described embodiments of the present invention have many advantages. Although the present invention will be described in considerable detail with reference to certain preferred embodiments thereof, other alternative embodiments are possible. Therefore, the spirit and scope of the claims should not be limited to the description of the preferred embodiments, nor the alternative embodiments, contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of an exemplary fully wireless embodiment of the low maintenance commode 5 according to the invention. Movement of removable retractable brushes 10 is shown by arrows around the rim 20 of the commode 5 . The wireless power supply 30 is also depicted.
[0014] FIG. 2 is a top view of selected elements of the low maintenance commode 5 with the programmable input/output display 35 depicted along with removable retractable brushes 10 shown in the retracted position. Extension of the brushes during rotation in the forward direction around the rim 20 is illustrated by arrows.
[0015] FIG. 3 is an example of a removable retractable brush 10 with arrows showing rotation of the brush during normal operation in one preferred embodiment.
[0016] FIG. 4A is a partially cutaway perspective top view under the rim 20 of a possible tire and ball bearing brush rotation mechanism embodiment of the low maintenance commode.
[0017] FIG. 4B is a partially cutaway perspective top view under the rim 20 of a possible chain and sprocket ball bearing brush rotation mechanism embodiment of the low maintenance commode.
[0018] FIG. 4C is a partially cutaway perspective top view under the rim 20 of a possible belt and spool ball bearing brush rotation mechanism embodiment of the low maintenance commode.
[0019] FIG. 5 is a perspective view of an exemplary partial wireless embodiment of the low maintenance commode 5 according to the invention. The power supply 30 is depicted here plugged into an AC outlet.
[0020] FIG. 6 is a side view of an exemplary automatic flushing embodiment of the low maintenance commode 5 .
[0021] FIG. 7 is a side view of an exemplary embodiment of the low maintenance commode 5 where the rotation means is built inside the seat 70 .
[0022] FIG. 8 is a side view of another exemplary rotation means of the low maintenance commode 5 not using ball bearings.
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIGS. 1-3 depict an automatic toilet bowl cleaning system comprising: at least one removable retractable brush 10 movably attached to a rigid adjustable vertical to horizontal tension control guide 11 adapted for travel along an outer track 12 spanning the outer horizontal circumference of an upper rim 20 inside a toilet bowl 40 , wherein an inner track 13 is rigidly attached using a bolt or rivet (not shown) through threads 14 to an inside under cover of said upper rim 20 , thus allowing the outer track 12 to spin freely within said upper rim 20 .
[0024] FIGS. 4A-C and FIG. 8 show a fixed reversible motor 100 powered by a power supply 30 engaging a brush rotation mechanism 15 positioned between a water tank 16 and said toilet bowl 40 operable to engage said at least one removable retractable brush 10 along said outer trackl 2 , said at least one removable retractable brush 10 being forced into engagement with the vertical walls of said toilet bowl 40 by said rigid adjustable vertical to horizontal tension control guide 11 when said motor 100 is rotating in a forward direction and retracting horizontally to said upper rim 20 of said toilet bowl 40 when said motor 100 is rotating in a backward direction. Pathways connecting said toilet bowl 40 and said water tank 16 exist on most all commercially available toilets. Therefore, these same pathways can be used to route liquids such as anti rust or antiseptic chemicals 17 from either inside or outside the water tank 16 to said toilet bowl 40 , dousing said at least one removable retractable brush 10 while said chemicals 17 flow with water to settling at the water line inside the bowl 40 just below optional electrical debris sensors 50 (See FIGS. 2 and 5 ). These electrical sensors 50 can be infrared sensors that detect debris obstructing their line of site, or other types of sensors currently in use, all of which, control the automatic flushing of a toilet bowl 40 .
[0025] At least one electrical switch (not shown) configured to relay power from said power supply 30 for control of said motor 100 can be used and programmed by a programmable input/output display 35 using a micro-processor (not shown) that can be programmed to discern whether a prior flushing, chemical soak, and scrubbing cycle actually removed the debris sensed by the sensors 50 , and decide whether to flush, soak, and scrub again. A predetermined number of cycles that does not remove the debris could cause the programmable input/output display 35 to flash a notice that operation has been stopped, indicating either that the brushes need adjusting or replacing, that the user is out of chemicals, or other such alert.
[0026] The automatic toilet bowl cleaning system does not require the use of ball bearings 2 as the rotation means ( FIGS. 4A-C ). Another rotation means is depicted in FIG. 8 where said inside under cover of said upper rim 20 of said toilet bowel 40 is rigidly affixed to said inner track 13 , thus rigidly holding in place said inner track 13 having a plurality of wheels 18 connecting between said inner track 13 and said outer track 12 , spanning the entire circumference of said upper rim 20 , allowing said outer track 12 to spin freely within said rim 20 of said toilet bowl while engaged by said brush rotation mechanism 15 . In this embodiment, the rigid vertical to horizontal tension control guides 11 can be wheels adjacent the outer track 12 that spin the brushes 10 when rotated by the brush rotation mechanism. Tension control may be maintained by the tinsel strength, composition, and size of the removable retractable brushes 10 employed. Alternatively, the control guides 11 may be spring loaded (not shown) to ensure uniform, continuous and effective cleaning pressure of the brushes 10 against the entire circumference of said toilet bowl 40 .
[0027] FIG. 7 depicts the automatic toilet bowl cleaning system 5 wherein a toilet seat 70 of said toilet bowel 40 rigidly envelopes and is affixed to said inner track 13 , thus holding in place said outer track by ball bearings 2 between said inner track 13 and said outer track 12 , spanning the entire circumference of said toilet seat 70 , wherein said outer track 12 has less vertical width than said inner track 13 , allowing said outer track 12 to spin freely within said toilet seat 70 of said toilet bowl 40 while engaged by said brush rotation mechanism 15 . Note that FIG. 7 could also contemplate the other, non-ball bearing, rotation means depicted in FIG. 8 as well.
[0028] Another embodiment of the automatic toilet bowl cleaning system contemplates an inside under cover of said upper rim 20 of said toilet bowel 40 , rigidly affixed to said inner track 13 , thus rigidly holding in place said inner track 13 and thus said outer track 12 by ball bearings 2 connecting between said inner track 13 and said outer track 12 , spanning the entire circumference of said upper rim 20 , allowing said outer track 13 to spin freely within said rim 20 of said toilet bowl 40 while engaged by a tire brush rotation mechanism 15 FIG. 4A , a chain and sprocket brush rotation mechanism 15 FIG. 4B , or a belt and spool brush rotation mechanism 15 FIG. 4C , all engaging said outer track 12 to cause spin around said rim 20 through a shaft 19 attached to said motor 100 .
[0029] FIG. 6 depicts another contemplated embodiment which includes using a second motor 21 within said water tank connected to electronic means (not shown) adapted to automatically flush said toilet bowl 40 by turning a second shaft 22 to lift the manual flush mechanism 23 , causing water to pass through said pathway, said second motor 21 controlled by said at least one electrical switch (not shown) configured to relay power from said power supply 30 for control of said second motor 21 . Alternatively, automatic flushing can be accomplished by the various prior art means of automatic flushing as described in Matsunaga and Layerty using said electronic sensor 50 and a solenoid valve (not shown), to operate a flush valve (not shown) which is either built into the flush valve or can be retrofitted to a conventional flush valve with an external operating handle 23 . The solenoid valve can also be controlled by external means separate and apart from the infra-red sensors 50 .
[0030] FIGS. 5-6 also depict another contemplated embodiment which includes using a third motor 31 positioned under said water tank 16 and behind said toilet bowl 40 for raising and lowering a toilet lid 32 and a toilet seat 70 of said toilet bowl 40 , said third motor 31 comprising a third shaft (not shown) extending from said third motor 31 adapted for connection to said toilet lid 32 and said toilet seat 70 such that rotation of said third shaft is operable to optionally cause said toilet lid 32 and toilet seat 70 to be raised or lowered, said third motor 31 receiving at least one electrical control signal from said at least one electrical switch (not shown). As described above, it is well known in the art to employ electric motors under the control of micro-processors to raise and lower toilet seats either before or after flushing, etc. (Veal). Similar apparatus is contemplated herein, and therefore, does not require further elaboration.
[0031] The automatic toilet bowl cleaning system further contemplates at least one electrical switch including current detection means for detecting over-current in the reversible motor 100 , the second motor 21 and/or the third motor 31 , said current detection means detecting over-current in any motor when movement of said at least one brush 10 is impeded such that the control circuit means deactivates any of said motors. This is also well known in the art.
[0032] The automatic toilet bowl cleaning system 5 further contemplates a programmable input/output display 35 connected to said at least one electrical switch (not shown) controlled by a microprocessor (not shown) to enable human programming of the schedule and automatic operation of the automatic toilet bowl cleaning system 5 . It is also contemplated that the automatic toilet bowl cleaning system 5 motors ( 100 , 21 and 31 ) are configured within waterproof housings. For example, said ball bearings 2 can be substantially enclosed within a waterproof housing within said rim 20 , and said inner track 13 of said ball bearings 2 is configured with a grease nipple 41 ( FIG. 4A ) for receiving grease to lubricate the ball bearings 2 .
[0033] Operation of the automatic toilet bowl cleaning system 5 contemplates said microprocessor (not shown) further comprising a timer (not shown) controlled by said microprocessor for the automatic scheduling and operation of the automatic toilet bowl cleaning system 5 to function in timed cycles comprising:
[0034] a close lid cycle,
[0035] at least one automatic flushing cycle,
[0036] at least one optional sensing cycle,
[0037] at least one chemical release cycle,
[0038] at least one cleaning cycle while brushes spin vertically in the forward direction,
[0039] at least one cleaning cycle while brushes retract and spin horizontally in the backward direction, and
[0040] an open lid cycle.
[0041] It is contemplated that each removable retractable brush 10 can be removably connected directly to a single ball of a ball bearing 2 ( FIGS. 4A-C ) in one embodiment or to a ball in socket wheel or tire controlled by said rigid adjustable vertical to horizontal tension control guide 11 in another embodiment ( FIG. 8 ) which can cause spin of the brushes 10 . Further, the inside under cover of said upper rim 20 can be rigidly affixed to a lower rim of the top of said toilet bowl 40 using a plurality of nuts and bolts (not shown) to permit easy access for replacement of the brushes 10 , the ball bearings 2 , and the brush rotation mechanism 15 .
[0042] FIG. 5 shows at least one chemical dispenser 17 attached to said water tank 16 and adapted to dispense chemicals to water passing through said pathways and controlled by a chemical valve (not shown) by at least one electrical switch (not shown). This structure is well known in the prior art, and is therefore not depicted in the drawings. A fully automated embodiment of the invention contemplates at least one electrical sensor 50 connected to said power supply 30 for viewing inside said toilet bowl 40 using at least one detector lens (not shown) positioned just above the water level inside of said toilet bowl 40 to automatically detect rust and stuck debris inside said toilet bowl 40 near the water line, controlled by said at least one electrical switch (not shown). The sensor 50 can also automatically detect and signal the microprocessor (not shown) to dispense chemicals through said chemical dispenser 17 controlled by a chemical valve (not shown) by said at least one electrical switch. This process can cause scrubbing and soaking to repeat until the debris is eliminated, or it can be used to alert the user that something is wrong.
[0043] The less automated method for automatically cleaning a toilet bowl 40 using an automatic toilet bowl cleaning system 5 , wherein a programmable input/output display implements human activated automatic scheduling and operation of the automatic toilet bowl cleaning system to function in timed cycle steps, could comprise the steps of:
[0044] manually flushing the toilet,
[0045] automatically cleaning while brushes 10 spin vertically in the forward direction along the walls of said toilet bowl 40 ,
[0046] cleaning while brushes 10 retract and spin horizontally in the backward direction along the walls of said toilet bowl 40 and along the upper rim 20 of said toilet bowl 40 when fully retracted, and
[0047] optionally repeating any previous steps as frequently and as intermittently as desired.
[0048] A bit more automation contemplates using a programmable input/output display 35 to control a microprocessor (not shown) to implement human activated automatic scheduling and operation of the automatic toilet bowl cleaning system 5 to function in timed cycle steps, further comprising the steps of:
[0049] closing a toilet lid 32 and toilet seat 70 of said toilet bowl 40 before cleaning, and
[0050] opening the toilet lid 32 after all prior soaking and cleaning steps complete.
[0051] The method for automatically cleaning a toilet bowl 40 using an automatic toilet bowl cleaning system 5 further contemplates using a programmable microprocessor display which implements human activated automatic scheduling and operation of the automatic toilet bowl cleaning system to function in timed cycle steps, further comprising the step of automatically releasing chemicals into said toilet bowl 40 and waiting a time period for soaking intermittently between any prior step.
[0052] The method for automatically cleaning a toilet bowl 40 using an automatic toilet bowl cleaning system 5 further contemplates using a programmable microprocessor display to implement human activated automatic scheduling and operation of the automatic toilet bowl cleaning system 5 to function in timed cycle steps, further comprising the step of automatically detecting debris which trigger the release of chemicals into said toilet bowl 40 for a pre-defined time period for soaking intermittently between any prior step.
[0053] The least automated method for automatically cleaning a toilet bowl 40 using an automatic toilet bowl cleaning system 5 further contemplates using at least one on/off switch (not shown) on a panel display 35 (“panel display” and “programmable input/output display are used interchangeable herein) which implements human activated automatic cleaning of a toilet bowl 40 in pre-programmed timed cycle steps, comprising the steps of cleaning while brushes 10 spin vertically in the forward direction along the walls of said toilet bowl 40 , and cleaning while brushes 10 retract and spin horizontally in the backward direction along the walls of said toilet bowl 40 and along the upper rim 20 of said toilet bowl when fully retracted.
[0054] The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and the scope of this invention being limited solely by the appended claims. Most prior art structure disclosed in the application that incorporates certain features in combination with applicant's invention is not depicted, but rather one skilled in the art should include that structure by reference to the prior art patents described herein for a more detailed description. | The invention contemplates automatic cleaning of an entire toilet bowel using an electrically powered motor that simultaneously spins flexible, but rigid, circular brushes that are substantially the same length as the height of the bowl in both vertical and horizontal directions, not only around the bowl, but also along the height of the bowl, with special attention to the two parts of the bowl that collect the most rust and debris: at the “water line” and “under the rim”. The longer one waits to clean a toilet bowl, the more likely an anti-rust chemical will be required to soak the water line and under the rim for a few minutes prior to brushing; and before administering chemicals, the toilet should be flushed. Automatically flushing, releasing chemicals, and soaking before cleaning (and then repeating until all debris is removed) requires a programmable microprocessor and debris sensor(s) to truly operate automatically. | 0 |
FIELD OF THE INVENTION
The invention relates to a segmented bend limiter and its methods of use. More specifically, the invention relates to a segmented bend limiter that comprises a plurality of segments, each comprising cooperatively joinable halves, where the segment halves are dimensioned and configured to be joined without using additional fasteners, the terminal segment in a chain of segments being secured and fastened by an end fastener.
BACKGROUND
A bend limiter is a device used to restrict bending of the flexible pipe. As the term is used in the art, a bend limiter includes a bend restrictor, bend stiffener, and/or bellmouth. Bend limiters are used to prevent possible the overbending of flexible flowlines, umbilicals and cables during installation and service. Typically, a bend limiter will lock or otherwise impede movement about two or more axes when a minimum bend radius is reached.
Bend limiters may be used onshore, offshore, and/or subsea and typically comprise a series of interlocking vertebrae joined to form a bend limiter having a desired length.
FIGURES
The figures supplied herein disclose various embodiments of the claimed invention.
FIG. 1 is a cutaway planar view in partial perspective of an exemplary semi-tubular sections of an interlocking bend limiter; and
FIG. 2 is a further cutaway planar view in partial perspective of an exemplary semi-tubular sections of an interlocking bend limiter showing an end cap piece.
DESCRIPTION OF EMBODIMENTS
Referring now to FIGS. 1 and 2 , interlocking bend limiter segment 10 comprises first semi-tubular section 20 a and second semi-tubular section 20 b . Second semi-tubular section 20 b is substantially identical to first semi-tubular section 20 a . First semi-tubular and second semi-tubular sections 20 a , 20 b are dimensioned and configured to be joined cooperatively at their respective interlocks, the first semi-tubular section interlock tab receiver dimensioned and adapted to receive the corresponding interlock tab of the second semi-tubular section, the portions of the conduits of the cooperatively joined first semi-tubular and second semi-tubular sections providing an enclosed fluid pathway therethrough. One or both of first semi-tubular and second semi-tubular sections 20 a , 20 b may comprise a plastic suitable for use, e.g., subsea.
Each of first semi-tubular section 20 a and second semi-tubular section 20 b comprises substantially spherical first end 22 , substantially semi-circular second end 26 , and substantially semi-tubular middle section 28 . First and second semi-tubular sections 20 a , 20 b are dimensioned and configured to be joined without using additional fasteners.
Substantially spherical first end 22 further comprises engaging section 24 disposed about an outer surface of substantially spherical first end 22 , its interior forming a portion of conduit 23 therethrough.
Substantially semi-circular second end 26 further comprises engaging section receiver 21 and interlock 30 .
Engaging section receiver 21 is dimensioned and adapted to engage engaging section 24 of substantially spherical first end 22 . The interior of engaging section receiver 21 defines a portion of a conduit therethrough. In embodiments, engaging section 24 is disposed about an outer surface of substantially spherical first end 24 and comprises ridge 27 . In these embodiments, engaging section receiver 21 of first semi-tubular section 20 a comprises channel 29 dimensioned and adapted to receive ridge 27 second semi-tubular section 20 b , and vice-à-versa.
Interlock 30 comprises interlock tab 32 and corresponding interlock tab receiver 34 .
Substantially semi-tubular middle section 28 is disposed intermediate substantially spherical first end 22 and substantially semi-circular second end 26 . The interior of substantially semi-tubular middle section 28 defines a portion of conduit 23 therethrough.
In certain embodiments, each of first and second semi-tubular sections 20 a , 20 b further comprises a plurality of alignment guides 50 . These are typically disposed integral with a portion of substantially tubular middle section 28 , where at least one of alignment guides 50 of first semi-tubular section 20 a is dimensioned and configured to cooperatively receive another of alignment guides 50 of second semi-tubular section 20 b . In typical configurations, alignment guides 50 comprise a post and a corresponding alignment guide receiver is dimensioned and configured to receive the post.
In certain embodiments, one or both of first semi-tubular and second semi-tubular sections 20 a , 20 b further comprises an armored portion.
As can be seen in FIG. 1 , when cooperative joined the interiors of first semi-tubular and second semi-tubular sections 20 a , 20 b define conduit 23 therethrough.
Referring now to FIG. 2 , using first semi-tubular and second semi-tubular sections 20 a , 20 b , interlocking bend limiter 100 may be constructed and comprise one or more segments 110 , where substantially spherical first ends 22 of interlocked first semi-tubular and second semi-tubular sections 20 a , 20 b of a first segment 110 are cooperatively received into substantially semi-circular second ends 26 ( FIG. 1 ) of a second segment 120 , thereby locking the first and second semi-tubular sections 20 a , 20 b of first segment 110 together. Interlocking bend limiter 100 is terminated using end piece 130 which is coupled to substantially spherical first ends 22 of second segment 120 . End piece 130 is dimensioned and adapted to lock together first and second semi-tubular sections 20 a , 20 b of second segment 120 together at an exposed end of the second segment. In some configurations, end piece 120 comprises a lock dimensioned and adapted to lock together second interlocking bend limiter section 120 , e.g. one or more fasteners 132 such as bolts, clamps, bands, or the like, or a combination thereof.
When joined and terminated, the joined first and second segments 110 , 120 are dimensioned and adapted to provide a predetermined amount of movement about at least two axes, e.g. an X and Y set of axes where one axis is positioned within the conduit defined by the interiors of first semi-tubular and second semi-tubular sections 20 a , 20 b.
In most configurations, assembly of the first and second segments 110 , 120 requires no bolts.
In the operation of currently preferred embodiments, referring to FIGS. 1 and 2 , interlocking bend limiter may be assembled by assembling first interlocking bend limiter segment 110 , formed by joining first semi-tubular section 20 a to substantially identical second semi-tubular section 20 b . As described above, first semi-tubular and second semi-tubular sections 20 a , 20 b each comprise substantially spherical first end 22 , interlocking second end 26 , and substantially semi-tubular section 28 disposed intermediate substantially spherical first end 22 and interlocking second end 26 . When joined, interlocking second end 26 of first semi-tubular section 20 a is cooperatively paired with interlocking second end 26 of second semi-tubular section 20 b.
Second interlocking bend limiter section 120 is assembled similarly, but second interlocking bend limiter section 120 is assembled about substantially spherical first end 22 of first interlocking bend limiter section 110 by positioning engaging section receiver 21 of second interlocking bend limiter section 120 about engaging section 24 of substantially spherical first end 22 of first interlocking bend limiter section 110 and engaging interlocking second end 26 of first semi-tubular section 110 with interlocking second end 26 of second semi-tubular section 20 b . As noted above, second interlocking bend limiter section 120 is substantially identical to first interlocking bend limiter section 110 .
When two or more interlocking bend limiter sections, e.g. 110 and 120 , have been assembled, end piece 130 is secured about substantially spherical first end 22 of the final interlocking bend limiter section in the chain, e.g. second interlocking bend limiter section 120 , such as by use of one or more fasteners 132 .
The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or an illustrative method may be made without departing from the spirit of the invention. | Interlocking bend limiter sections are substantially mirror images of each other and are joined to form an interlocking bend limiter segment without use of fasteners by engaging engaging each other's interlocking ends. An interlocking bend limiter comprises a plurality of interlocking bend limiter segment secured at an end by an end piece. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a seal for rock bits, and more particularly to improved seal and seal shield assemblies for retaining lubricant within the bearing area of a bit and sealing the bearings of the bit from abrasive materials in the borehole.
2. Brief Description of the Prior Art
Seal assemblies for use in applications involving a sliding, rotating or static journal member in a sleeve housing are in common use. As the seal assemblies often function in dynamic circumstances with differential pressure applied to the assemblies much effort has been directed to development and improvement of seal assemblies. The invention disclosed is applicable to the rotary cone rock bit but may be used in a variety of industrial applications.
Rotary cone rock bits in commercial use typically consist of a main bit body with multiple legs. Each leg supports a roller cone cutter on a bearing journal protruding from the leg. The cutter is typically maintained in position on the journal by a thrust-loaded ball bearing assembly. The annular space between the cutter cone and the bearing journal is filled with lubricant. Longevity of the rock bit assembly depends on maintaining appropriate clearance between the cutter cone bearing and bearing journal, and maintaining lubrication, which, in turn, is dependent on the seal assembly.
Roller cone rock bits have an axial opening through the main bit body for circulating drilling mud to wash the debris from drilling out through the bore hole. The seal assembly shields the bearing from contamination by the debris and retains the lubricant between the journal and cutter.
Problems are commonly encountered with sealed drilling bits in the following areas:
a. The destruction of the elastomer seal caused by the drill bit heating up and the elastomer seal adhering to the contacted steel members.
b. Abrasives and sharp particles contacting and thus cutting and abrading the seal, with further migration into the bearing, resulting in abrasion of the bearing and in the escape of lubrication.
c. Differential pressures on the seal assembly distorting the seal and allowing leakage.
d. Chemical decomposition of elastomer seal materials resulting from hydrogen sulfide, steam and other adverse substances encountered down hole.
PRIOR ART PATENTS
Galle, U.S. Pat. No. 3,361,494 discloses an O-ring seal.
Rife, U.S. Pat. No. 4,194,795 discloses the O-ring structure with a teflon shield located within the seal gland to retard shale from reaching and destroying the O-ring. Crow, U.S. Pat. No. 4,277,109, Oelke, U.S. Pat. No. 4,344,629, and Evans, et al, U.S. Pat. No. 4,452,539 disclose variations of the O-ring seal. Deane, et al, U.S. Pat. No. 4,466,622 discloses static elastomers supporting metal seal plates in lieu of dynamic O-rings.
The seal assemblies using dynamic O-rings are subject to the foregoing and other problems. The Deane patent allows contaminants into the seal gland causing abrasion and ultimate failure of the seal.
The present invention is distinguished over the prior art in general, and the foregoing patents in particular by a seal and seal shield assembly which is compression-loaded in an annular cavity to hold lubricant in the bit and protect against abrasive debris.
SUMMARY OF THE INVENTION
One of the objects of the invention is to provide an improved seal and seal shield assembly for rotary drill bits.
Another object of the invention is to provide a seal and seal shield assembly for a rotating, sliding or static journal member within a sleeve housing.
Another object of the invention is to provide a seal and seal shield assembly which maintains the pressure differential between the exterior of the seal assembly and the interior annular space between the journal bearing face and the cutter cone bearing face.
Still another object of the invention is to provide a seal and seal shield assembly to provide high positive pressure to the bearing surfaces to be sealed.
Still another object of the invention is to provide a seal and seal shield assembly with chemically inert contact surfaces.
Yet another object of the invention is to provide a seal and seal shield assembly with contact surfaces of self-lubricating materials.
Another object of the invention is to provide a seal and seal shield assembly which is self-compensating for pressure differentials.
Another object of the invention is to provide a seal and seal shield assembly which maintains equal pressure on axial and radial seal surfaces.
A further object of the invention is to provide multiple seal and seal shield assemblies which can be installed contiguously to improve sealing effectiveness.
It is a further object of the invention to provide a seal and seal shield assembly with shielding which extrudes from the mouth of the seal cavity.
Other objects of the invention will become apparent from time to time throughout the specification and claims as hereinafter related.
The above noted and other objects of the invention are accomplished by a novel seal and seal shield assembly for rotary drill bits having a journal member comprising a first bearing member, and a rolling cutter with a bore having an open end rotatably mounted thereon comprising a second bearing member. The rolling cutter has a counterbore at the open end defining an annular cavity. The seal and seal shield assembly is compression-loaded in the cavity to retain lubricant in the bit. The seal assembly has a pair of annular rings each with a radially extending wall and an axially extending wall defining an annular seal gland. An elastic spring member compression-loaded in the seal biases the exterior surfaces against the bearing surfaces. A flat malleable annular disc with lubricating properties is positioned at the outer face of the seal assembly and a rigid annular disc is positioned in supporting relation thereto. A second flat malleable annular disc is positioned at the outer face of the rigid disc adjacent to the journal member seal thrust face. The malleable annular disc members deform under pressure and extrude to seal voids at the bearing surfaces and to prevent the entrance of abrasive particulate matter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial sectional view of a roller cone rock bit journal and cutter cone assembly showing the seal and seal shield assembly location.
FIG. 2 is an axial sectional view of the seal assembly of this invention with a seal shield prior to compression-loading of the seal and seal shield assembly.
FIG. 3 is an axial sectional view of the seal assembly of this invention subsequent to compression-loading of the seal and seal shield assembly.
FIG. 4 is an exploded view of the seal and seal shield assembly of this invention.
FIG. 5 is a sectional view of an embodiment of the invention having a plurality of contiguous seal assemblies.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings by numerals of reference, in FIG. 1 there is shown a portion of a drill bit 1 having a body (not fully shown) with a leg portion 2 with a spindle or journal 3, and a cutter cone assembly 4. The drill bit is a conventional roller cone drill bit used for drilling rock and earth formations. Rotary drill bits of this general type comprise a bit body (not shown) threadably connected to a drill string member (not shown), the bit body having multiple legs, a portion of a typical leg 2 being shown in FIG. 1.
Roller cone cutter 4 is rotatably mounted on the journal 3 and has a plurality of inserts 5 for crushing rock and other materials in drilling. Various bearing assemblies (not shown), including friction bearings, roller bearings, and ball bearings, may be located in the bearing area between the cutter cone 4 and the journal 3.
The embodiment shown has a non-loaded, ball bearing assembly comprising a cutter cone ball bearing race 6, a journal ball bearing race 7, and a multiplicity of retainer balls 8, which are not loaded but function to retain the cone cutter 4 on the journal 3.
Each leg includes a lubrication system comprising a reservoir (not shown) located in the upper portion thereof. The reservoir communicates with a lubrication passage 9 which is connected with a multiplicity of passages in the journal to provide lubricant to the various bearing assemblies.
The seal and seal shield assembly 15 of the present invention is positioned between the cone cutter 4 and the journal 3 in the annular seal cavity 10. The annular seal cavity 10 is defined by the cutter cone seal thrust surface or journal end bearing surface 11, the cone cutter seal bearing surface or cutter side wall 12, the journal seal thurst surface or journal end bearing surface 16, and the journal seal bearing surface or journal peripheral surface 14. The journal seal thrust surface 16 and the journal seal bearing surface 14 are integrally connected and form fixed walls of the annular seal cavity 10, the journal seal bearing surface 14 representing a flange surface in relation to the journal 3. The cone cutter seal thrust face 11 and the cone cutter seal bearing surface 12 are integrally connected, the said surfaces being formed by an annular recess in the open end of the axial bore of the cone cutter 4.
The seal and seal shield assembly 15 (not shown in FIG. 1) is located in the annular seal cavity 10 to retain lubricant in the bearing area between the cutter cone 4 and the journal 3 and to prevent debris in the well bore from entering the bearing area. In FIG. 2, the seal and seal shield assembly 15 of the present invention is shown in the annular seal cavity 10 in a relaxed condition prior to compression-loading. A portion of the cone cutter 4 is depicted in close relationship to a portion of the journal 3.
The seal and seal shield assembly 15 comprises an inner seal ring 17 (a flexibly rigid material, preferably having lubricating properties, such as a teflon alloy or Ryton™), an outer seal ring 18 (a flexibly rigid material, preferably having lubricating properties, such as a teflon alloy or Ryton™), an annular spring member 19 (an elastic or elastomeric material such as a fluoro-elastomer, Alfas™, Viton™ or Kalrez™), a seal shield wiper ring 20, a seal shield stiffener ring 21, and a seal shield extrusion ring 22.
Inner seal ring 17 is cylindrical with an arcuate inner surface 23. Inner seal ring 17 engages journal bearing surface 14, cone cutter seal thrust surface 11, cone cutter seal surface 12, and spring member 19. Outer seal ring 18 is cylindrical with an arcuate inner surface 24. The outer seal ring 18 engages cone cutter seal surface 12, journal bearing surface 14, wiper ring 20, and spring member 19. Annular spring member (O-ring) 19 is compressed between inner seal ring surface 23 and outer seal ring surface 24.
Seal wiper ring 20 (preferably formed of a malleable material having lubricating properties and resistant to corrosion such as lead, gold or silver), has a flat rectangular cross-section and is positioned against outer seal ring 18 with its inner radial surface against the journal seal bearing surface 14 and outer radial surface against the cone cutter seal surface 12.
A seal shield stiffener ring 21 (preferably formed of a rigid abrasion and corrosion-resistant material such as steel or a non-ferrous material such as graphite) having a flat rectangular cross-sectional configuration with a rounded inner radial surface 25, is positioned against seal wiper ring 20 with its inner radial surface located against journal seal bearing surface 14 and its outer radial surface located against cone cutter seal surface 12.
Extrusion ring 22, with a flat rectangular cross-sectional configuration, is located against seal shield stiffener ring 21 with its inner radial surface located against the journal seal bearing surface 14 and its outer radial surface located against the cone cutter seal surface 12 and with the other axial surface located against the journal seal thrust surface 16. The extrusion ring 22 is formed of a malleable material having lubricating properties and resistant to corrosion such as lead, gold or silver. Lead is additionally desirable in rock bit applications as it is chemically inert and not subject to corrosion by hydrogen sulfide and other chemicals that may be encountered.
In FIG. 3, the seal and seal shield assembly 15 of the present invention is shown fully installed. Axial compressive forces are applied to the seal and seal shield assembly 15 by the cone cutter seal thrust surface 11 and the journal seal thrust surface 16. Spring member 19 is compressed and biases seal rings 17 and 18 against the cone cutter seal thrust surface 12 and against the journal seal bearing surface 14, the cone cutter seal bearing surface 12 and the seal shield wiper ring 20.
Seal wiper ring 20 is biased against the seal shield stiffener ring 21, the seal shield stiffener ring 21 against the seal shield extrusion ring 22, and the seal shield extrusion ring 22 against the journal seal thrust face 16. In installed configuration, therefore, the seal and seal shield assembly 15 is biased against all surfaces defining the annular seal cavity 10.
In dynamic operation, the load applied to the seal and seal shield assembly 15 deforms malleable seal shield wiper ring 20 and malleable seal shield extrusion ring 22, extruding portions of wiper ring 20 and extrusion ring 22 into any voids that may occur at adjacent contact surfaces. Rounded inner radial surface 25 of seal shield stiffener ring 21 facilitates the migration of extruded malleable material into the space between the surface 25 and the journal seal bearing surface 14. This extrusion eliminates voids at the interfaces of seal shield members and their adjacent contacted surfaces, and material from the extrusion ring 22 is slowly extruded into outer annular space or peripheral opening 35 preventing the entrance of particulate matter and other foreign materials into the annular seal cavity 10.
In dynamic operation, the various thrust and radial surfaces may exhibit relative movement, with the contact surfaces experiencing less relative friction being the dynamic interfaces. The self-lubricating properties of materials comprising the seal shield wiper ring 20 and the seal shield extrusion ring 22 facilitate dynamic interfaces at their respective surfaces.
The spring member 19 remains static in relation to the inner seal ring inner surface 23 and the outer seal ring inner surface 24 under all conditions. It is therefore not subject to deterioration due to dynamic stresses. Furthermore, the spring member 19 is protected from contaminants and from chemical attack by the inner seal ring 17, the outer seal ring 18, the seal wiper ring 20, the seal shield stiffener ring 21 and the seal shield extrusion ring 22.
From the foregoing description it may be seen that the present seal and seal shield assembly 15 provides an efficient seal between the journal 3 and the cone cutter 4 retaining lubricating film within the bearing area between the journal 3 and the cone cutter 4 and preventing the entry of drilling debris.
In FIG. 5, there is shown another embodiment of the invention which illustrates the installation of multiple seal and seal shield assemblies in a cascaded configuration. A journal 41 and a cutter cone 42 are shown in cross-sectional view. Cutter cone 42 has two counterbores 43 and 44 with a shoulder 45 therebetween.
The seal and seal shield assembly of this embodiment comprises separate seal and seal shield assemblies assembled in spaced longitudinal relation between cutter cone 42 and the journal 41 in the annular seal cavities. One annular seal is defined by the cutter cone shoulder 45, the body seal bearing surface 46, the journal seal surface 47, and the surface of counterbore 43. The body seal surface 46 and the journal seal bearing surface 47 are integrally connected.
The seal and seal shield assembly 49 is located in the first annular seal cavity 48 to retain lubricant in the bearing area between cutter cone 42 and journal 41 and to prevent debris in the well bore from entering the bearing area. In FIG. 5, the seal and seal shield assembly 48 is shown in the annular seal cavity 49 in a relaxed condition prior to compression-loading. A portion of cone cutter 42 is shown in close relationship to a portion of the journal 41.
The seal and seal shield assembly 48 comprises inner seal ring 50 (a flexibly rigid material, preferably having lubricating properties, such as a teflon alloy or Ryton™), outer seal ring 51 (a flexibly rigid material, preferably having lubricating properties, such as a teflon alloy or Ryton™), annular spring member 52 (an elastic or elastomeric material such as a fluoro-elastomer, Alfas™, Viton™ or Kalrez™), a seal shield wiper ring 55, seal shield stiffener ring 54, and seal shield extrusion ring 53. Inner seal ring 50 is cylindrical with an arcuate inner surface 56. Inner seal ring 50 engages journal bearing surface 47, cone cutter surface 43 and spring member 52.
Outer seal ring 51 is cylindrical with an arcuate inner surface 57. The outer seal ring 51 engages cone cutter surface 43, journal bearing surface 47, wiper ring 55, and spring member 52. Annular spring member (O-ring) 52 is compressed between inner seal ring surface 56 and outer seal ring surface 57.
Seal wiper ring 55 (preferably formed of a malleable material having lubricating properties and resistant to corrosion such as lead, gold or silver), having a flat rectangular cross-section is positioned against journal seal bearing surface 46. A seal shield stiffener ring 54 (preferably formed of a rigid abrasion and corrosion-resistant material such as steel or a non-ferrous material such as graphite) of flat rectangular cross-sectional configuration is positioned against seal wiper ring 55 with its inner radial surface located against journal seal bearing surface 47 and its outer radial surface located against cone cutter seal surface 43.
Extrusion ring 53 (preferably formed of a malleable material having lubricating properties and resistant to corrosion such as lead, gold or silver), with a flat rectangular cross-sectional configuration, is located against seal shield stiffener ring 54 with its inner radial surface located against journal seal bearing surface 47 and its outer radialsurface located against cone cutter seal surface 43 and the other axial surface located against the journal seal thrust face 46.
Wiper ring 58, preferably formed of a malleable material having lubricating properties and resistant to corrosion such as lead, gold or silver), with a flat rectangular cross-sectional configuration, is located against spacer ring 59 (preferably formed of a rigid abrasion and corrosion-resistant material such as steel or a non-ferrous material such as graphite) with its inner radial surface located against journal seal bearing surface 47 and its outer radial surface located against cone cutter seal surface 43 and with the other radial surface located against seal ring 50. Spacer ring 59 has a first outside diameter 60 fitting counterbore 43 and a second, smaller outside diameter 61 fitting the second counterbore 44.
A wiper ring 62 fits the second counterbore 44 and abuts the smaller O.D. portion 61 of spacer ring 59. The other side of wiper ring 62 abuts one side of a second seal and seal shield assembly 63. The seal and seal shield assembly 63 is located in the second annular seal cavity 64 and is shown in a relaxed condition prior to compression-loading.
The second seal and seal shield assembly 63 comprises inner seal ring 65 (flexibly rigid material, preferably having lubricating properties, such as a teflon alloy or Ryton™), outer seal ring 66 (a flexibly rigid material, preferably having lubricating properties, such as a teflon alloy or Ryton™), annular spring member 67 (an elastic or elastomeric material such as a fluoro-elastomer, Alfas™, Viton™ or Kalrez™), and seal shield wiper ring 68.
Inner seal ring 65 is cylindrical with an arcuate inner surface 69. Inner seal ring 65 engages journal bearing surface 47, cone cutter surface 44 and spring member 67. Outer seal ring 66 is cylindrical with an arcuate inner surface 70. The outer seal ring 66 engages cone cutter surface 44, journal bearing surface 47, wiper ring 62, and spring member 67. Annular spring member (O-ring) 67 is compressed between inner seal ring surface 69 and outer seal ring surface 70.
The embodiment depicted in FIG. 5 is particularly useful in applications involving significant pressure differentials between the environments on the inner and outer journal surfaces. Also, this embodiment, as well as the first embodiment, is applicable to sealing a rotary shaft in structures other than rotary cone drill bits. In particular, this improved bearing seal and bearing seal shield assembly provides sealing and seal protection for rotary shafts operating in an abrasive environment, such as rotary drilling, boring, and grinding tools, and the like.
While this invention has been described fully and completely, with special emphasis on two preferred embodiments, it should be understood that, within the scope of the appended claims, this invention may be practiced otherwise than as specifically described herein. | A seal and seal shield assembly for rotary drill bits having a journal member comprising a first bearing member, and a rolling cutter with a bore having an open end rotatably mounted thereon comprising a second bearing member. The rolling cutter has a counterbore at the open end defining an annular cavity. The seal and seal shield assembly is compression-loaded in the cavity to retain lubricant in the bit. The seal assembly has a pair of annular rings each with a radially extending wall and an axially extending wall defining an annular seal gland. An elastic spring member compression-loaded in the seal biases the exterior surfaces against the bearing surfaces. A flat malleable annular disc with lubricating properties is positioned at the outer face of the seal assembly and a rigid annular disc is positioned in supporting relation thereto. A second flat malleable annular disc is positioned at the outer face of the rigid disc adjacent to the journal member seal thrust face. The malleable annular disc members deform under pressure and extrude to seal voids at the bearing surfaces and to prevent the entrance of abrasive particulate matter. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a multi-component system for modifying, degrading or bleaching lignin, lignin-containing materials or similar substances and to processes for its use.
[0003] 2. The Prior Art
[0004] The sulfate process and the sulfite process are mentioned as the processes currently used chiefly for pulp production. With both processes, pulp is produced by cooking and under pressure. The sulfate process operates with the addition of NaOH and Na 2 S, while Ca(HSO 3 ) 2 + SO 2 is used in the sulfite process.
[0005] All the processes have as the primary objective, removing of the lignin from the plant material, wood or annual plants used.
[0006] The lignin which, with the cellulose and the hemicellulose, makes up the main constituent of the plant material (stem or trunk) must be removed. Otherwise, it is not possible to produce papers which are non-yellowing and which can be subjected to high mechanical stress.
[0007] Wood pulp production processes operate with stone grinders (mechanical wood pulp) or with refiners (TMP), which defibrillate the wood by grinding after appropriate pretreatment (chemical, thermal or chemical-thermal).
[0008] These wood pulps still comprise most of the lignin. They are used primarily for the production of newspapers, illustrated journals and the like.
[0009] The possibilities of the use of enzymes for degradation of lignin have been researched for some years. The action mechanism of such lignolytic systems was clarified only a few years ago. Then it became possible to obtain adequate amounts of enzyme with the white rot fungus Phanerochaete chrysosporium under suitable growing conditions with additions of inductor. The previously unknown lignin peroxidases and manganese peroxidases were discovered by this research. Since Phanerochaete chrysosporium is a very effective degrader of lignin, attempts were made to isolate its enzymes and to use them in a suitable form for lignin degradation. However, this was not successful, since it was found that the enzymes lead above all to repolymerization of the lignin and not to degradation thereof.
[0010] Similar circumstances also apply to other lignolytic enzyme species, such as laccases, which degrade the lignin oxidatively with the aid of oxygen instead of hydrogen peroxide. It was found that similar processes occur in all cases. In fact, free radicals are formed which react with one another again and thus lead to polymerization.
[0011] There are thus currently only processes which operate with in vivo systems (fungus systems). The main key points of optimization experiments are so-called biopulping and biobleaching.
[0012] Biopulping is understood as meaning treatment of chopped wood chips with live fungus systems. There are 2 types of forms of application:
[0013] 1. Pretreatment of chopped chips before refining or grinding in order to save energy during the production of wood pulps (for example TMP or mechanical wood pulp). One advantage is the improvement which usually exists in the mechanical properties of the pulp, but a disadvantage is the poorer final whiteness.
[0014] 2. Pretreatment of chopped chips (softwood/hardwood) before cooking of the pulp (kraft process, sulfite process).
[0015] The objective is reduction in cooking chemicals, improvement in cooking capacity and extended cooking. Improved kappa reduction after cooking in comparison with cooking without pretreatment is also achieved as an advantage.
[0016] Disadvantages of these processes are clearly the long treatment times (several weeks), and above all the unsolved risk of contamination during treatment if sterilization of the chopped chips, which is uneconomical, is to be dispensed with.
[0017] Biobleaching likewise operates with in vivo systems. The cooked pulp (softwood/hardwood) is seeded with fungus before bleaching and is treated for days to weeks. Only after this long treatment time is a significant reduction in kappa number and increase in whiteness found. This renders the process uneconomical for implementation in the usual bleaching sequences.
[0018] Another application carried out usually with immobilized fungus systems is the treatment of waste waters from the manufacture of pulp, in particular bleaching waste waters. This treatment is for decolorization thereof and reduction of the AOX (reduction of chlorinated compounds in the waste water caused by chlorine or chlorine dioxide bleaching stages).
[0019] It is furthermore known to employ hemicellulases and also xylanases and mannanases as bleaching boosters.
[0020] These enzymes are said to act chiefly against the xylan which is reprecipitated after the cooking process and partly masks the residual lignin. Degradation thereof increases the accessibility of the lignin to the bleaching chemicals (above all chlorine dioxide) used in the subsequent bleaching sequences. The savings in bleaching chemicals demonstrated in the laboratory were confirmed to only a limited extent on a large scale. Thus, this type of enzyme can at best be classified as a bleaching additive.
[0021] Chelating substances (siderophors, such as ammonium oxalate) and biosurfactants are assumed to be a cofactor, alongside the lignolytic enzymes.
[0022] The Application PCT/EP87/00635 describes a system for removing lignin from material containing lignin-cellulose with simultaneous bleaching. This system operates with lignolytic enzymes from white rot fungi with the addition of reducing and oxidizing agents and phenolic compounds as mediators.
[0023] In DE 4,008,893 C2, mimic substances which simulate the active center (prosthetic group) of lignolytic enzymes are added in addition to the redox system. It was thus possible to achieve a considerable improvement in performance.
[0024] In the Application PCT/EP92/01086, a redox cascade with the aid of phenolic or non-phenolic aromatics coordinated in oxidation potential is employed as an additional improvement.
[0025] The limitation for use on a large industrial scale is the applicability at low pulp densities (up to not more than 4%) for all three processes. For the last two Applications the risk of leaching out of metals when using chelating compounds, can lead above all to destruction of the peroxide in the subsequent peroxide bleaching stages.
[0026] Processes in which the activity of peroxidase is promoted by means of so-called enhancer substances are known from the three publications WO 94/12619, WO 94/12620 and WO 94/12621.
[0027] The enhancer substances are characterized with the aid of their half-life in WO 94/12619.
[0028] According to WO 94/12620, enhancer substances are characterized by the formula A═N—N═B, in which A and B are each defined cyclic radicals.
[0029] According to WO 94/12620 enhancer substances are organic chemicals which contain at least two aromatic rings, at least one of which is substituted in each case by defined radicals.
[0030] All three publications relate to dye transfer inhibition and to the use of the particular enhancer substances, together with peroxidases, as a detergent additive or detergent composition in the detergent sector. A possible use for the treatment of lignin is referred to in the description of these WO Applications. However, the Applicants' own experiments with the substances disclosed completely in these publications have shown that they showed no activity as mediators. Thus, they did not increase the bleaching action of the peroxidases during treatment of lignin-containing materials.
[0031] WO 94/29510 describes a process for enzymatic delignification in which enzymes are employed together with mediators. Compounds having the structure NO—, NOH— or HRNOH are generally disclosed as mediators.
[0032] Of the mediators disclosed in WO 94/29510, 1-hydroxy-1H-benzotriazole (HBT) gives the best results in the delignification. However, HBT has various disadvantages: It is available only at high prices and not in adequate amounts.
[0033] It reacts under delignification conditions to give 1H-benzotriazole. This compound is relatively poorly degradable, and can represent considerable environmental pollution in larger quantities. It leads to damage to enzymes to a certain extent. Its rate of delignification is not at all that high.
SUMMARY OF THE INVENTION
[0034] It is an object of the present invention to provide systems for modifying, degrading or bleaching lignin, lignin-containing materials or similar substances, which systems have overcome the disadvantages mentioned above.
[0035] The present invention relates to a multi-component system for modifying, degrading or bleaching lignin, lignin-containing materials or similar substances comprising
[0036] a. if appropriate at least one oxidation catalyst and
[0037] b. at least one suitable oxidizing agent and
[0038] c. at least one mediator, wherein the mediator is an N-aryl-N-hydroxyamide.
[0039] It has surprisingly been found that the novel multi component system with mediators selected from the class of the N-aryl-N-hydroxyamides does not have the drawbacks of the prior art multicomponent systems.
[0040] Mediators which are preferably employed in the multi-component system according to the invention are compounds of the general formula (I), (II) or (III)
[0041] and salts, ethers or esters thereof, wherein
[0042] A is a monovalent homoaromatic or heteroaromatic mononuclear or dinuclear radical and
[0043] D is a divalent homoaromatic or heteroaromatic mononuclear or dinuclear radical, and
[0044] wherein these aromatics can be substituted by one or more identical or different radicals RI chosen from the group consisting of a halogen, hydroxyl, formyl, cyano, carbamoyl or carboxyl radical, an ester or salt of the carboxyl radical, a sulfono radical, an ester or salt of the sulfono radical, a sulfamoyl, nitro, nitroso, amino, phenyl, aryl-C 1 -C 5 -alkyl, C 1 -C 12 -alkyl, C 1 -C 5 -alkoxy, C 1 -C 10 -carbonyl, carbonyl-C 1 -C 6 -alkyl, phospho, phosphono or phosphono-oxy radical and an ester or salt of the phosphonooxy radical, and where carbamoyl, sulfamoyl, amino and phenyl radicals can be unsubstituted or monosubstituted or polysubstituted by a radical R 2 and the aryl-C 1 -C 5 -alkyl, C 1 -C 12 -alkyl, C 1 -C 5 -alkoxy, C 1 -C 10 -carbonyl and carbonyl-C 1 -C 6 -alkyl radicals can be saturated or unsaturated, branched or unbranched and can be monosubstituted or polysubstituted by a radical R 2 , wherein
[0045] R 2 is identical or different and is a hydroxyl, formyl, cyano or carboxyl radical, an ester or salt of the carboxyl radical or a carbamoyl, sulfono, sulfamoyl, nitro, nitroso, amino, phenyl, C 1 -C 5 -alkyl, C 1 -C 5 -alkoxy or C 1 -C 5 -alkylcarbonyl radical, and in each case two radicals R 1 or R 2 can be linked in pairs via a bridge [—CR 3 R 4 ] m , where m is 0, 1, 2, 3 or 4, and
[0046] R 3 and R 4 are identical or different and are a carboxyl radical, an ester or salt of the carboxyl radical or a phenyl, C 1 -C 5 -alkyl, C 1 -C 5 -alkoxy or C 1 -C 5 -alkylcarbonyl radical, and one or more non-adjacent groups [—CR 3 R 4 —] can be replaced by oxygen, sulfur or an imino radical which is optionally substituted by a C 1 to C 5 alkyl radical, and two adjacent groups [—CR 3 R 4 —] can be replaced by a group [—CR 3 ═CR 4 —] and
[0047] B is a monovalent acid radical, present in amidic form, of acids chosen from the group consisting of a carboxylic acid having up to 20 carbon atoms, carbonic acid, a half-ester of carbonic acid or of carbamic acid, sulfonic acid, phosphonic acid, phosphoric acid, a monoester of phosphoric acid or a diester of phosphoric acid and C is a divalent acid radical, present in amidic form, of acids chosen from the group consisting of monocarboxylic and dicarboxylic acids having up to 20 carbon atoms, carbonic acid, sulfonic acid, phosphonic acid, phosphoric acid or a monoester of phosphoric acid.
[0048] Mediators which are particularly preferred in the multi-component system according to the invention are compounds of the general formula (IV), (V), (VI), (VII) or (VIII):
[0049] and salts, ethers or esters thereof, wherein
[0050] Ar 1 is a monovalent homonuclear or heteroaromatic mononuclear aryl radical and
[0051] Ar 2 is a divalent homoaromatic or heteroaromatic mononuclear aryl radical,
[0052] which can be substituted by one or more identical or different radicals R 7 chosen from the group consisting of a hydroxyl, cyano or carboxyl radical, an ester or salt of the carboxyl radical, a sulfono radical, an ester or salt of the sulfono radical, or a nitro, nitroso, amino, C 1 -C 12 -alkyl, C 1 -C 5 -alkoxy, C 1 -C 10 -carbonyl or carbonyl-C 1 -C 6 -alkyl radical,
[0053] where amino radicals can be unsubstituted or monosubstituted or polysubstituted by a radical R 8 , and the C 1 -C 12 -alkyl, C 1 -C 5 -alkoxy, C 1 -C 10 -carbonyl and carbonyl-C 1 -C 6 -alkyl radicals can be saturated or unsaturated, branched or unbranched and can be monosubstituted or polysubstituted by a radical R 8 ,
[0054] wherein R 8 is identical or different and is a hydroxyl or carboxyl radical, an ester or salt of the carboxyl radical or a sulfono, nitro, amino, C 1 -C 5 -alkyl, C 1 -C 5 -alkoxy or C 1 -C 5 -alkylcarbonyl radical, and
[0055] in each case two radicals R 7 can be linked in pairs via a bridge [—CR 3 R 4 ] m , where m is 0, 1, 2, 3 or 4, and
[0056] R 3 and R 4 have the meanings already given, and one or more non-adjacent groups [—CR 3 R 4 —] can be replaced by oxygen, sulfur or an imino radical which is optionally substituted by a C 1 to C 5 alkyl radical, and two adjacent groups [—CR 3 R 4 —] can be replaced by a group [—CR 3 ═CR 4 —],
[0057] R 5 is identical or different monovalent radicals chosen from the group consisting of a hydrogen, phenyl, aryl-C 1 -C 5 -alkyl, C 1 -C 12 -alkyl, C 1 -C 5 -alkoxy or C 1 -C 10 -carbonyl radical, where phenyl radicals can be unsubstituted or monosubstituted or polysubstituted by a radical R 9 and the aryl-C 1 -C 5 -alkyl, C 1 -C 12 -alkyl, C 1 -C 5 -alkoxy and C 1 -C 10 -carbonyl radicals can be saturated or unsaturated, branched or unbranched, and can be monosubstituted or polysubstituted by a radical R 9 , wherein
[0058] R 9 is identical or different and is a hydroxyl, formyl, cyano or carboxyl radical, an ester or salt of the carboxyl radical, or a carbamoyl, sulfono, sulfamoyl, nitro, nitroso, amino, phenyl, C 1 -C 5 -alkyl or C 1 -C 5 -alkoxy radical and
[0059] R 6 is divalent radicals chosen from the group consisting of an ortho-phenylene, meta-phenylene or para-phenylene, aryleno-C 1 -C 5 -alkyl, C 1 -C 12 -alkylene or C 1 -C 5 -alkylenedioxy radical, where phenyl radicals can be unsubstituted or monosubstituted or polysubstituted by a radical R 9 and the aryleno-C 1 -C 5 -alkyl, C 1 -C 12 -alkylene and C 1 -C 5 -alkylenedioxy radicals can be saturated or unsaturated, branched or unbranched and can be monosubstituted or polysubstituted by a radical R 9 , wherein
[0060] p is 0 or 1 and
[0061] q is an integer from 1 to 3.
[0062] Preferably, Ar 1 is a phenyl radical and Ar 2 is an ortho-phenylene radical, where Ar 1 can be substituted by one to five and Ar 2 can be substituted by up to four identical or different radicals chosen from the group consisting of a C 1 -C 3 -alkyl, C 1 -C 3 -alkylcarbonyl or carboxyl radical, an ester or salt of the carboxyl radical, a sulfono radical, an ester or salt of the sulfono radical, and a hydroxyl, cyano, nitro, nitroso and amino radical, where amino radicals with two different radicals can be chosen from the group consisting of hydroxyl and C 1 -C 3 -alkylcarbonyl.
[0063] R 5 is preferably a monovalent radical chosen from the group consisting of a hydrogen, phenyl, C 1 -C 12 -alkyl or C 1 -C 5 -alkoxy radical, where the C 1 -C 12 -alkyl radicals and C 1 -C 5 -alkoxy radicals can be saturated or unsaturated and branched or unbranched.
[0064] R 6 is preferably a divalent radical chosen from the group consisting of an orthophenylene or paraphenylene, C 1 -C 12 -alkylene or C 1 -C 5 -alkylenedioxy radical, where the phenylene, C 1 -C 12 -alkyl and C 1 -C 5 -alkylenedioxy radicals can be saturated or unsaturated, branched or unbranched and can be monosubstituted or polysubstituted by a radical R 9 .
[0065] R 9 is preferably a carboxyl radical, an ester or salt of the carboxyl radical or a carbamoyl, phenyl or C 1 -C 3 -alkoxy radical.
[0066] Examples of compounds which can be employed as mediators (component c) in the multi-component system according to the invention are N-hydroxyacetanilide, N-hydroxypivaloylanilide, N-hydroxyacrylanilide, N-hydroxybenzoylanilide, N-hydroxymethylsulfonylanilide, N-hydroxy-N-phenyl-methylcarbamate, N-hydroxy-3-oxo-butyrylanilide, N-hydroxy-4-cyanoacetanilide, N-hydroxy-4-methoxyacetanilide, N-hydroxyphenacetin, N-hydroxy-2,3-dimethylacetanilide, N-hydroxy-2-methylacetanilide, N-hydroxy-4-methylacetanilide, 1-hydroxy-3,4-dihydroquinolin-(1H)-2-one, N,N′-dihydroxy-N,N′-diacetyl-1,3-phenylenediamine, N,N′-dihydroxysuccinic acid dianilide, N,N′-dihydroxy-maleic acid dianilide, N,N′-dihydroxy-oxalic acid dianilide, N,N′-dihydroxy-phosphoric acid dianilide, N-acetoxyacetanilide, N-hydroxymethyloxalylanilide and N-hydroxymaleic acid monoanilide.
[0067] Preferred mediators are N-hydroxyacetanilide, N-hydroxyformanilide, N-hydroxy-N-phenyl-methylcarbamate, N-hydroxy-2-methylacetanilide, N-hydroxy-4-methylacetanilide, 1-hydroxy-3,4-dihydroquinolin-(1H)-2-one and N-acetoxyacetanilide.
[0068] The multi-component system according to the invention comprises mediators which are cheaper than the mediators known from the prior art, in particular cheaper than HBT.
[0069] Furthermore, an increase in the rate of delignification is achieved when the mediators according to the invention are employed.
[0070] The multi-component system according to the invention preferably comprises at least one oxidation catalyst.
[0071] Enzymes are preferably employed as oxidation catalysts in the multi-component system according to the invention. In the context of the invention, the term enzyme also includes enzymatically active proteins or peptides or prosthetic groups of enzymes.
[0072] Enzymes which can be employed in the multi-component system according to the invention are oxidoreductases of classes 1.1.1 to 1.97 according to International-Enzyme Nomenclature, Committee of the International Union of Biochemistry and Molecular Biology (Enzyme Nomenclature, Academic Press, Inc., 1992, pages 24-154).
[0073] The enzymes of the classes mentioned below are preferably employed:
[0074] Enzymes of class 1.1, which include all dehydrogenases which act on primary and secondary alcohols and semiacetals and have NAD + or NADP + (subclass 1.1.1), cytochromes (1.1.2), oxygen (O 2 ) (1.1.3), disulfides (1.1.4), quinones (1.1.5) as acceptors or have other acceptors (1.1.99).
[0075] Enzymes of this class which are particularly preferred are those of class 1.1.5 with quinones as acceptors and enzymes of class 1.1.3 with oxygen as the acceptor.
[0076] Cellobiose: quinone-1-oxidoreductase (1.1.5.1) is particularly preferred in this class.
[0077] Enzymes of class 1.2 are furthermore preferred. This enzyme class includes those enzymes which oxidize aldehydes to give the corresponding acids or oxo groups. The acceptors can be NAD + , NADP + (1.2.1), cytochromes (1.2.2), oxygen (1.2.3), sulfides (1.2.4), iron/sulfur proteins (1.2.5) or other acceptors (1.2.99).
[0078] The enzymes of group (1.2.3) with oxygen as the acceptor are particularly preferred here.
[0079] Enzymes of class 1.3 are furthermore preferred.
[0080] This class comprises enzymes which act on CH—CH groups of the donor.
[0081] The corresponding acceptors are NAD + , NADP + (1.3.1), cytochromes (1.3.2), oxygen (1.3.3), quinones or related compounds (1.3.5), iron/sulfur proteins (1.3.7) or other acceptors (1.3.99).
[0082] Bilirubin oxidase (1.3.3.5) is particularly preferred.
[0083] Here also, the enzymes of class (1.3.3) with oxygen as the acceptor and (1.3.5) with quinones and the like as the acceptor are particularly preferred.
[0084] Enzymes of class 1.4 which act on CH—NH 2 groups of the donor are furthermore preferred.
[0085] The corresponding acceptors are NAD + , NADP + (1.4.1), cytochromes (1.4.2), oxygen (1.4.3), disulfides (1.4.4), iron/sulfur proteins (1.4.7) or other acceptors (1.4.99).
[0086] Enzymes of class 1.4.3 with oxygen as the acceptor are also particularly preferred here.
[0087] Enzymes of class 1.5 which act on CH—NH groups of the donor are furthermore preferred. The corresponding acceptors are NAD + , NADP + (1.5.1), oxygen (1.5.3), disulfides (1.5.4), quinones (1.5.5) or other acceptors (1.5.99).
[0088] Enzymes with oxygen (O 2 ) (1.5.3) and with quinones (1.5.5) as acceptors are also particularly preferred here.
[0089] Enzymes of class 1.6 which act on NADH or NADPH are furthermore preferred.
[0090] The acceptors here are NADP + (1.6.1), hemoproteins (1.6.2), disulfides (1.6.4), quinones (1.6.5), NO 2 groups (1.6.6) and a flavin (1.6.8), or some other acceptors (1.6.99).
[0091] Enzymes of class 1.6.5 with quinones as acceptors are particularly preferred here.
[0092] Enzymes which are furthermore preferred are those of class 1.7 which act on other NO 2 compounds as donors and have cytochromes (1.7.2), oxygen (O 2 ) (1.7.3), iron/sulfur proteins (1.7.7) or others (1.7.99) as acceptors.
[0093] Class 1.7.3 with oxygen as the acceptor is particularly preferred here.
[0094] Enzymes which are furthermore preferred are those of class 1.8 which act on sulfur groups as donors and have NAD + , NADP + (1.8.1), cytochromes (1.8.2), oxygen (O 2 ) (1.8.3), disulfides (1.8.4), quinones (1.8.5), iron/sulfur proteins (1.8.7) or others (1.8.99) as acceptors.
[0095] Class 1.8.3 with oxygen (O 2 ) and (1.8.5) with quinones as acceptors is particularly preferred.
[0096] Enzymes which are furthermore preferred are those of class 1.9 which act on hemo groups as donors and have oxygen (O 2 ) (1.9.3), NO 2 compounds (1.9.6) and others (1.9.99) as acceptors.
[0097] Group 1.9.3 with oxygen (O 2 ) as the acceptor (cytochrome oxidases) is particularly preferred here.
[0098] Enzymes of class 1.12 which act on hydrogen as the donor are furthermore preferred.
[0099] The acceptors are NAD + or NADP + (1.12.1) or others (1.12.99).
[0100] Enzymes of class 1.13 and 1.14 (oxygenases) are furthermore preferred.
[0101] Enzymes which are furthermore preferred are those of class 1.15 which act on superoxide radicals as acceptors.
[0102] Superoxide dismutase (1.15.1.1) is particularly preferred here.
[0103] Enzymes of class 1.16 are furthermore preferred.
[0104] NAD + or NADP + (1.16.1) or oxygen (O 2 ) (1.16.3) act as acceptors.
[0105] Enzymes of class 1.16.3.1 (ferroxidase, for example ceruloplasmin) are particularly preferred here.
[0106] Enzymes which are furthermore preferred are those which belong to group 1.17 (action on CH 2 groups, which are oxidized to —CHOH—), 1.18 (action on reduced ferredoxin as the donor), 1.19 (action on reduced flavodoxin as the donor) and 1.97 (other oxidoreductases).
[0107] The enzymes of group 1.11 which act on a peroxide as the acceptor are furthermore particularly preferred. This sole subclass (1.11.1) contains the peroxidases.
[0108] Enzymes which are particularly preferred here are the cytochrome C peroxidases (1.11.1.5), catalase (1.11.1.6), peroxidase (1.11.1.6), iodide peroxidase (1.11.1.8), glutathione peroxidase (1.11.1.9), chloride peroxidase (1.11.1.10), L-ascorbate peroxidase (1.11.1.11), phospholipid hydroperoxide glutathione peroxidase (1.11.1.12), manganese peroxidase (1.12.1.13) and diarylpropane peroxidase (ligninase, lignin peroxidase) (1.11.1.14).
[0109] The enzymes of class 1.10 which act on biphenols and related compounds are especially preferred. They catalyze the oxidation of biphenols and ascorbates. NAD + , NADP + (1.10.1), cytochromes (1.10.2), oxygen (1.10.3) or others (1.10.99) function as acceptors.
[0110] Enzymes of class 1.10.3 with oxygen (O 2 ) as the acceptor are in turn particularly preferred among these.
[0111] Particularly preferred enzymes of this class are the enzymes catechol oxidase (tyrosinase) (1.10.3.1), L-ascorbate oxidase (1.10.3.3), o-aminophenol oxidase (1.10.3.4) and laccase (benzenediol:oxygen oxidoreductase) (1.10.3.2), the laccases (benzenediol:oxygen oxidoreductase) (1.10.3.2) being particularly preferred.
[0112] The enzymes mentioned are commercially obtainable or can be obtained by standard processes. Possible organisms for production of the enzymes are, for example, plants, animal cells, bacteria and fungi. In principle, both naturally occurring organisms and organisms modified by genetic engineering can be producers of enzymes. Parts of one-cell or multicell organisms, above all cell cultures, are also conceivable as producers of enzymes.
[0113] White rot fungi, such as Pleurotus, Phlebia and Trametes, for example, are used for the particularly preferred enzymes, such as those from group 1.11.1, but above all 1.10.3, and in particular for the production of laccases.
[0114] The multi-component system according to the invention comprises at least one oxidizing agent. Oxidizing agents which can be employed are, for example, air, oxygen, ozone, H 2 O 2 , organic peroxides, peracids, such as peracetic acid, performic acid, persulfuric acid, pernitric acid, metachloroperoxybenzoic acid and perchloric acid, perborates, peracetates, persulfates, peroxides or oxygen species and free radicals thereof, such as OH; OOH; singlet oxygen, superoxide (O 2 + ) ozonide, the dioxygenyl cation (O 2 + ), dioxirane, dioxetanes or Fremy radicals.
[0115] Those oxidizing agents which either can be generated by the corresponding oxidoreductases, for example dioxiranes from laccases plus carbonyls, or which can regenerate the mediator chemically or can react with the mediator directly are preferably employed.
[0116] The invention also relates to the use of substances which are suitable according to the invention as mediators for modifying, degrading or bleaching lignin, lignin-containing materials or similar substances.
[0117] The activity of the multi-component system for modifying, degrading or bleaching of lignin, lignin-containing materials or similar substances is often increased further if Mg 2+ ions are also present in addition to the constituents mentioned. The Mg 2+ ions can be employed, for example, as salt, such as, for example, MgSO 4 . The concentration is in the range from 0.1 to 2 mg/g of lignin-containing material, preferably 0.2-0.6 mg/g.
[0118] In some cases, a further increase in the activity of the multi-component system according to the invention can be achieved by the multi-component system also comprising, in addition to the Mg 2+ ions, complexing agents, such as, for example, ethylenediaminetetraacetic acid (EDTA), diethylenetriaminepentaacetic acid (DTPA), hydroxyethylenediaminetriacetic acid (HEDTA), diethylene-triaminepentamethylenephosphonic acid (DTMPA), nitrilotriacetic acid (NTA), polyphosphoric acid (PPA) and the like. The concentration is in the range from 0.2 to 5 mg/g of lignin-containing material, preferably 1-3 mg/g.
[0119] The multi-component system according to the invention is used in a process for the treatment of lignin, for example, by mixing the components a) to c) selected in each case with an aqueous suspension of the lignin-containing material simultaneously or in any desired sequence.
[0120] A process using the multi-component system according to the invention in the presence of oxygen or air under normal pressure up to 10 bar in a pH range from 2 to 11 at a temperature from 20 to 95° C., preferably 40-95° C., and a pulp consistency of 0.5% to 40% by weight is preferably carried out. The pulp consistency percentage by weight is based upon the total weight of the system.
[0121] An unusual and surprising finding for the use of enzymes in bleaching pulp is that when the multi-component system according to the invention is employed, an increase in the pulp consistency causes a considerable increase in the kappa reduction that is possible.
[0122] A process according to the invention is preferably carried out at pulp consistencies of 8% to 35% by weight, particularly preferably 9% to 15% by weight, for economic reasons. The pulp consistency percentage by weight is based upon the total weight of the system.
[0123] Surprisingly, it has furthermore been found that an acid wash (pH 2 to 6, preferably 4 to 5) or Q stage (pH 2 to 6, preferably 4 to 5) before the enzyme mediator stage leads to a considerable reduction in kappa number in some pulps in comparison with treatment without this specific pretreatment. Chelating agents which are employed in the Q stage are the substances customary for this purpose (such as, for example, EDTA or DTPA). They are preferably employed in concentrations of 0.1% to 1% (w/w based on dry pulp), particularly preferably 0.1% to 0.5% (w/w based on dry pulp).
[0124] Preferably, 0.01 to 100,000 IU of enzyme per g of lignin-containing material are employed in the process according to the invention. Particularly preferably, 0.1 to 100, and especially preferably 1 to 40 IU of enzyme per g of lignin-containing material are employed (1 U corresponds to the conversion of 1 μmol of 2,2′-azino-bis(3-ethyl-benzothiazoline-6-sulfonic acid diammonium salt) (ABTS)/minute/ml of enzyme).
[0125] 0.01 mg to 100 mg of oxidizing agent per g of lignin-containing material are preferably employed in the process according to the invention. 0.01 to 50 mg of oxidizing agent per g of lignin-containing material are particularly preferably employed.
[0126] 0.5 to 80 mg of mediator per g of lignin-containing material are preferably employed in the process according to the invention. 0.5 to 40 mg of mediator per g of lignin-containing material are particularly preferably employed.
[0127] At the same time, reducing agents which, together with the oxidizing agents present, serve to establish a particular redox potential, can be added.
[0128] Reducing agents which can be employed are sodium bisulfite, sodium dithionite, ascorbic acid, thio compounds, mercapto compounds or glutathione and the like.
[0129] The reaction proceeds with the addition of air or oxygen or under an increased oxygen or air pressure in the case of laccase, and with hydrogen peroxide in the case of the peroxidases (for example lignin peroxidases or manganese peroxidases). The oxygen can also be generated here in situ, for example, by hydrogen peroxide+catalase, and the hydrogen peroxide can be generated in situ by glucose+GOD or other systems.
[0130] Agents which form free radicals or agents which trap free radicals (trapping of, for example, OH or OOH radicals) can furthermore be added to the system. These can improve the interaction between the redox and free radical mediators.
[0131] Other metal salts can also be added to the reaction solution.
[0132] These are important, in interaction with chelating agents, as agents which form free radicals or redox centers. The salts form cations in the reaction solution. Such ions are, inter alia, Fe 2+ , Fe 3+ , Mn 2+ , Mn 3+ , Mn 4+ , CU 2+ Ca 2+ , Ti 3+ Cer 4+ and Al 3+ .
[0133] The chelates present in the solution can furthermore serve as mimic substances for the enzymes, for example for the laccases (copper complexes) or for the lignin peroxidases or manganese peroxidases (hemocomplexes). Mimic substances are to be understood as those substances which simulate the prosthetic groups of (in this case) oxidoreductases and can catalyze, for example, oxidation reactions.
[0134] NaOCl can furthermore be added to the reaction mixture. This compound can form singlet oxygen by interaction with hydrogen peroxide.
[0135] Finally, it is also possible to operate with the use of detergents. Possible detergents are nonionic, anionic, cationic and amphoteric surfactants. The detergents can improve the penetration of the enzymes and mediators in the fiber.
[0136] It may likewise be necessary for the reaction to add polysaccharides and/or proteins. Polysaccharides which are to be mentioned here in particular are glucans, mannans, dextrans, levans, pectins, alginates or plant gums and/or intrinsic polysaccharides formed by the fungi or polysaccharides produced in the mixed culture with yeasts, and proteins which may be mentioned here in particular are gelatins and albumin.
[0137] These substances chiefly serve as protective colloids for the enzymes.
[0138] Other proteins which can be added are proteases, such as pepsin, bromelin, papain and the like. These can serve, inter alia, to achieve better access to the lignin by degradation of the extensin C, a hydroxyproline-rich protein, present in wood.
[0139] Other possible protective colloids are aminoacids, simple sugars, oligomeric sugars, PEG types of the most diverse molecular weights, polyethylene oxides, polyethyleneimines and polydimethylsiloxanes.
[0140] The process according to the invention can be employed not only for delignification (bleaching) of sulfate, sulfite, organosol or other pulps and of wood pulps. The process of the invention can also be used for the production of pulps generally, whether from woody or annual plants, when defibrillation is by the customary cooking processes (possibly combined with mechanical processes or pressure). Thus, very gentle cooking to kappa numbers which can be in the range of about 50-120 kappa, is ensured.
[0141] For bleaching of pulps and also for the production of pulps, the treatment can be repeated several times, either after washing and extraction of the treated pulp with NaOH or without these intermediate steps. This leads to kappa values which can be reduced considerably further still and to considerable increases in whiteness. An O 2 stage can likewise be employed before the enzyme/mediator treatment, or, as has already been mentioned, an acid washing or Q stage (chelating stage) can also be carried out.
[0142] Other objects and features of the present invention will become apparent from the following Examples, which disclose the embodiments of the present invention. It should be understood, however, that the Examples are designed for the purpose of illustration only and not as a definition of the limits of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
Enzymatic Bleaching with N-hydroxyacetanilide and Softwood Sulfate Pulp
[0143] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0144] A) 56.5 mg of N-hydroxyacetanilide are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0145] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0146] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0147] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0148] Thereafter, the pulp is washed over a nylon screen (30 gm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0149] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 2
Enzymatic Bleaching with N-benzoyl-N-phenylhydroxylamine and Softwood Sulfate Pulp
[0150] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0151] A) 80 mg of N-benzoyl-N-phenylhydroxylamine are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0152] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U -conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0153] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0154] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0155] Thereafter, the pulp is washed over a nylon screen (30 μm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0156] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 3
Enzymatic Bleaching with N-hydroxy-3-oxobutyranilide and Softwood Sulfate Pulp
[0157] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0158] A) 72.5 mg of N-hydroxy-3-oxobutyranilide are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0159] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0160] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0161] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0162] Thereafter, the pulp is washed over a nylon sieve (30 Am) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0163] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 4
Enzymatic Bleaching with N-hydroxy-4-cyanoacetanilide and Softwood Sulfate Pulp
[0164] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0165] A) 66 mng of N-hydroxy-4-cyanoacetanilide are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0166] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0167] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0168] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0169] Thereafter, the pulp is washed over a nylon screen (30 gm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0170] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 5
Enzymatic Bleaching with Phenyl N-hydroxy-N-phenylcarbamate and Softwood Sulfate Pulp
[0171] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0172] A) 86 mg of phenyl N-hydroxy-N-phenylcarbamate are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0173] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0174] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0175] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0176] Thereafter, the pulp is washed over a nylon screen (30 μm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0177] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 6
Enzymatic Bleaching with N-hydroxy-N-phenylformamide and Softwood Sulfate Pulp
[0178] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0179] A) 51.5 mg of N-hydroxy-N-phenylformamide are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0180] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0181] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0182] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0183] Thereafter, the pulp is washed over a nylon screen (30 μm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0184] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 7
Enzymatic Bleaching with N-hydroxy-N-phenyl-pivalamide and Softwood Sulfate Pulp
[0185] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0186] A) 72.5 mg of N-hydroxy-N-phenyl-pivalamide are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0187] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0188] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0189] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0190] Thereafter, the pulp is washed over a nylon screen (30 μm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0191] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 8
Enzymatic Bleaching with 1-hydroxy-3,4-dihydroquinolin-2(1H)-one and Softwood Sulfate Pulp
[0192] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0193] A) 61.2 mg of 1-hydroxy-3,4-dihydroquinolin-2(1H)-one are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0194] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0195] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0196] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0197] Thereafter, the pulp is washed over a nylon screen (30 μm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0198] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 9
Enzymatic Bleaching with N-hydroxy-(2-methyl)-acetanilide and Softwood Sulfate Pulp
[0199] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0200] A) 60.1 mg of N-hydroxy-(2-methyl)-acetanilide are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0201] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0202] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0203] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0204] Thereafter, the pulp is washed over a nylon screen (30 Am) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0205] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
EXAMPLE 10
Enzymatic Bleaching with Ethyl 4-(N-acetyl-hydroxylamino)-benzoate and Softwood Sulfate Pulp
[0206] 5 g of bone-dry pulp (softwood O 2 delignified), pulp consistency 30% (about 17 g moist) are added to the following solutions:
[0207] A) 83.7 mg of ethyl 4-(N-acetyl-hydroxylamino)-benzoate are added to 20 ml of tap water, while stirring, and the pH is adjusted with 0.5 mol/l of H 2 SO 4 solution such that pH 4.5 results after addition of the pulp and the enzyme.
[0208] B) An amount of laccase from Trametes versicolor is added to 5 ml of tap water such that an activity of 15 U (1 U=conversion of 1 μmol of ABTS/minute/ml of enzyme) per g of pulp results.
[0209] Solutions A and B are brought together and topped up to 33 ml. After addition of the pulp, the mixture is mixed with a dough kneader for 2 minutes.
[0210] The pulp is then introduced into a reaction bomb preheated to 45° C. and incubated under an increased oxygen pressure of 1-10 bar for 1-4 hours.
[0211] Thereafter, the pulp is washed over a nylon screen (30 gm) and extracted for 1 hour at 60° C. at a pulp consistency of 2% with 8% of NaOH per g of pulp.
[0212] After renewed washing of the pulp, the kappa number is determined. See Table 1 for the result.
TABLE 1 Results of EXAMPLES 1 to 10 Mediator Enzyme Incu- Ligin dosage dosage bation degra- [mg/5 g [U/g of time dation Substance of pulp] pulp] [hours] [%] N-Hydroxyacetanilide 56.5 15 2 28.9 N-Benzoyl-N-phenylhydroxyl- 80 15 2 24.8 amine N-Hydroxy-3-oxo-butyroanilide 72.5 15 2 16.1 N-hydroxy-4-cyanoacetanilide 66 15 2 35.6 Phenyl N-hydroxy-N-phenyl- 86 15 2 20.0 carbamate N-Hydroxy-N-phenylformamide 51.5 15 2 22.2 N-Hydroxy-N-phenyl-pival- 72.5 15 2 19.6 amide 1-Hydroxy-3,4-dihydroquino- 61.2 15 2 23.7 lin-2(1H)-one N-Hydroxy-(2-methyl)-ace- 60.1 15 2 34.0 tanilide Ethyl 4-(N-acetyl-hydroxyl- 83.7 15 2 40.0 amino)-benzoate
[0213] While several embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims. | Multi-component system for modifying, degrading or bleaching lignin, lignin-containing materials or similar substances, includes
(a) if appropriate at least one oxidation catalyst;
(b) at least one suitable oxidizing agent; and (c) at least one mediator, wherein the mediator is chosen from the group consisting of N-aryl-N-hydroxyamides. | 3 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application No. 61/632,386, filed Jan. 24, 2012, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
Microfluidic channels and the control of fluid and/or fluid suspended particle flow within them are useful in many applications. Drug discovery and diagnosis of disease, for example may require the control of movement of reagents and biological samples to and from chambers where reactions may take place. Sorting of cells for example may require cells arriving from one or more sources to be sent to one or more destinations. Such sorting may require a high speed valves to redirect the flow of fluid and particles dynamically based on analysis of the type of cells or particles arriving, on a cell by cell or particle by particle basis.
One method to affect fluid flow within a channel is to create a vapor bubble within the channel, or adjacent to the channel so as to affect the flow within the channel. Small 10-100 μm vapor bubbles can be created within 1-100 μS of turning on a laser and they will also re-condense into liquid in approximately the same time frame when the laser is turned off.
It was disclosed by Jian et al., LASER-ACTUATED MICRO-VALVES AND MICRO-PUMPS, 16th International Solid-State Sensors, Actuators and Microsystems Conference, Jun. 5-9, 2011, that vapor bubbles have been created by the heating effect of a laser light being absorbed by a gold target on the channel wall. U.S. Pub. No. 2011/0030808, disclosed that vapor bubbles have been created in cavities adjacent to a channel with electrometric walls so as to deflect the walls and create changes in the fluid flow within the channel. U.S. Pub. No. 2008/0261295 disclosed that lasers are used to trap particles by surrounding them with light, but not through vapor bubble creation.
The prior art, e.g., U.S. Pub. No. 2011/0030808, has several shortcomings; first in an application where cells or particles within the fluid are sorted into one of two paths for example, even though particles may be selectively deflected to enter one or the other channel, fluid flow is present in both paths at all times, thus the sample fluid containing the particles of interest is continuously diluted. This type of dilution is not present in “Sort in air” systems (e.g., U.S. Pat. No. 6,281,018 and U.S. Pat. No. 5,700,692), where only the sample of interest is sent into the collection chamber. A further shortcoming of U.S. Pub. No. 2011/0030808 is that it requires the construction of flexible flow channels of an electrometric substance, where as a glass or quartz cuvette would be more durable.
The prior art (e.g., Jian et al.) also has shortcomings in that it requires an opaque target to be deposited on one side of the flow channel walls, further because heat is absorbed by the walls and then transferred to the fluid, the action is very slow in the several millisecond regime.
BRIEF SUMMARY OF THE INVENTION
In many embodiments, a fluidic switch is created within a microfluidic pathway having one or more inlets, and one or more outlets, with fluid flow within one or more channels being substantially blocked or allowed by the presence or absence of a vapor bubble. The vapor bubble spatial position and time of creation are changed by optical switches or spatial light modulators, or controlling of laser emission.
In many embodiments, vapor bubbles are created in a medium by non-linear means, including but not limited to, multiple photon absorption due to the high power density (greater than 1 MW/cm squared) of the focused light. The medium would not normally absorb a significant fraction of the light (less than 10% absorption).
In many embodiments, the light of the laser is in the far ultraviolet or far infrared portions of the spectrum, where significant absorption of the light will occur within the dimensions of the channel cross section, by virtue of the light absorption coefficient of the fluid being several orders of magnitude greater at these frequencies than in the visible spectrum.
In many embodiments, the resistance to flow is maintained at a constant value, by way of allowing a bubble to re-condense in one channel while creating a new bubble in a different channel, or even at a different point in the same channel.
In many embodiments, fluid is flowed through a microfluidic pathway and a cavitation bubble is created using an optical element within the pathway to block fluid flow within the fluidic pathway.
In many embodiments, a system includes a microfluidic pathway for flowing a fluid, a laser source, and an optical element adapted to receive energy from the laser source and direct the energy to the fluid within microfluidic pathway. The optical element delivers energy to the fluid at a power density greater than 1 MW/cm 2 to create a cavitation bubble within the microfluidic pathway and thereby block flow of the fluid.
In many embodiments, a system includes a microfluidic pathway for flowing a fluid, a deep ultraviolet or deep infrared laser source, and an optical element adapted to receive energy from the laser source and direct the energy to the fluid within microfluidic pathway. The optical element delivers energy to the fluid at a power density to create a cavitation bubble within the microfluidic pathway and thereby block flow of the fluid.
In many embodiments, a fluid is flowed into an inlet channel of a microfluidic pathway at a constant flow rate, the microfluidic pathway including a first and second outlet channels fluidically connected to the inlet channel. A first cavitation bubble is created within the first outlet channel to block fluid flow out of the first outlet channel. A second cavitation bubble is created within the second outlet channel to block fluid flow out of the second outlet channel. Creation of the second cavitation bubble is initiated during or after the first cavitation bubble dissolves such that the constant flow rate is maintained.
In many embodiments, a system includes a microfluidic pathway for flowing a fluid. The microfluidic pathway includes an inlet channel and first and second outlet channels fluidically connected to the inlet channel. The system also includes a laser source and an optical element adapted to receive energy from the laser source and direct the energy to the fluid within the first and second outlet channels. The system also includes a controller adapted to use the laser source and optical element to perform a method in which a fluid is flowed into an inlet channel of a microfluidic pathway at a constant flow rate, the microfluidic pathway including a first and second outlet channels fluidically connected to the inlet channel. A first cavitation bubble is created within the first outlet channel to block fluid flow out of the first outlet channel. A second cavitation bubble is created within the second outlet channel to block fluid flow out of the second outlet channel. Creation of the second cavitation bubble is initiated during or after the first cavitation bubble dissolves such that the constant flow rate is maintained.
In many embodiments, the cavitation bubble is 1-100 μm in diameter.
In many embodiments, the power density is greater than 1 MW/cm 2 .
In many embodiments, the microfluidic pathway about the cavitation bubble is rigid.
In many embodiments, a laser source is directed at the optical element to create the fluidic switch.
In many embodiments, the optical element delivers energy to the fluid at a power density greater than 1 MW/cm2.
In many embodiments, the laser source delivers deep ultraviolet or deep infrared energy.
In many embodiments, the fluid flow is halted by the fluidic switch.
In many embodiments, the optical element comprises a spatial holographic light modulator, a diffractive or reflective MEMS based module, an acousto-optic light deflector.
In many embodiments, the fluid absorbs less than 10% energy from incident light.
In many embodiments, the fluid does not include any doping additives to alter energy absorption.
In many embodiments, blockage of the flow is maintained by allowing the cavitation bubble to re-condense while creating a new cavitation bubble at a different location within the fluid.
In many embodiments, blocking the fluid flow in the first outlet channel is reestablished by allowing the second cavitation bubble to re-condense while creating a new cavitation bubble in the first outlet channel at a different location than where the first cavitation bubble was created
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system diagram, according to many embodiments.
FIG. 2 is a diagram of a microfluidic switch, according to many embodiments.
FIG. 3 is a diagram of a microfluidic switch, according to many embodiments.
FIG. 4 is a drawing of the light absorption spectrum of water.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a microfluidic pathway 10 , depicted as an inverted Y where fluid enters from the top 18 and is sent in to one of the two paths 19 or 20 of the inverted Y as desired. A laser source 11 emitting laser beam 12 creates microfluidic switches (cavitation/vapor bubbles 15 , 16 ) at one or the other branch of the Y by means of the optical element 13 so as to switch the flow of fluid to the branch that is not blocked. The laser source 11 can be any suitable laser type, such as a q-switching or cw diode laser, or a plurality of such lasers commonly focused. The laser source can include a control system, such as a general purpose or specific purpose computer, which is configured to operate the laser source 11 , optical element 13 , as well as flow controls (e.g., pumps, gates) for the microfluidic pathway 10 .
The microfluidic pathway according to known methodologies, such as disclosed in the references noted above, and in U.S. Pat. No. 6,769,444, which is incorporated by reference. For example, the microfluidic pathway 10 can be constructed from an etched substrate that is located between an upper substrate and lower substrate. Alternatively, the microfluidic pathway can be constructed from micro-tubing. Generally, the microfluidic pathway 10 will include a suitably transparent portion for passing laser light, or other energy. The microfluidic pathway 10 can be interconnected with various chambers and additional pathways. The internal width and height of the microfluidic pathway 10 can be substantially equal or unequal. In some embodiments, at least one of the width and height is approximately 50 μm, and can range from 5-200 μm. Although flexible membrane passages can be used to define at least a portion of the microfluidic pathway 10 , as is known in the art, the entire bounds of the microfluidic pathway 10 , at the point where the vapor bubble is created, can be constructed from a substantially rigid (e.g., glass, crystal, hard polymer) material, such as a glass or quartz cuvette.
The optical element 13 is actuated typically in less than 1 mS, preferably in 10 μS, in response to typically, but not restricted to, an electrical pulse, so as to switch the spatial destination of the laser beam within the microfluidic pathway 10 . Accordingly, resistance to flow is maintainable creating new bubbles at different locations within the microfluidic pathway 10 , as prior bubbles dissolve back into the fluid. For example, a first cavitation bubble can be created at a first location within the microfluidic pathway 10 to block fluid flow (substantially or completely). Over time, the first cavitation bubble will dissolve and flow will be restored. When this occurs, or before this occurs, a second cavitation bubble can be created at a second location within the microfluidic pathway 10 to continually block fluid flow. It follows that this process can be repeated as needed over a greater time period. Further, a predetermined time period can occur between dissolving the first cavitation bubble and creation of the second cavitation bubble, such that the fluid moves in pulses according to the length of the predetermined time period.
Particles of interest can be located between the first and second bubbles to gate movement of the particles. For example, the first bubble 16 can be created in outlet channel 20 of a Y channel, and the second bubble 15 can be created in a second outlet channel 19 of the Y channel. Alternating the creation of the first and second bubbles 15 / 16 causes fluid and particles of interest to flow into the channel in which a bubble is not present. For example, the second bubble 15 can be initiated at a particular time period (e.g., 3-20 μS) after the first bubble 16 is initiated. The particular time period can be such that the second bubble 15 is formed while the first bubble 16 is collapsing back into fluid, or immediately thereafter. In this manner, particles of interest can be routed to specific portions of the microfluidic pathway 10 while maintaining (i.e., not allowing the flow rate to drop below predetermined level) the flow rate into the inlet channel 17 . The controller can be configured to operate the laser source and optical element to perform such a method. The outlet channels 20 / 19 can be routed to a device for further analysis, such as a flow cytometer.
The optical element may be constructed of, but not limited to a single element such as a spatial holographic light modulator, a diffractive or reflective MEMS based module, an acousto-optic light deflector, or may be composed of multiple of such devices or fast shutters. The optical element 13 can be computer controlled and actuated by one or more servo motors to move the focusing point of the optical element 13 .
In many embodiments, the channel, which is typically only 50 μm wide, is filled with a transparent fluid, predominantly consisting of water. Water, or solutions of predominantly water, absorb less than 10% of the incident light, in the visible or near visible wavelengths, over a distance of 50 μm as shown in FIG. 4 . Cavitation will not occur or will only occur with difficulty since the laser radiation is not absorbed. U.S. Pub. No. 2011/0030808 mitigates this problem by having an adjacent channel where a fluid with a dye or particles which absorb the laser radiation flows in parallel with the stream to be deflected, the laser being focused on the adjacent channel. Jian et al. mitigates the absorption problem by providing a sputtered gold target on the walls of the channel, the laser being focused on the gold target. It should be understood that embodiments disclosed herein may operate without such targets or other doping additives to modify absorption of the fluid.
Thus, fluid may be transparent to the laser light, for example greater than 90% transmission in a 50 μm wide pathway, but yet cavitation can occur since the laser is focused to a point within the flow of fluid such that the energy density of the laser photon flux is greater than about 1 MW/cm-squared, preferably 10 MW/cm-squared. At such a density of photon flux, non-linear effects such as multi photon absorption by a single electron of a fluid atom, can lead to the creation of plasma, which then increases the absorption coefficient beyond what would be measured at low photon flux densities. The energy thus absorbed causes a cavitation bubble of size around 1-100 μm in diameter (e.g., large enough to completely fill the pathway of a microfluidic channel) to appear over a timer period of about 10 μS (e.g., 3-20 μS). Due to the high energy density, the cavitation bubble is a mixture of plasma and of the gaseous phase of the liquid.
More complex fluid flow architectures are possible and are shown by way of example only in FIG. 2 and FIG. 3 . In FIG. 2 , a plurality of inlet channels 25 and outlet channels 26 may selectively block access to a central chamber by the creating one or more vapor bubbles 27 . Blocking of the outlet channels 26 can occur in the manner described above, i.e., in an alternating fashion such that flow inlet is maintained into the inlet channels 25 . In FIG. 3 , a plurality of inlet channels 31 and outlet channels 33 may be selectively blocked by the presence of one or more vapor bubbles 32 . Blocking of the outlet channels 33 can occur in the manner described above, i.e., in an alternating fashion such that flow inlet is maintained into the inlet channels 33 .
A particular wavelength of laser may be used such that the fluid itself absorbs a significant fraction, for example greater than 50% absorption of the incident light in a distance of 50 μm. In FIG. 4 it is shown in the both charts (logarithmic and standard) that water has a very high absorption coefficient (approaching 10 6 cm −1 ) for deep ultraviolet energy (e.g., 10-100 nm, although greater or narrower ranges can be used depending on available lasers) in a 50 μm wide channel. In FIG. 4 it is shown in the greater chart that water has a very high absorption coefficient (between 10 4 -10 5 cm −1 ) for deep infrared energy (900-3000 nm, although greater or narrower ranges can be used depending on available lasers). Thus, energy sources, such as lasers, providing such types of energy can deliver energy at a substantially lower density to create cavitation bubbles in water.
All patents, patent applications, and other publications cited in this application are incorporated by reference in the entirety.
Although the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but merely as illustrations of some of the presently preferred embodiments. Many possible variations and modifications to the invention will be apparent to one skilled in the art upon consideration of this disclosure. | Fluid is flowed into an inlet channel of a microfluidic pathway at a flow rate, the microfluidic pathway including a first and second outlet channels fluidically connected to the inlet channel. A first cavitation bubble is created within the first outlet channel to block fluid flow out of the first outlet channel. A second cavitation bubble is created within the second outlet channel to block fluid flow out of the second outlet channel. Creation of the second cavitation bubble is initiated during or after the first cavitation bubble dissolves such that the flow rate is maintained. | 5 |
This invention is concerned with the extraction and recovery of copper and zinc from aqueous chloride liquors such as leach liquors obtained from a chlorination roast-leach of copper-lead-zinc sulphide ores or concentrates. A particular sequence of steps has been developed for the separation of copper and zinc from chloride solutions and their recovery.
The conventional refining of zinc usually comprises a hydrometallurgical route, alone or in combination with pyrometallurgy. Roasted concentrates are dissolved with dilute sulphuric acid to produce a solution containing zinc sulphate plus impurities. After a series of process steps to remove the impurities, the zinc is recovered by electrolysis, and the depleted zinc sulphate solution and regenerated sulphuric acid are returned to the leaching step. However, due to their mineralogy, some of the fine-grained, complex, zinc-bearing ores do not respond to the production of concentrates. Such complex sphalerite ores are to be found in large quantity in countries such as Canada, Australia and Norway. Differential flotation is relatively unsuccessful, and only at considerable loss of values.
Throughout Canada, there are many known deposits of zinc sulphides, mainly fine-grained sphalerite and galena, which are difficult to process by differential flotation for separation and recovery. Indeed, in treating the New Brunswick area ores, the present technology recovers only about 65% of the values by such means. Not only is there an economic loss to the plant, but the tailings, containing significant amounts of sulphides, oxidize and produce acid which continues to leach the remaining base metals. Thus an environmental problem is also created. At one New Brunswick location, for example, the total proven and probable reserves approximate 120 million tons averaging 9% Zn, 0.5% Pb, 1% Cu and 2 oz/ton Ag. Like McArthur River deposits in Australia, and such deposits elsewhere, much research has been devoted in the past to maximize metals recovery from the New Brunswick ores, and like the other ores, without much apparent success.
Present technology for treating such complex lead-copper-zinc sulphide ores includes a hydrometallurgical approach of leaching ores or concentrates in sulphuric acid. Following such leaching, the solution is purified by many step-wise operations involving precipitation and cementation, until finally a purified zinc solution is produced which is amenable to electrolysis for zinc cathode recovery. A variation of the conventional hydrometallurgical leaching route is a roast-leach process, followed by stage-wise purification steps. The limitation of the hydrometallurgical route or the roast-leach route is the number of process steps required to obtain a pure zinc product. Also, the tailings still contain sulphides and create environmental problems. In addition, conventional technology does not provide for the recovery of high-purity by-products.
Some investigations have been made of solvent extraction of various metals including zinc or copper from relatively simple chloride solutions. In the literature, tributylphosphate has been tested as extractant in separating zinc from impurities such as cadmium in chloride systems. Other extractants have been tested to extract zinc from chloride systems including carboxylic acids such as naphthenic acid, and Versatic 911 (trademark); primary and secondary amines; di-2-ethylhexylphosphoric acid; and mixtures of a substituted quinoline extractant (e.g. Kelex 100-trademark) and a carboxylic acid extractant (e.g. Versatic 911).
In the Espindesa process for treating solutions resulting from roasting and leaching of a pyrite cinder, a secondary amine extractant was used for zinc from chloride solution, followed by scrubbing, then water stripping and re-extracting with D2EHPA.
Some investigations have been reported on copper extraction from crude ferric chloride solution. A pilot process for treating sulphide concentrates used an oxime reagent LIX 64N (trademark-Hankel) for copper extraction (see J. C. Paynter, J. South African I.M.M., November 1973, pp. 158-170). In the Minimet process operating on sulphide ores and concentrates (see J. M. Demarthe, L. Gandon and A. Georgeaux, in Extractive Metallurgy of Copper-Hydrometallurgy and Electrowinning, Vol. 2, Proceedings of International Symposium, 1976, AIME, Pub. Port City Press, Baltimore, U.S.A., pp. 825-848) copper, from a cupric chloride leach, is extracted with LIX 65N, chloride is removed by water or CuSO 4 solution scrubbing, and stripping is accomplished with spent electrolyte from conventional electrowinning of copper sulphate solution.
Thus while some solvent extraction operations on certain specific chloride solutions have been reported, the extraction of complex copper-zinc-lead, etc., liquors such as would result from the chlorination-leach of complex galena-sphalerite-chalcopyrite ores, and recovery of metals, has not been dealt with. It would be desirable to develop a fully integrated chlorination-solvent extraction-electrowinning process able to handle such complex ores.
Summary of the Invention
An integrated process has been developed for extracting copper and zinc from aqueous chloride solutions containing lead, copper, zinc and impurities, comprising
(a) separating lead from the aqueous chloride solution by at least one of crystallization, precipitation and solvent extraction;
(b) solvent extracting the resulting aqueous solution with a first water-immiscible organic liquid comprising a copper-chelating extractant reagent to load copper into the organic phase;
(c) scrubbing the Cu-loaded organic phase with at least one aqueous liquid selected from water and Na 2 SO 4 solution to remove impurities;
(d) stripping the Cu from this first organic phase with aqueous CuSO 4 -H 2 SO 4 solution and passing the Cu-containing sulphate strip solution to a Cu electrowinning stage;
(e) scrubbing this stripped organic phase with water to remove sulphate, and recycling this first organic liquid to extraction stage (b);
(f) solvent extracting the remaining aqueous chloride solution with a second water-immiscible organic liquid comprising tributylphosphate to load zinc thereon;
(g) scrubbing the Zn-loaded organic phase with aqueous ZnCl 2 -NaCl solution to remove impurities;
(h) stripping the Zn from this second organic phase with aqueous ZnCl 2 -HCl solution and passing the Zn-containing chloride strip solution to a Zn electrowinning stage; and
(i) separating impurities from the residual aqueous phase sufficiently to avoid detrimental build-up thereof, and recovering chloride solution for recycle.
As an example of a preferred overall process, sulphide ore or concentrate containing copper, zinc, lead and iron, is fed to a furnace where the material is chlorinated at a temperature within about 300°-700° C. Next, under an oxidizing atmosphere, at about 425°-475° C., some iron is volatilized as gaseous FeCl 3 while the remainder is converted to Fe 2 O 3 . In the following brine leaching stage, essentially all the iron (Fe 2 O 3 ) remains insoluble with the residue. After hot filtration, the leach liquor is allowed to cool to crystallize PbCl 2 from solution. The resultant supernatent liquor, which is then fed to solvent extraction, usually contains
zinc in about 20 to about 40 g/L
copper in about 0.1 to about 2 g/L
lead in about 0.1 to about 2 g/L
iron-less than about 0.1 g/L
and other minor impurities, about 2-4 M (preferably 3 M) in NaCl at a pH with about 1 to 5 (preferably 2-4). The copper and zinc are recovered by solvent extraction sequentially, as discussed in detail below, yielding separate copper and zinc solutions for electrowinning, and the final raffinate is returned to the leach circuit after removing and treating a bleed stream to avoid detrimental impurity build-up. The lead chloride may be recovered as high purity lead, preferably by fused salt electrolysis with chlorine being recycled.
DESCRIPTION OF THE DRAWINGS
The FIG. 1 drawing is a flowsheet of the overall process for the treatment of Pb/Cu/Zn materials.
FIG. 2 is a diagram of a preferred solvent extraction copper recovery circuit showing number of stages and recycle features.
FIG. 3 is a similar diagram of a preferred solvent extraction zinc recovery circuit.
DETAILED DESCRIPTION
The process can operate on any chloride solution containing lead, copper, and zinc. Frequently, this feed solution can be derived from ores, concentrates, mattes or tailings, particularly sulphides, by a chlorination roast, oxidation of any iron, and a leach. The chlorinated calcine is leached in an aqueous acidic media, most suitably a brine media having a salt concentration equivalent to about 2-4 M NaCl at a pH of about 1 to 5 (preferably 3 M NaCl at pH 2-4). Such a leach liquor may contain
zinc in about 20 to about 40 g/L
lead in about 6 to about 10 g/L
copper in about 0.1 to about 2 g/L
iron in leass than about 0.2 g/L
and other impurities such as Cd, Bi, Ag, etc. The solid residue would be discarded as tailings or treated for further recovery of iron, gold, silver, etc. Suitable chloride solutions can be derived from other materials and by other routes.
Lead is separated from the chloride solution by at least one step selected from: crystallization of lead chloride; precipitation, e.g. as PbSO 4 ; or by solvent extraction, e.g. preferably utilizing quaternary amine extraction reagents. The preferred route to lead metal recovery is by fused salt electrolysis of lead chloride crystals.
COPPER EXTRACTION
After removal of substantially all of the lead, the chloride liquor is extracted to remove copper. A copper-chelating extractant reagent in a suitable organic solvent is used. Many tests were carried out to select the most suitable extraction reagent considering equilibrium Cu distribution, kinetics, metal discrimination, scrubbing and stripping, and rate of phase separation. While other reagents gave satisfactory performance, our test results indicated that oxime-type copper-chelating reagents would be most suitable with alkyl-substituted salicylaldoxime reagents preferred. One preferred salicylaldoxime has the formula: ##STR1## These oximes are dissolved in a water-immiscible diluent such as liquid hydrocarbons. Other oxime-type copper-chelating extraction reagents which may be used include SME529 (Shell-trademark) and LIX 65N, the choice depending upon chloride concentration and pH. The amount of Cu reagent dissolved in the total solvent or diluent is normally within about 1 to 10% by volume.
It has been found necessary to scrub the copper-loaded organic phase to remove chloride impurity. Chloride removal is required to convert to a sulphate system amenable to conventional electrowinning. Water itself or sodium sulphate solution are suitable scrub liquids. Room temperature was found more effective than 50° C. for scrubbing chloride. Stripping of copper from the organic is accomplished by a sulphuric acid solution containing some copper (as CuSO 4 ). A preferred strip solution contains about 25-35 g Cu/L and about 120-180 g H 2 SO 4 /L, usually about 30 Cu/L and 150 g H 2 SO 4 /L. A sulphate return electrolyte from the Cu electrowinning is a very suitable stripping medium.
After stripping the loaded solvent with the acidified CuSO 4 solution, the stripped solvent phase would be recycled to the Cu extraction. With continual recycle, some sulphate may be released into the chloride feed liquor. Scrubbing with water (e.g. at O/A of 5/1 and room temperature) was found most effective for sulphate removal from the stripped solvent phase. After 500 cycles through extraction-stripping of a salicylaldoxime reagent in a hydrocarbon diluent, no evidence of reagent degradation was evident and solvent losses were minimal (<0.25 ppm of salicylaldoxime reported in aqueous chloride solution).
ZINC EXTRACTION
The residual aqueous chloride liquor (Cu raffinate) is next solvent-extracted to remove zinc. We have found TBP (tributylphosphate) to be a preferred zinc extraction reagent due to the ease of stripping therefrom. The TBP will be diluted with a water-immiscible solvent such as hydrocarbon liquids, e.g. aliphatic such as kerosene or aromatic such as toluene. Most suitably, the amount of TBP in the organic phase will be within about 30 to about 80% by wt., preferably about 60% if treating high zinc liquors. It has been found desirable to pre-equilibrate the TBP-solvent phase with aqueous HCl. Tests have shown no evidence of significant TBP loss or degradation with continual use (500 cycles).
The zinc-loaded organic phase is scrubbed to remove impurities such as copper and lead. A scrub solution of ZnCl 2 -NaCl in water was found preferred in removing extracted Cu and Pb yet without loss of zinc. The Zn preferably ranges from about 15 to 40 g Zn/L and the NaCl from about 120 to 200 g NaCl/L. One preferred scrub solution is about 25 g Zn/L in 3 M NaCl at pH 3.5-4.
Zinc is stripped from the organic phase with an aqueous ZnCl 2 -HCl solution, preferably having about 10-20 g Zn/L in HCl at pH about 1. About 10 to 20 g HCl/L is a suitable range. The stripped solvent will still contain about 1-1.5 g Zn/L and will be recycled to Zn extraction without further scrubbing.
The residual chloride liquor phase (Zn raffinate) usually is recycled to an initial leach stage. It may be necessary to purify part of this residual liquor to avoid build-up of impurities such as Cd, Bi, etc. Purification steps which may be used include ion exchange, and precipitation, preferably to remove substantially all cations and anions other than chloride.
The following Example is illustrative.
A sulphide ore concentrate, having the analysis shown in Table 1, was fed to a furnace where it was chlorinated at about 375° C.
TABLE 1______________________________________Analysis of Ore and Concentrate (%)Analysis Ore Concentrate______________________________________Zn 9.02 29.9Cu 0.42 0.74Pb 3.15 9.48Fe 31.7 19.9S 37.9 36.6SiO 0.22Ag.sup.+2 118* 270*______________________________________ *g/tonne
Elemental sulphur was condensed and recovered as a byproduct. The chlorinated material was transported to a second furnace, where, under an oxidizing atmosphere at 450° C., some iron was volatilized as FeCl 3 while the remainder was converted to Fe 2 O 3 . The resulting calcine was leached with brine (concentration about 3 M NaCl) while hot, and hot filtration carried out. The leach solution (filtrate) had the approximate analysis in g/L 28.5 Zn, 0.4 Cu, 8.5 Pb, <0.1 Fe, 3 M NaCl and pH about 4.
On cooling the leach solution, PbCl 2 crystallized out lowering the level of Pb in the supernatent to about 0.4 g/L. No further lead removal step was considered necessary and after filtering off the PbCl 2 , the leach solution was fed to the Cu extraction.
Continuous Cu extraction was run in a series of stagewise mixer settlers of 620 mL capacity. The extractant was 5% by vol. of the salicylaldoxime type Acorga P5300 (trademark-Acorga Ltd.) extractant in Shell 140 (trademark) hydrocarbon solvent. It is understood that this P5300 extractant contains about 25% by wt. of the anti-isomer of 5-nonyl salicylaldoxime and about 72% p-nonylphenol. The residence time in each mixer was 0.5 minutes and an A/O ratio of 3.5 was used (311 mL aqueous, 89 mL organic). Typical results for a 2 to 4-stage run are shown in Table 2, indicating good extraction of copper and increasing discrimination over zinc, lead and iron with an increasing number of stages.
Scrubbing was carried out at room temperature using both Na 2 SO 4 and water as the scrub solutions, as indicated by the earlier bench-scale tests. Scrubbing was performed at an O/A of 5/1, (300 mL organic, 60 mL aqueous) in 6 stages. The scrubbed solvent was stripped in 3 stages, O/A 6/1, using a strip solution containing 28.7 g Cu/L in 150 g H 2 SO 4 /L. The results of scrubbing and subsequent stripping at room temperature, shown in Table 3, indicate that water was as effective as Na 2 SO 4 for scrubbing of chloride, and that a relatively high purity of copper strip feed to electrowinning resulted. Narrower dispersion bands and, therefore, better coalescence rates were achieved with the water scrub solution. A residual amount of approximately 0.7 g Cu/L remained on the stripped solvent in equilibrium with the stripping copper sulphate solution. This residual amount could be removed, if desired, by stripping with a solution containing 150 g H 2 SO 4 /L, to produce a stripped solvent containing about 0.01 g Cu/L, but at an extra cost. Prior to recycling the stripped solvent to Cu extraction, the solvent was scrubbed with water to remove any sulphate present. The loaded strip solution was fed to an electrolysis stage and Cu electrowon as described below.
The raffinate from the copper circuit, fed to a six-stage zinc extraction circuit, contained 28.5 g Zn/L, 0.016 g Cu/L, 0.40 g Pb/L, 0.003 g Fe as Fe +3 /L, 3.0 M NaCl at pH 1.39. The extractant was 60% TBP is Solvesso 150 (trademark) hydrocarbon diluent, pre-equilibrated with 50 g HCl/L at O/A 5/1. Extraction was at ambient temperature at an O/A 2.1/1 (237 mL/min solvent, 113 mL/min aqueous) in 6 stages to obtain a loading of 13.6 g Zn/L. The retention time in each mixer was 1.8 minutes. Following extraction, the loaded solvent was stripped in 6 stages at ambient temperature and O/A 2.5/1 using 15 g Zn/L at pH 1.0 (HCl). No scrubbing was attempted in the initial zinc circuits, but subsequently, following a series of electrowinning studies, scrubbing stages were added.
TABLE 2______________________________________Copper Extraction Circuit - Extractant 5% P5300 in Shell 140 Discrimination Extraction in LoadingStage Equil. Raffinate Solvent % Cu Cu/ Cu/ Cu/No. pH Cu Cu Ext'd Zn Pb Fe______________________________________2 1.29 0.013 1.33 96.3 1700 1320 15003 1.30 0.004 1.36 98.8 2300 1360 19004 1.29 0.002 1.40 99.8 3500 1400 2300______________________________________
TABLE 3__________________________________________________________________________Scrubbing of Organic for Chloride Removal (6 Stages) Scrub Stripped Loaded Strip Solution Solution Solvent FreeScrubEquil. Analysis Cu Cl.sup.- Cu Acid Cl Zn Pb Fe Purity in StripSolutionpH Cl.sup.- (g/L) ppm g/L g/L ppm ppm ppm ppm Cu/Zn Cu/Pb Cu/Fe__________________________________________________________________________50 g/LNa.sub.2 SO.sub.44.2 44 ppm 0.73 10 39.3 129 12.4 6 1 60 6550 39000 6500Water4.17 33 0.67 10 40.3 129 16 5 5 95 8000 8000 425__________________________________________________________________________
The results for the extraction and stripping circuits are shown in Tables 4 and 5. A residual value of about 2.4 g Zn/L remained in the solvent after stripping. In spite of the fact that no scrub stages were included, the purity of the aqueous strip solution with respect to Pb, Fe and Cu was reasonably good as is shown in Table 6. Scrubbing would have improved the Zn purity in the loaded strip solution shown in Table 6, and is recommended.
Smooth, compact copper deposits were electrowon at 35° C. and 269 A/m 2 (25 A/ft 2 ) current density from the strip electrolytes (Table 3) using 10 mg/L Jaguar C13 (trademark of Stein, Hall & Co. for a HMW guar gum derivative) as the addition agent to promote smooth copper deposition. The current efficiency for the 26 h deposits was 98-99%. These results are in good agreement with those obtained for copper electrowinning from simulated electrolytes.
Smooth, compact, dendrite-free, 24 h zinc deposits were electrowon at 35° C. and 323 A/m 2 (30 A/ft 2 ) from a zinc strip electrolyte (38.7 g Zn/L and impurities, in ppm, of 10 Pb, 0.5 Cu, 0.06 Cd, 0.1 Co, 0.6 Fe, 0.1 Ni, <0.1 As, <5 Sb) using a diaphragm cell with electrolyte circulation (by air-sparging) and with 15 mg/L tetrabutyl-ammonium chloride as the addition agent. The current efficiency of 88.9% was improved to 96.2% when the electrolyte was treated with activated carbon prior to electrowinning the zinc. The activated carbon treatment, which removed entrained organic matter from the electrolyte, also improved the quality of the zinc deposits.
As a result of our tests, both bench scale and pilot plant, the flowsheets shown in FIGS. 2 and 3 have been developed for Cu and Zn recovery circuits in a commercial-scale plant.
TABLE 4______________________________________Zinc Extraction Circuit - 60% TBP In Solvesso 150Feed Raffinate Extrac-Zn Zn Loaded Solvent (g/L) tion (%)(g/L) pH (g/L) pH Zn Pb Fe Cu Zn______________________________________28.5 1.39 2.05 1.0 12.6 .005 .0005 .0002 92.8______________________________________
TABLE 5______________________________________Zinc Stripping CircuitStrip Feed Stripped Solvent Loaded StripZn pH (g/L) (g/L)(g/L) Feed Equil. Zn Pb Fe Zn Pb Fe______________________________________15 1.0 0.83 2.35 .001 .0009 39.5 0.010 0.0007______________________________________
TABLE 6______________________________________Purity in Extraction and Stripping Circuits Zn/Pb Zn/Fe Zn/Cu______________________________________Loaded Solvent 2,480 24,800 62,000Loaded Strip 3,950 56,400______________________________________
Based on assumed daily feed of 909.8 tonnes (1003 tons) of concentrate to chlorination roasting and assuming 95% overall recovery in the chlorination-leaching-purification stages, the production would be 259.2 tonnes (285.8 tons) of zinc per day. For a 350 day operation, this is equivalent to 90,703 tonnes (100,000 tons) of zinc annually, corresponding to an hourly solution feed to solvent extraction of 6013 L/min (1323 gal/min) based on a leach solution feed, in g/L, of 30 Zn, 0.4 Cu, 0.4 Pb, 0.002 Fe, in 3.0 M NaCl at pH 4.0. These rates and concentrations were used in the sizing of the circuits.
COPPER CIRCUIT
Extraction of copper is shown in FIG. 2 in 4 stages of mixer-settlers, using 5% Acorga P5300 in an aliphatic kerosene diluent such as Shellsol LX 154 (trademark). At an A/O ratio of 3.5/1, 6013 L/min aqueous (1323 gal/min) and 1718 L/min solvent (378 gal/min), the solvent will load to 1.4 g Cu/L. The retention time in the mixer is 0.5 min. Following extraction, the solvent is scrubbed with water in 6 stages, at an O/A ratio of 5, to remove chloride from the solvent. The mixing time is 1 min. The copper is recovered from the solvent by stripping in 3 stages with return electrolyte from electrowinning, containing 30 g Cu/L and 150 g H 2 SO 4 /L, at an O/A ratio of 6 and with a retention time in the mixer of 1 min. Sulphate remaining on the solvent after stripping is removed in 3 stages of water scrubbing at an O/A of 8 for 1 min, and the solvent recycled. All settlers were designed on a basis of 73.4 L/min/m 2 (1.5 gal/min/ft 2 ) settler area.
ZINC CIRCUIT
Zinc extraction is shown in FIG. 3 in 6 stages at an O/A ratio of 2.2 and a flow of 13,225 L/min (2910 gal/min) of 60% TBP in Shell Solvesso 150 (trademark) aromatic diluent. A retention time of 1.8 minutes is used in the mixer. The solvent is scrubbed in 3 stages at an O/A of 3, for 1 minute, with a solution consisting of 25 g ZnCl 2 /L in 3 M NaCl. Zinc is recovered from the solvent by 6 stages of stripping using return electrolyte containing 15 g Zn/L at pH 1.0 in HCl at an O/A of 2.5 for 1.8 minutes. Prior to recycling the stripped solvent to extraction, the solvent is acid equilibrated with 50 g HCl/L at an O/A of 5 for 1.8 minutes. | The solvent extraction separation and recovery of copper and zinc from complex chloride liquors; e.g. those resulting from the low temperature chlorination and leach of a copper-lead-zinc sulphide ore or concentrate; are described, including the selection of sequence, conditions, extractants, scrubbing and stripping media and adaptations for electrowinning and recycle. High purity copper sulphate and zinc chloride electrolytes are produced for subsequent direct electrowinning. Lead may also be recovered. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wrappers for smoking products such as cigarettes. Cigarettes are conventionally made by wrapping tobacco in paper which is made from flax or other cellulosic fibers and calcium carbonate filler. Papers of this general description are standard in today's cigarettes and are available from a number of sources. The burning cigarette releases smoke which may be classified as sidestream when it emanates from the lit end of the cigarette or mainstream when it is drawn through the tobacco column to the smoker. The present invention is directed to an improved wrapper manufacturing method and resulting wrapper that materially reduces the quantity of sidestream smoke.
2. Description of the Art
Various attempts have been made to reduce the level of sidestream smoke. However, none has been successful to the point of significant commercial exploitation. For example, U.S. Pat. No. 4,225,636 to Cline et al issued Sept. 30, 1980 is directed to the use of high porosity carbon coated cigarette papers disclosed to provide substantial reductions in both mainstream and sidestream smoke. U.S. Pat. No. 3,744,496 to McCarty et al issued July 10, 1973 is also directed to a carbon filled wrapper which is preferably treated with compounds such as alkali metal hydroxides, bicarbonates and carbonates. It also has been recognized that some smoking articles wrapped in tobacco leaf release lower amounts of sidestream smoke, but such wrappers are not practical for use on cigarettes. These products, as well as those resulting from other attempts at sidestream reduction, have suffered either from excessive cost or adverse effects relating to mainstream particulate deliveries, draw, taste, or other factors such as burn rate. U.S. Pat. No. 4,461,311 to Mathews, Mattina and DeLucia dated July 24, 1984 describes a further improvement in wrappers incorporating extraordinary amounts of alkali metal salts. While successfully reducing sidestream smoke, cigarettes with such wrappers have exhibited taste modifications noticeable to some smokers. Therefore, none of these approaches has represented an entirely satisfactory solution for decreasing sidestream smoke from cigarettes.
As those skilled in this art will appreciate, it is conventional to incorporate any of a wide variety of filler compounds in papers for cigarette wrappers. The above-described U.S. Pat. No. 3,744,496 to McCarty et al issued July 19, 1973, for example, discloses the use of carbon as a filler. U.S. Pat. No. 4,461,311 to Mathews, Mattina and DeLucia teaches the use of calcium carbonate, and a series of patents to Cline or Cline et al., including U.S. Pat. No. 4,231,377 dated Nov. 4, 1980, teaches the use of various magnesium compound fillers. It has been also suggested that conventional clays may be one of a number of materials suitable as fillers for cigarette wrapper papers. Examples of such teachings include U.S. Pat. No. 2,181,614 to Striefling dated Nov. 28, 1939. Moreover, conventional clays have been taught as suitable for fillers for smokeable compositions, per se. Finally, fillers such as attapulgite clay are known for use in tobacco smoking preparations as taught in U.S. Pat. No. 3,049,449 to Allegrini dated Aug. 14, 1962, for example.
In spite of the foregoing information available to those skilled in this art, it remains desired to obtain improved reductions in sidestream smoke efficiently and without adverse effects on other smoking properties such as taste or ash color.
SUMMARY OF THE INVENTION
The present invention relates to a wrapper for a smokeable article and to the smoking article, itself, both providing substantial reduction in sidestream smoke without significant adverse effect on properties such as mainstream particulate matter and puff count. These results are obtained by modifying cigarette wrapper paper formulations. The paper formulation is modified to contain certain inorganic fillers in sufficient amount to provide a total superficial surface area of filler in the paper of greater than eighty square meters per one square meter of the paper. In addition, the paper contains one or more carboxylic acid salts in sufficient amount to result in a continuous, coherent ash when the cigarette or other smoking article is smoked. Surprisingly, the wrapper paper as decribed in the present invention results in a smoking article with very significant reductions in sidestream smoke while only minimally affecting other burn properties.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view in partial section of a smoldering cigarette in accordance with the invention.
FIG. 2 is a graph illustrating improvements in sidestream smoke reduction in accordance with the invention as the surface area of filler in the cigarette paper increases.
FIG. 3A illustrates schematically and in perspective and section a non-porous filler.
FIG. 3B illustrates schematically and in perspective and section a porous filler.
FIG. 4 is a graph illustrating the effect of addition of a carboxylic salt, namely potassium acetate, on sidestream smoke reduction in combination with a filler in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the invention will be described in connection with preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
During the smoking of a cigarette, a large fraction of the total smoke generated by combustion of the tobacco is released from the lit end of the cigarette as sidestream smoke. The relative amounts of mainstream and sidestream smoke in a given instance will depend upon the manner in which the cigarette is smoked. If the cigarette is placed in an ashtray for prolonged intervals between puffs, sidestream becomes a very large fraction of the total smoke produced. whether the cigarette is held by the smoker or rests in an ashtray during the interval between puffs, the sidestream rises as a concentrated and highly visible plume of smoke. Moreover, this concentrated plume continues to emanate from the lit end of a cigarette even while air is being drawn in during the puff, so that sidestream smoke is constantly released in large quantities throughout the consumption of a cigarette, regardless of whether consumption is largely by smoldering or by puffing. At times, the sidestream smoke plume is carried by air currents into the vicinity of other persons who may find it objectionable. Therefore, cigarettes producing markedly less sidestream are highly desirable.
In accordance with the present invention, sidestream smoke particulate matter is greatly reduced by modifications of the paper used to wrap the tobacco column. Prior attempts to reduce sidestream smoke by wrapper modifications have involved the use of papers which were technically or economically impractical, which modified taste, which were aesthetically unacceptable, or which resulted in drastically increased mainstream smoke delivery and puff count. In contrast, the modifications of the present invention do not result in retarded burn rate or elevated delivery of mainstream tar; they do not adversely affect the appearance of the cigarette or ash; and they do not require the use of exotic materials or manufacturing processes. For example, cigarettes made with the wrapper of the present invention afford normal enjoyment to the smoker but diminish the possibility of stray smoke being objectionable to bystanders.
In accordance with the invention, these highly desirable beneficial effects are obtained by using a particular type of filler in combination with one or more carboxylic acid salts in wrapper materials for smokeable articles. Such wrapper materials may otherwise be conventional cigarette papers made from flax and/or other cellulosic fibers containing, if desired, one or more other inorganic fillers, typically calcium carbonate. Other suitable mineral fillers will be apparent to those skilled in this art. The particular fillers include inorganic materials having a superficial surface area of at least about 20 m 2 /g and preferably at least about 25 m 2 /g. They are useful in filler content ranges broadly of from about 5 percent to about 50 percent of paper by weight in accordance with this invention.
While the use of fillers and carboxylic acid salts has been known for many years as additives to cigarette papers for the purposes of improving burn characteristics, in conventional use the fillers are not normally selected from materials having the specified superficial surface area and in combination with carboxylic acid salts. The remainder of the paper composition of the present invention will comprise conventional materials such as cellulose fibers, preferably flax, other fillers and burn enhancers. Total superficial surface area for purposes of the present invention is defined generally as the difference between total surface area of the filler material and the surface area contributed by the voids or pores in the filler material.
While it is not desired to limit the invention to any particular theory, it is believed that the particular paper compositions described in this invention function by modifying certain mass transport processes occurring in a smoldering cigarette. This may be understood by referring to FIG. 1, which is a schematic perspective illustration of a smoldering cigarette in partial section. Hot cone of coal 1 and its accompanying inorganic ash 2 will advance gradually to the right towards the unburnt portion of the cigarette comprising a tobacco rod 3 and surrounded by a paper wrapper 4. Because of the very high temperature of coal 1 (about 900° C.) and concomitant combustion efficiencies, no visible smoke issues from the coal. However, in the intermediate region 5 between the advancing coal and the more distant parts of the unburnt cigarette, various destructive distillation and partial combustion processes occur. Externally region 5 may be observed as a black char line 6 which comprises the not yet completely combusted organic substance of the paper wrapper 4 along with the inorganic fillers incorporated originally in the wrappers.
As will be understood, char line 6 and its final combusted state (all inorganic in nature) are much more premeable than original wrapper 4. This condition permits the easy egress of visible smoke as evidenced by the rising plume 7 issuing from this region of a smoldering cigarette.
The nature and origin of this visible smoke may be understood by considering it as a fog, i.e., a suspension of small liquid droplets in a gas phase, resulting from the supercooling and spontaneous nucleation of the vapor phase of certain high boiling compounds generated in the above-mentioned destructive distillation process. Once such a fog is formed, it exhibits great stability and can only be depleted of its liquid droplet content by highly efficient mechanical filtration means not available at char line 6. In the practice of the present invention, this supercooling and spontaneous nucleation of the vapor phase is greatly diminished by incorporating certain fillers in the paper wrapper. These fillers function by providing enlarged condensing surface areas resulting in a large fraction of the fog droplet precursor vapors condensing as liquid layers on the cooler filler particle surfaces. Such phase transformations (gas - liquid) are extremely rapid and efficient, thus relieving the requisite supersaturation necessary for fog (smoke) generation.
It might be expected that this condensing mechanism would offer only temporary and inconsequential relief from smoke generation since the ever-advancing coal will soon re-boil these condensed liquids to yield the original vapors which are responsible for smoke generation in the first place. However, when this occurs, the re-boiling takes place on the outer periphery of the cigarette, where the ambient environment (air) is much enhanced in oxygen content compared to the interior of the cigarette where the vapors were first generated. Because of this enhanced oxygen content, these vapors are believed to be efficiently burnt or broken down to gaseous products which cannot nucleate to form visible smoke on cooling because of their lower molecular weight.
As described herein throughout the body of this document percent sidestream reduction results are demonstrated with reference to a control cigarette made with a conventional cigarette paper. This paper is characterized by a permeability of 30 cm/min (as measured by the CORESTA method at a pressure differential of 1 centibar), a basis weight of 25 g/m 2 , a filler content of 30 percent chalk, a fiber content of 69 percent flax, and a burn promoter mixture of 0.3 percent potassium citrate and 0.6 percent sodium citrate. (The superficial surface area of the chalk in the control wrapper is only 3 m 2 /g. Both the control cigarettes and cigarettes made in accordance with the invention wrappers contained the same, standard American tobacco blend with a bulk density of 0.265 g/cm 3 .
Surface Area Requirements
As shown in FIG. 2, the percent sidestream smoke reduction initially incrases as the total superficial surface area of the filler in the paper increases. This total superficial surface area is the product of the specific superficial area of the filler in units of m 2 /g, the weight fraction of filler in paper, and the basis weight of paper g/m 2 . (The contribution of the fiber portion of the paper is negligible). It is further seen in FIG. 2 that the rate of increase in percent sidestream smoke reduction diminishes to nearly zero when the total superficial surface area in the paper exeeds 150 m 2 of filler per m 2 of paper. It is believed that this effect is caused by other rate limiting processes in the transport of gases being condensed on the condensing surface. In other words when sufficient condensing area is supplied, it no longer is the rate limiting step in the process of condensing the gaseous components.
The specific superficial surface areas of the various fillers were obtained using the well known BET method [Brunauer, Emmett, Teller, J. Amer. Chem Soc. 60, 309 (1938)] and known properties of the porous nature of the particular filler. Since the BET method involves the adsorption of the very small nitrogen gas molecule, it gives the total surface area of the filler, which comprises the superficial surface area and the area contributed by any pores or voids in the actual filler particle. In accordance with the invention, the area provided by these voids or pores is ineffective as condensation sites since the time available in a smoldering cigarette will not permit the diffusion of gases into these pores or voids. Referring to FIGS. 3A and 3B, for example, there are shown two filler particles 10, 11 of the same superficial surface area but differing vastly in their total surface area due to fissures 12 as the section clearly demonstrates. A striking example is the use of zeolites, which are inherently porous because of the presence of minute pores arising from their unique crystal structure, as sidestream reducing fillers. If these molecular size pores are empty, the BET measurements for the adsorption of nitrogen give a total specific surface areas of about 150 m 2 /g. However, if the zeolite has been exposed to water (such as would always be the case during paper making) these pores become completely filled with water molecules. These water molecules are so tenaciously held that subsequent BET measurements give only the superficial surface area of some 4 m 2 /g. Consequently, zeolites are no more effective in reducing sidestream smoke than a nonporous filler of about the same superficial surface area, namely conventional chalk.
Most fillers which are of use in the practice of the invention are not porous, but are instead comprised of small impermeable crystals. In such cases the very convenient BET measurements may be used as a direct measure to evaluate the effective condensation area (superficial surface area).
Thermal Stability of the Filler Structure
The desired large surface area of the filler must not decrease significantly during heating of the filler as the hot coal approaches and passes by. Some filler, which have a large surface area at room temperature, fail to satisfy this requirement due to melting, fusing, or collapse of the filler particles. For example, the total surface area of a filler, Silcron 900, a silica hydrogel manufactured by SCM Pigments Corp., decreases drastically following exposure to elevated temperatures (from 47 m 2 /g to 6 m 2 /g following heating to 400° C.). If this former value is used, the predicted sidestream smoke reduction based on that value will not result. (The actual observed sidestream smoke reduction with this filler is in good agreement with data shown in FIG. 2 when the latter surface area value is used.)
It should not be inferred from the foregoing that all thermally unstable fillers lose surface area during heating. some fillers behave just the opposite and comprise an important class of sidestream smoke reducing fillers. These fillers in general are certain crystalline solids which on heating to modest temperatures chemically decompose to form new crystalline phases, which differ in density from that of the original solid. When this transformation occurs, the original crystals shatter and generate additional surface area. Examples of these fillers are hydrates (CaSO 4 .2H 2 O), hydroxides (Ca(OH) 2 ), carbonates (MgCO 3 ), peroxides (MgO 2 ). These compounds thermally decompose to yield a new crystalline phase and a gaseous byproduct (H 2 O, CO 2 , or O 2 ) in the temperature range of 200° to 500° C. To realize the advantage of this thermally generated surface area there must not be any liquid phase (such melting or eutectic formation) during the transformation. If this is not the case, the liquid will serve to sinter the filler particles together and lead to an actual decrease in surface area.
Effect of Carboxylic Acid Salts
In addition to providing a large condensing surface the present invention also requires the presence of certain additives which serve to generate a coherent and continuous ash. This is achieved by incorporating carboxylic acid salts such as potassium citrate or sodium acetate into the paper, preferably at a level of 6 to 12 percent. These salts function by lightly sintering not only the char of the partially decomposed paper but also that of the final inorganic ash. If such salts are not provided, both the char and the ash structures will exhibit large cracks and fissures. Since in the interior of the cigarette the generated gases are at an appreciable positive pressure, they will preferantially escape through such fissures, completely bypassing the provided condensing surfaces. This obviously will vitiate the efficacy of the condensing sites. However, once the benefit obtained from the elimination of fissures is achieved, additional amounts of carboxylic acid salt will result in loss of surface area due to excessive sintering of the filler particles. Thus provision of an excess of a carboxylic acid salt (>12%) will actually worsen sidestream smoke reduction. These effects are shown in FIG. 4 where the sidestream reduction curve drops off after about 12 percent.
Aesthetic, Health, Manufacturing, and Economic Requirements
The filler must not only satisfy the criteria established above relating to surface area and thermal stability in order for it to be usable in cigarette paper, it should also provide attractive cigarette paper.
To be useful the filler obviously must meet health and safety requirements and preferably avoid insoluble salts of certain heavy metals, such as zinc, cadmium or lead, where during the combustion of the cigarette paper there is a potential for chemical reduction of the metal ions to yield poisonous metal vapors.
The filler in addition to providing condensation sites preferably is essentially water insoluble and affordable.
Examples of Suitable Filler Compositions
(1) Clays
Attapulgite clay. This clay possesses a thermally stable, superficial surface area (200 m 2 /g) which far exceeds that of more conventional clays, such a kaolinite or bentonite.
(2) Oxides
Fumes silica and alumina. Both of these oxides formed by burning of their respective chlorides have enormous superficial surface areas (200-600 m 2 /g) and are thermally stable. This characteristic should be contrasted to that for more conventional hydrated silicas which collapse during heating and thereby lose their effectiveness in reducing sidestream smoke.
(3) Peroxides
Peroxides of magnesium, calcium and strontium can be used in this invention. They all decompose thermally at modest temperatures to yield increased superficial surface areas.
(4) Carbonates
Carbonates of magnesium, calsium, strontium and barium, which possess superficial surface areas exceeding about 20 m 2 /g, can be used in this invention. (These carbonates can be distinguished from the conventional carbonates of commerce, which possess a superficial surface area <10 m 2 /g.)
(5) Phosphates
Phosphates of magnesium, strontium, and barium, which possess superficial surface areas exceeding about 20 m 2 /g, can be used in this invention.
(6) Sulphates
Sulphates of calcium, strontium and barium, which possess superficial surface areas exceeding about 20 m 2 /g, can be used in this invention.
(7) Aluminates
Aluminates of magnesium, calcium, strontium, and barium, which possess superficial surface areas exceeding about 20 m 2 /g, can be used in this invention.
(8) Silicates
Silicates of magnesium, calcium, strontium, barium, sodium, and potassium, which possess superficial surface areas exceeding about 20 m 2 /g, can be used in this invention. Only those sodium and potassium silicates which are water insoluble can be used.
EXAMPLES
Example 1
A cigarette wrapper was made containing 50 percent flax fibers, 10 percent attapulgite clay (Attagel 40 manufactured by the Engelhard Chemicals Co.), 30 percent chalk, and 10 percent potassium acetate as a burn additive to sinter the ash and provide a coherent and continuous ash. The wrapper had a basis weight of 40 g/m 2 and a CORESTA permeability of 12 cm/min. A cigarette paper of this composition has about 125 m 2 of superficial surface area per m 2 of paper. Cigarettes were made with this wrapper at a length of 70 mm, without filters and with a standard American tobacco blend with a density of 0.265 g/cm 3 . The sidestream reduction achieved with these cigarettes compared to the control cigarettes (conventional cigarettes) described previously was about 50 percent.
Example 2
Example 1 was repeated except that a potassium acetate was replaced with potassium citrate. The sidestream smoke reduction remained approximately the same at 50 percent.
Example 3
Example 1 was repeated except that the attapulgite clay content was increased to 15 percent and the chalk content was reduced to 25 percent. Cigarette paper of this composition has a superficial surface area of about 160 m 2 per m 2 of paper. The sidestream smoke reduction was about 55 percent.
Example 4
Example 1 was repeated except that the attapulgite clay content was increased to 20 percent and the chalk content was reduced to 20 percent. Cigarette paper of this composition has a superficial surface area of approximately 200 m 2 per m 2 of this paper. The sidestream smoke reduction was about 60 percent.
Example 5
Example 4 was repeated except that the basis weight of the paper was reduced to 35 g/m 2 . Cigarette paper of this composition and basis weight has a superficial surface area of approximately 175 m 2 of paper. The sidestream smoke reduction was about 55 percent.
Example 6
A cigarette paper was made containing 50 percent flax fiber, 40 percent fumed alumina (Alumina Oxid C, manufactured by the Degussa Corp.), and 10 percent potassium citrate. The wrapper had a basis weight of 40 g/m 2 and a CORESTA permeability of 10 cm/min. A cigarette paper of this composition has a superficial surface area of approximately 400 m 2 per m 2 of paper. Cigarettes were made as in Example 1. The sidestream smoke reduction was nearly 70 percent.
Example 7
Example 6 was repeated except that the content of fumed alumina was reduced to 20 percent and the portion taken out was replaced with chalk. The cigarette paper of this composition had a superficial surface area of approximately 225 m 2 per m 2 of paper. The sidestream smoke reduction was about 65 percent.
Example 8
A cigarette wrapper was made containing 50 percent flax fiber, 40 percent activated alumina (Grade CP2 manufactured by the Alcoa Co.), and 10 percent potassium citrate. The wrapper had a basis weight of 40 g/m 2 and a CORESTA permeability of 15 cm/min. The cigarette paper of this composition had a superficial surface area of about 140 m 2 per m 2 of paper. The sidestream smoke reduction was about 50 percent.
Example 9
A cigarette paper was made containing 50 percent flax fiber, 20 percent fumed silica (Cabosil EH-5 manufactured by the Cabot Corp.), 20 percent chalk and 10 percent potassium acetate. The wrapper had a basis weight of 40 g/m 2 and a CORESTA permeability of 12 cm/min. The cigarette paper of this composition had an exceedingly high superficial surface area of over 1000 m 2 per m 2 of paper. The sidestream smoke reduction was about 65 percent, however, the ash was nearly black.
Example 10
Example 9 was repeated except that fumed silica content was increased to 40 percent and chalk was not included in the paper composition. The sidestream smoke reduction was about 65 percent and the ash was also nearly black.
While the examples are illustrated using calcium carbonate as an additional filler, other fillers may be used in combination with the high superficial surface area filler or it may constitute the only filler. Also, the burn enhancer may vary as to composition, for example sodium citrate or sodium acetate may be used, and in amount, for example, from about 6 percent up to about 15 percent by weight. It will be recognized by those skilled in the art that the shape of the curve of FIG. 2 will be consistent although it may shift somewhat with different tobacco compositions. In accordance with the invention, the curve is believed characteristic and the described effect on sidestream reduction occurs in each case.
It is a further result of particularly preferred embodiments of the present invention that the cigarette ash is very similar to the ash on conventional cigarettes. This is particularly significant with attapulgite clay, fumed alumina and activated alumina since some other high surface area fillers such as fumed silica (380 m 2 /g) while reducing sidestream smoke, tend to result in a dark ash.
Modifying any conventional cigarette paper formulation by the addition of such fillers in accordance with the invention, results in a decrease in the level of sidestream smoke. However, the effect of this treatment can be maximized by using paper with low porosity and by maintaining sheet bulk at a high level consistent with low porosity. For a given level of filler addition, lower porosity causes further decreases in sidestream smoke. In accordance with preferred embodiments of the invention the paper porosity is in the range of from 5 to 30. The porosities are expressed as CORESTA permeability (superficial velocity, in centimeters per minute, of air flowing through a porous paper at a pressure differential of one centibar).
Thus it is apparent that there has been provided, in accordance with the invention, a sheet material adapted for use as a wrapper for smoking articles that fully satisfies the aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | Sheet material especially useful in forming wrappers for smokeable articles such as cigarettes that results in reduced sidestream smoke. The sheet is formed by incorporating as a filler in a cellulosic web an amount of high (at least about 20 M 2 /g) superficial surface area filler in the range generally of about 5 to 50 percent by weight in the finished sheet resulting in a web superficial surface area of at least about 80 M 2 per square meter of web. The cellulosic material may be flax fiber or other natural cellulosic fibers conventionally used for such wrappers. Additional fillers may be used up to a total of about 50 percent, and burn modifier salts included. Examples of salts include the sodium or potassium salts of acids such as carbonic, formic, acetic, propionic, malic, lactic, glycolic, citric, tartaric, fumaric, oxalic, malonic, succinic, nitric, and phosphoric. The sheet can be formed by any conventional papermaking method. When such papers are used as cigarette wrappers, they effect a reduction of the total particulate matter in sidestream smoke of up to about 70 percent without serious deterioration of other desirable properties. In addition the sheet of the invention provides normal ash appearance in a smoking article. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus for drilling a deviated bore hole and for drilling a straight section of bore hole which may be horizontal or at any angle from the terminus of a small radius curved bore hole.
2. Prior Art
There have been many efforts to develop apparatus for successfully drilling small radius deviated well bores. Prominent among those working in this field was J. A. Zublin, to whom many patents have issued. Typical of his efforts in this field is U.S. Pat. No. 2,631,820, which teaches the use of a curved drill guide to maintain a curved drill course in spite of radial forces working against the drill guide. Included in the use of the drill guide is a heavy duty flexible drill pipe as taught in U.S. Pat. No. 2,515,366.
Zublin again directed his attention to a curved drill guide in U.S. Pat. No. 2,664,270. In addition, this patent teaches the use of a rib, attached to the outside of the drill guide, to help stabilize the guide while rotating the flexible drill pipe of U.S. Pat. No. 2,515,366. The patentee used two or more ribs attached to the bottom end of the drill guide, as shown in the drawings, in order to limit the curvature of the well bore. Otherwise, there was a tendency to form a U-shaped well bore.
In U.S. Pat. No. 2,669,430, the patentee taught an apparatus for drilling devitated well bores utilizing a number of straight tubular drill guide sections. These so-called "straight" drill guide sections were stacked on the sectional drill collars, end to end, and designed so that the drill guide sections were rotatable relative to each other. Used in conjunction with a whipstock, they imparted flexibility to the drill string on making the curved drill path but became rigid for lateral drilling.
Another Zublin patent, U.S. Pat. No. 2,672,321, discloses a clutch mechanism useful with the curved drill guide of U.S. Pat. No. 2,515,366. The drill guide and clutch mechanism carried the drill string weight during drilling operations. In practice, the bearings of this clutch were not able to withstand the thrust loads required in normal drilling operations.
Other art in this field is represented in the following U.S. Pat. Nos.
2,336,338
2,344,277
2,402,003
2,515,365
2,634,097
2,680,358
2,684,581
OBJECTS OF THE INVENTION
It is a primary object to provide a drill guide for use in drilling laterally extended well bores.
A further object is to provide an improved orientation clutch assembly to be used in conjunction with said drill guide.
Another object is to provide an improved flexible drill guide which is bendable through a curved well bore and which will tend to guide a drill bit in an essentially straight drill path, which can be horizontal.
An additional object is to provide an improved flexible drill guide which is resistant to rotation in the well bore while the drill bit is rotating.
A further object of the invention is to provide an improved stabilizer system for more precise guiding of drilling direction using the drill guides of the invention.
These and other objects of the present invention will become apparent upon reading the following summary and detailed description of the preferred embodiments of the invention.
SUMMARY OF THE INVENTION
An apparatus for guiding the direction of drilling a well bore deflected from the vertical comprising: a flexible, resilient tubular member, said tubular member having disposed along at least a major portion of its length a plurality of shaped cuts, said cuts extending around the circumference of said tubular member but not severing said tubular member, and said tubular member not being normally curved throughout its entire length.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of one embodiment of the flexible drill guide of the invention, depicted extending downward in a well bore;
FIG. 2A-C is a plan sectional view of the clutch mechanism used with the flexible drill guide of the invention;
FIG. 3 is a schematic representation of a flexible drill guide having a noramlly curved configuration;
FIG. 3A is a schematic representation of one embodiment of a flexible drill guide having a normally partially curved configuration.
FIG. 4A-C is a plan, partially cut away view of the flexible drill guide of FIG. 3, illustrating the configuration of the stabilizer shoes attached thereto and the cuts made therein to impart flexibility;
FIG. 5 is a cross-sectional view on the line 5--5 of FIG. 4A showing the positioning of the stabilizer fins attached to the upper end of the flexible drill guide;
FIG. 6 is a cross-sectional view on the line 6--6 of FIG. 4C showing the positioning of the stabilizer fins attached to the lower end of the flexible drill guide;
FIG. 7 is a laid out section of the flexible drill guide of FIG. 3, showing the cut made therein;
FIG. 8 is a laid out section of the flexible drill guide of FIG. 9, showing the cut made therein;
FIG. 9 is a schematic representation of one embodiment of a flexible drill guide embodiment having a noramlly partially curved configuration;
FIG. 10A-C is a plan view of the flexible drill guide of FIG. 9, showing the fin arrangement therein;
FIG. 11 is a schematic representation of the flexible drill guide embodiment having a normally straight configuration but which is bendable through a relatively short radius; and
FIG. 12A-C is a plan view of the flexible drill guide of FIG. 11, showing the fin arrangement therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is illustrated schematically one embodiment of the flexible drill guide 10 positioned in a vertical well bore 12, being lowered to commence drilling a bore hole deviated from the perpendicular. The drill guide 10 surrounds and is carried by a sectional, flexible drill stem 14 which is referred to hereinafter as a drive pipe. The drill guide 10 illustrated in FIG. 1 is referred to as a "normally curved" drill guide.
The basic geometric configuration of the normally curved drill guide 10 has been known for a number of years. Typical of these is the curved drill guide 10 of FIG. 1 of U.S. Pat. No. 2,631,820. In utilizing the normally curved drill guide 10 of the present invention, the operator lowers the drill guide to virtually any point in a previously drilled well bore 12 and, selecting the proper azimuth, commence to drill a deviated hole using the drill bit 18 attached to the end 64 of an interiorly disposed drive pipe 14 and clutch member 37. The normally curved drill guide 10 carries stabilizer fins 22, 24 and 26 which act to prevent rotation of the drill guide 10 while the drill bit 18 is being operated. It has been found that the number and placement of the stabilizer fins is a critical factor in maintaining the proper drill path and azimuth. These will be discussed in more detail hereinafter.
It has now been discovered that for drilling the straight portion of a deviated hole, after the curve has been drilled with the normally curved drill guide 10 of FIG. 1 (shown schematically in FIG. 3), a flexible drill guide having at least a portion of its length normally straight, as illustrated in FIGS. 3A, 9 and 11, should be used. It is preferred that at least a portion of its straight section should be on the bit end of the flexible drill guide.
Thus, in FIG. 3A there is illustrated an embodiment of the flexible drill guide 10' of the invention wherein the straight portion Y' thereof comprises about one-third of the length of the drill guide 10'. However, this is just an approximation and is not critical. What is important is that at least some part of the bit end 11b of the drill guide be essentially straight, compared to the noramlly curved portion Z' of the drill guide 10'.
Another embodiment of the invention is illustrated in FIG. 9, wherein a greater portion of the flexible drill guide 80 is essentially straight. These are the lengths X and Y, while the portion Z is curved. In this embodiment, approximately two-thirds of the drill guide 80 is straight. Again, this proportion is a rough approximation, and is not critical.
The normally curved-straight drill guides 10' and 80, as illustrated in FIGS. 3A and 9, should be used for entering a deviated hole which has been kicked off from the side of an open well bore. The normally straight drill guide 82 shown in FIG. 11 is a variation of the drill guide of FIG. 3A and 9, and would be used when the deviated hole is kicked off from the bottom of a vertical hole or when some other device is used to insert the normally straight drill guide into a side track.
The normally straight 82 and curved-straight 10' and 80 drill guides of FIGS. 11, 3A and 9, respectively, are preferably each constructed from single pieces of annealed steel tubing. Each drill guide receives a series of special cuts 100 (and 106). The cuts are illustrated in FIGS. 7 and 8, in template form showing relative dimensions of the radial and longitudinal portions of the cuts.
The cuts 100 are spaced at essentially equal distances apart along the length of the drill guides 80 and 82. The cuts 100 are made radially across the guide and intersect a longitudinal cut 102 having ends 104 and 104'. The radial cut 100 is made at an angle to the plane of the drill guide 80. This permits the drill pipe 80 to be bent somewhat and the cut surfaces are able to act as bearing surfaces.
It has been found that either the short cut 20 of FIG. 7, or the longer cut 100 of FIG. 8 may be used with the straight drill guide 82 and the curved-straight drill guide 80. Alternatively, there may be used a combination of short and long cuts, as illustrated in FIG. 9, with the longer cuts 100 used in the curved portion of the guide 80.
The cuts 100, of the normally straight 82 and the curved-straight 80 drill guides are placed at a predetermined distance from one another to provide the needed flexibility for the guides 80 and 82 to traverse both the horizontal and curved sections of the deviated hole.
As previously mentioned, the stabilizer fins are used to maintain the desired angle of declination and azimuth while drilling the straight portion of the deviated hole using the normally straight drill guide 82 and the curved-straight drill guide 80. Referring to FIG. 9, the drill guide 80 has an upper set of fins 90 and a lower set of fins 92 placed thereon. Also, there are preferably two sets of fins 88 and 91 placed at intermediate locations along the length of the drill guide 80. Preferably, the upper set of intermediate fins 91 should be placed just above the curved portion Z of the drill guide 80. It is preferred that the lower intermediate fins 88 be placed just below the curved portion Z of the drill guide 80. However, the positions of these intermediate fins 88 and 91 are not critical and can be varied for particular drilling requirements.
For the purpose of position for the upper 90 and lower 92 fins on the curved-straight drill guide 80, the direction of curvature side shall be referred to as the "face" side of the drill guide 80. Referring to FIGS. 9 and 10A-C, it will be seen that the upper fins 90 are preferably positioned to provide at least one fin 90" on the side opposite the face side of the drill guide 80. The lower fins 92 are preferably placed on the drill guide 80 to provide at least one fin 92 on the side opposite the face side of the drill guide 80.
All four sets of fins 90, 90', 90" and 91, 91', 91" and 92, 92', 92" and 88 (rest not shown in FIG. 10A-C) are preferably placed around the circumference of the drill guide 80 to provide a configuration essentially as shown in FIG. 6.
With regard to the fins of the normally straight drill guide, shown in FIG. 11, reference is made to FIG. 12A-C. For purpose of explanation, the cut side of the drill guide 82 shall be referred to as the face side. It has been unexpectedly found that the best stabilization results are achieved by placing at least one fin 94 on the face side of the upper end of the normally straight drill guide 82. A plurality of fins 94' and 94" should be spaced about the circumference of the upper end of the drill guide 82, essentially as shown in FIG. 6.
At the lower, drill bit end of the normally straight drill guide 82, at least one fin 98" should preferably be placed on the side opposite the face side of the drill guide 82. A plurality of additional fins 98 and 98' are spaced circumferentially around the lower end of the drill guide, essentially as shown in FIG. 6.
While the normally curved drill guide 10 configuration is known in the art, it has been unexpectedly found that the addition thereto of stabilizer fins 22 and 26, as shown in FIGS. 3, 5, 6 and 4A-C, provide stabilization to the normally curved drill guide 10 previously unattainable. The upper end fins 22 and 22' are placed around the circumference of the upper end of the drill guide in the manner shown in FIG. 5, preferably placed opposite each other.
On the lower end of the normally curved drill guide 10 are a similar series of circumferentially placed finds 26, 26' and 26". However, one fin 26 is preferably placed on the cut side of the drill guide 10. The remaining fins 26' and 26" are spaced equidistantly apart around the circmference of the drill guides' 10 lower end.
At essentially the longitudinal mid point of the drill guide 10 there are placed a third series of fins 24, 24' and 24" spaced equidistantly around the circumference of the drill guide 10. As with the lower fins 26, 26' and 26", one fin 24 is preferably placed on the cut side of the drill guide 10.
As previously mentioned, use of the normally straight 82, curved-straight 80 or curved-straight 10' drill guide permits drilling of an essentialy straight deviated hole after traversing the kickoff portion of the well. The drilling is accomplished by rotation of the drill bit 18 attached to the clutch mechanism 37, which in turn is attached to a plurality of connected drive pipe 14. Drilling fluid is conducted to the drill bit 18 through the normal drill pipe (not shown) connected to the upper terminus of the drive pipe 14.
Since the drive pipe 14 is segmented, suitable pressure resistant tubing 16 traverses the interior of the drive pipe 14 and terminates at the end of the drive pipe 14 connected to the upper end sub 32 of the clutch mechanism 27 in a manner to be more fully described hereinafter. It is preferred to utilize a reinforced elastomer in constructing the drilling fluid tubing 16. The elastomer should preferably be capable of withstanding the temperature encountered in drilling to extended depths and be resistant to drilling chemicals and hydrocarbons. Such elastomers are typically, neoprene, ethylene-propylene-diene type terpolymers, ethylene-propylene copolymers, SBR alone or blended with other elastomers, natural rubber and the like, either alone or suitably blended with other materials.
The lowermost end of the elastomer tubing 16 is securedly connected to the lower terminus of the drive pipe 14 by suitable clamping means 30, as shown in FIG. 2A. The drive pipe 14 is connectable to the upper end sub 32 of the clutch mechanism 37.
The clutch mechanism 37 is used in reorienting the drill guide 36 in order to change direction of drilling. As mentioned previously, the drive pipe 14 is connected through the clutch 37 to the drill bit 66. The drill guide 36 does not rotate with the drive pipe 4 and drill bit 66.
With the drill guide 36 being frictionally engaged with the bore hole and the clutch mechanism 37 being freely rotatable therein, there is provided means for securing the clutch 37 to the drill guide 36 to permit rotation of the drill guide to a new direction.
Referring to FIG. 2A-C, there is shown the drill guide 36 of the invention, having connected thereto an upper clutch 34 and a bottom cap 60. Disposed within the bore 21 of the drill guide 36 is the clutch mechanism 37, which includes a top sub 32, connectable to the drive pipe 14, means 56 for conducting drilling fluid through a clutch mechanism 37, and a bottom sub 64, connectable to a drill bit 66.
There is additionally provided a lower clutch dog 44 having a face 40 engageable with an opposing face 42 on the upper clutch 34. Resilient urging means 38 are positioned between the lower clutch dog 44 and the upper clutch 34 to prevent engagement of the opposing faces 40 and 42 during normal drilling operations. As shown in FIG. 2B, the resilient urging means illustrated is a spring member 38.
The spring 38 would be compressed during the period when the drill string would be pulled up, and friction would be restricting upward movement of the drill guide 36.
There is normally provided an inner drive pipe 74 connected within the drill guide 36. The inner drive pipe 74 is segmented in the same manner as the drive pipe 14 to allow bending thereof to follow the contour of the drill guide 36. In order to conduct drilling fluid through the bore 28 of the clutch mechanism 37, suitable conduit 56 is connected within the inner drive pipe 74, using suitable clamps 58 or other fastening means.
For assembly purposes, there is shown in FIG. 2B a top sub adapter 54 connecting the inner drive pipe 74 to the top sub 32. In like manner, a bottom sub adapter 72 connects the lower end of the inner drive pipe 74 to the bottom sub 64. It should be recognized that other suitable means can be used to connect the inner drive pipe 74 to the top sub 32 and the bottom sub 64.
It is preferred that there be provided a fluid sealing means 47 and 68 between the drill guide 36 and the clutch mechanism 37. As illustrated in FIGS. 2B and 2C, seals 47 and 48 are positioned on the bore surface of the top clutch 34 to seal against the outer surface of the top sub 32. In practice, the seals 47 and 48 can be any suitable configuration and can be placed on either the top clutch 34 of the top sub 32 of the clutch mechanism 37.
Similar seals 67 and 68 are preferably provided to seal between the bore surface of the bottom cap 60 and the other surface of the bottom sub.
When the drill stem is placed under a load as a consequence of placing weight on the drill bit 66, there is some compression but essentially no drilling weight placed on the inner drive pipe 74. However, compression of the inner drive pipe 74 will normally cause some shortening of the clutch mechanism 37. The drilling weight is carried by the drill guide 36. In order to prevent binding and friction between the clutch mechanism 37 and the drill guide 36, there is provided means 46 and 62 for reducing friction. These means are illustrated as bearings 46 and 62.
Preferably, there are provided an upper set of bearings 46 positioned to ride between the top sub 32 and the top clutch 34 of the drill guide 36. A second, lower set of bearings 62 are positioned to ride between the bottom sub 64 of the clutch mechanism 37 and the bottom cap 60 of the drill guide 36. | A guide for drilling a straight section of a bore hole deflected from the vertical. The apparatus comprises either a normally straight or a curved-straight tubular member which has a plurality of generally circumferential cuts disposed along the length of the guide. The cuts allow the guide to be bent sufficiently to enter and traverse a short radius curve and then return to its normal configuration for guiding the drilling of the straight portion of the deflected bore hole. A clutch mechanism disposed in the drill guide permits engagement of the guide by the drill string for orientation of the guide. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the enzymatic treatment of the cellulose portion of corn hulls to convert a substantial portion thereof to glucose.
2. Description of the Prior Art
Cellulose is the earth's most abundant resource. The estimated annual accretion, including trees and annual plants, is on the order of 22 billion tons as compared to 100 million tons for corn starch. In contrast to oil and coal, cellulose is a directly renewable resource. The energy for its synthesis comes from the sun and its building blocks are derived from CO 2 in the atmosphere.
Cellulose is a water-insoluble polymer of linearly linked β-1,4 glucose residues and may be hydrolyzed to sugars. Intertwining of long cellulose chains into fibrils and fibers is involved in imparting crystallinity and insolubility to the polymer. Cellulose occurs naturally in perennial and annual plants as cell wall structural material and in fungi and even in certain bacteria. Sources which are generally considered to be of potential commercial importance for conversion of cellulose into sugars or other chemicals include the following:
Wood and lumbering by-products
Pulp and paper wastes
Industrial and municipal wastes
Annual plant wastes
Agricultural residues
Food processing residues
The state of the art of cellulose conversion through mid-1974 was presented at an NSF-sponsored symposium entitled "Cellulose as a Chemical and Energy Resource," University of California at Berkeley, June 25-27, 1974. The proceedings were published as Symposium No. 5 of Biotechnology and Bioengineering, C. R. Wilke, Editor, published by John Wiley & Sons, Inc., New York, N. Y., 1975.
The state of the art through mid-1975 was presented at (1) the Eighth International Cellulose Conference, SUNY College of Environmental Science and Forestry, Syracuse, New York, May 19-23, 1975, and (2) Symposium on Enzymatic Conversion of Cellulose Materials: Technology and Applications, U.S. Army Natick Development Center, Natick, Mass. Sept. 8-10, 1975.
Particularly pertinent publications relating to the conversion of cellulose waste products to glucose are: Andren, Robert K. et al., "Production of Sugars from Waste Cellulose by Enzymatic Hydrolysis, Part I: Primary Evaluation of Substrates;" Presented at 8th Cellulose Conference, SUNY, Syracuse, NY, May 19-23, 1975, and Spano, L. A. et al., "Enzymatic Hydrolysis of Cellulose Wastes to Glucose," Publication from U.S. Army Natick Development Center, Sept. 8, 1975.
OBJECTS
It is the principal object of the present invention to provide a process for enzymatically converting cellulose derived from corn hulls to glucose.
This object and other objects and advantages will be apparent from the present specifications and the appended claims.
SUMMARY OF THE INVENTION
Corn hulls are subjected to a liquid extraction treatment whereby the major portion of the cellulose is liberated from the other constituents of the corn hulls and the resulting cellulose fraction is enzymatically treated to convert a substantial portion of the cellulose to glucose.
DETAILED DESCRIPTION OF THE INVENTION
Corn hulls from a wet milling operation contain relatively large amounts of impurities in admixture with the fibrous, corn hull fraction. These impurities are in the form of "fine material" and contain the predominant amount of non-fibrous substances, such as a starch, protein, oil containing material, lignified tip cap, etc. Removal of these materials may be accomplished by any convenient method, for instance, by screening through a screen of -6 U.S. Standard mesh. The particle size range of the corn hulls containing the predominant amount of impurities may vary, of course, depending upon the particular manner in which the corn hulls are treated and handled during the milling operation. Residual starch which may be present in the corn hulls after the screening operation can be removed by an enzymatic solubilization treatment, for instance, with alpha-amylase.
The relatively purified corn hulls may be considered to comprise three predominant substances or materials: a cellulose fraction, a hemicellulose fraction and a non-carbohydrate fraction. A specific process for obtaining these fractions is disclosed in our U.S. Pat. application Ser. No. 689,232 filed May 24, 1976, now U.S. Pat. No. 4,038,481, entitled "Method for Treatment of Corn Hulls" which is incorporated herein by reference.
These fractions are obtained by contacting corn hulls with a sufficient amount of alkali to hydrolyze the hulls to affect liberation of the hemicellulose fraction so that it may be solubilized in water and to solubilize the non-carbohydrate fraction. Three fractions are recovered comprising a water solution of hemicellulose, an organic solvent extract of the non-carbohydrate fraction and an insoluble residue comprising the cellulose fraction.
In the preferred process for obtaining the cellulose fraction to be enzymatically saccharified, the alkaline hydrolysis is performed using an aqueous system wherein the hemicellulose and the non-carbohydrate fractions are solubilized leaving behind the insoluble cellulose fraction.
The two other fractions may be recovered by adding a sufficient amount of water miscible organic solvent to the alkaline solution to precipitate the hemicellulose. Exemplary of water-miscible organic solvents which may be utilized are acetone, methanol, ethanol, propanol, isopropanol, secondary butyl alcohol, tertiary butyl alcohol and mixtures thereof. The solvent supernate contains the non-carbohydrate fraction and this fraction may be recovered by any convenient means, for instance, by evaporating the solvent.
Cellulase derived from Aspergillus species, Trichoderma viride, or other cellulose producing organisms may be used for converting the cellulose fraction to glucose. The conditions under which the cellulose fraction is treated with the cellulase may vary widely but, in general, the conditions are those which the prior art has recognized as being optimum for this enzyme.
Surprisingly, the cellulose derived from corn hulls is extremely susceptible to enzymatic saccharification. Because of this, lesser quantities of enzyme are necessary to achieve a relatively high degree of conversion compared to cellulose derived from a number of other sources. Also, the desired degree of conversion can be achieved in a shorter period. While we do not wish to be bound to any theory or explanation for this phenomenon, it may be due to the particular form or structure of the liberated corn hull cellulose. It has been observed that the cellulose derived from corn hulls has a higher degree of water absorptivity than other types of cellulose which indicates that the former has a more open structure. This apparently permits easy access of the enzyme to the cellulose fibers where the enzyme can more readily catalyze the degradation of the cellulose to glucose.
In order to more clearly describe the nature of the present invention, a specific example will hereinafter be described. It should be understood, however, that this is done solely by way of example, and is intended neither to delineate the scope of the invention nor limit the ambit of the appended claims.
EXAMPLE
This Example illustrates the treatment of cellulose derived from corn hulls with cellulase derived from Aspergillus sp. also compares the amount of glucose formed by this treatment with the amount of glucose formed by treating another source of cellulose.
Corn hulls from a wet milling operation were wet screened through a -6 screen at about 50° C to substantially remove the fine fiber, most of the starch and some of the protein and lipid material present. 9.5 kilos, dry basis, of the screened material having a moisture content of 65 percent was mixed with 5.7 liters of water in a 190 liter jacketed tank. To the mixture held at a temperature of 70° C was added 635 g of calcium oxide and the mixture stirred for three hours. Portions of the mixture were processed in 3.785 liter Waring blender in a batchwise fashion for thirty seconds. Water was added during blending to promote mixing. A total of 84 liters of water was utilized.
The material was dewatered in a centrifuge to separate the soluble hemicellulose and non-carbohydrate from the cellulose cake. The cellulose cake was then slurried in about 84 liters of water and again centrifuged. The cake was then reslurried, screened through a U.S. No. 20 mesh screen to remove tip caps and hull materials, and again dewatered by centrifugation.
As a control cellulose preparation, 5 g of C-100 bleached sulfite pulp (International Filler Corp., North Tonawanda, N.Y.) was pretreated by suspension in 200 ml of deionized water. The pH of the suspension was adjusted to 12.4 with 50 percent NaOH solution. The suspension was then held at ambient temperature for one hour, filtered, and the resultant cake washed with water to a pH of 8.5.
5 g of corn hull cellulose having a moisture content of about 92 percent, prepared as described above, and 5 g of the pretreated C-100 sulfite pulp were individually suspended in 200 ml of deionized water. The suspensions were buffered with 0.7 ml of glacial acetic acid and the pH adjusted to 4.3 with NaOH solution. 560 mg of cellulase AP 3 containing 30,000 units of Aspergillus sp. cellulase per gram (Amano Pharmaceutical Co., Ltd., Nagoya, Japan) was added to each suspension and the reaction held at a temperature of 50° C for sixteen hours. The final reaction H was 4.3. After sixteen hours the suspensions were filtered and the glucose content of the filtrates determined as reducing sugar by a Fehling's solution method. The results are shown in Table I:
TABLE I______________________________________ Glucose Yield Based on Approx. Based on Cellulose Content Total Solids (%, d.b.) (%, d.b.)______________________________________C-100 Cellulose 10 10Corn Hull Cellulose 58 35______________________________________
The data in Table I show that treatment of corn hull cellulose prepared by the process of the present invention with cellulase derived from Aspergillus sp. resulted in the production of almost six times as much glucose on an approximate cellulose content basis and 3.5 times as much glucose on a total solids basis as did similar treatment of bleached sulfite pulp.
The terms and expressions which have been employed are used as terms of description and not of limitation, and it is not intended, in the use of such terms and expressions, to exclude any equivalents of the features shown and described or portions thereof, since it is recognized that various modifications are possible within the scope of the invention claimed. | Corn hulls are subjected to a liquid extraction treatment whereby the major portion of the cellulose is liberated from the other constituents of the corn hulls and the resulting cellulose fraction is enzymatically treated to convert a substantial portion thereof to glucose. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/976,639 filed Apr. 8, 2014; the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The invention generally relates to devices used to contain fires and, more particularly, to an outdoor fire containment device commonly known as a fire pit. Specifically, the invention relates to a fire pit configured to reduce the amount of smoke produced from the fire burning in the device.
[0004] 2. Background Information
[0005] People enjoy burning small camp fires in their backyards. These fires are used for general enjoyment and for cooking. One drawback with a backyard campfire—especially one made from a soft wood or a wood containing water—is the smoke generated from the fire. The smoke can infiltrate the owner's house and neighbors' houses. This problem has led some cities and communities to completely ban backyard campfires. Some people use fire pits to control and contain their camp fires. In some communities, the use of a fire ring or fire pit is mandatory. A problem with some fire pits is that parts of them become hot and are thus dangerous to those who unexpectedly contact the hot elements of the fire pit.
SUMMARY OF THE DISCLOSURE
[0006] The disclosure provides a device for containing a camp fire that reduces the amount of smoke produced by the fire. The device reduces the amount of smoke by supplying air to the top of the fire to increase the combustion and thus reduce the smoke produced. In one configuration of the device, the air supplied to the top of the fire is heated prior to being introduced to the top of the fire.
[0007] The disclosure also provides a configuration wherein the preheating of the air simultaneously cools the outer surface of the device.
[0008] The disclosure provides the body of the device in the shape of right-cylinder with a generally closed-off bottom wall and an upper lip that overhangs the sidewall. The diameter of the device is about twice the height. Combustion air is provided to the fire under the overhanging lip. This configuration has been found to reduce the amount of smoke produced by a fire burning in the device.
[0009] The disclosure provides one configuration having a double sidewall design such that the two concentric spaced sidewalls define the air flow passage for introducing the combustion air to the top of the fire. This air flow passage is disposed essentially continuously about the circumference of the device. Another configuration uses a plurality of individual passages to deliver the air.
[0010] A grilling screen may be used directly on top of the device or held over the device by a stand.
[0011] The body of the device is supported by a plurality of legs to allow air to be drawn into the device from the bottom wall of the device. Shields are used on the inside of the bottom wall of the bottom to prevent these holes from directly clogging and to prevent ashes to fall out of the device through the holes.
[0012] The disclosure also provides a combustion chamber having a width designed relative to its height such that air supplied to the top of the fire is able to reach the center of the fire for good combustion. An overhanging lip is used to direct the air radially inwardly.
[0013] The individual features may be combined in different combinations than specifically described below to form different configurations of the device of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of an exemplary configuration of the smokeless outdoor fire pit.
[0015] FIG. 2 is a section view taken along line 2 - 2 of FIG. 1 .
[0016] FIG. 3 is a section view taken along line 3 - 3 of FIG. 1 .
[0017] FIG. 4 is a section view taken along line 4 - 4 of FIG. 1 .
[0018] FIG. 5 is a front view of the fire pit of FIG. 1 .
[0019] FIG. 6 is a right side elevation view of FIG. 5 .
[0020] FIG. 7 is a left side elevation view of FIG. 5 .
[0021] FIG. 8 is a rear elevation view of FIG. 5 .
[0022] FIG. 9 is a top plan view of FIG. 5 .
[0023] FIG. 10 is a bottom plan view of FIG. 5 .
[0024] Similar numbers refer to similar parts throughout the specification.
DETAILED DESCRIPTION OF THE INVENTION
[0025] An exemplary configuration of fire pit device of the disclosure is indicated generally by the numeral 2 in the accompany drawings. Device 2 generally includes a main body 4 supported above the ground by a plurality of legs 6 . A rim 8 is disposed about the top of main body 4 . Rim 8 may be used to support cooking tools, grills, or as a protective bumper. Device 2 provides a safe and convenient place for one to burn a small fire that can be used for cooking or general enjoyment. The fire is burned in the cavity defined by main body 4 . Device 4 may be made from any of a variety of fire-resistance materials. Main body 4 may be fabricated from steel and protected with a heat-resistant paint.
[0026] One feature of device 2 is that it is configured to reduce the amount of smoke produced by the fire burning in main body 4 . The reduction in smoke is achieved by supplying heated combustion air to the top of the fire. This air is supplied through a plurality of upper air supply openings 10 defined by main body 4 adjacent the upper end 12 of main body 4 . Openings 10 may extend about the entire circumference of body 4 . Openings 10 may be evenly spaced. Air is supplied to upper air supply openings 10 through an air supply duct 14 that extends from an inlet 16 disposed adjacent the lower end 18 of main body 4 to openings 10 . In one configuration of device 2 , air supply duct 14 is disposed about the entire circumference of main body 4 with only a plurality of supports 20 interrupting the air flow through duct 14 . Supports 20 are disposed closer to lower end 18 than upper end 12 . In another configuration, duct 14 may be divided into a plurality of adjacent or spaced ducts. Positioning air duct 14 along the sidewall of main body 4 allows the air flowing up through duct 14 to be heated before it exits duct 14 to aid the combustion.
[0027] In the exemplary configuration, duct 14 is defined by inner 30 and outer 32 concentric sidewalls of body 4 . The lower ends of sidewalls 30 and 32 are spaced and not connected to define inlet 16 . The upper ends of sidewalls 30 and 32 are joined together by a cap 34 so that all openings 10 define the outlet of duct 14 . In another configuration, the lower ends of walls 30 and 2 are joined and a plurality of inlets 16 are defined. When a fire is burning in main body 4 , inner sidewall 30 is heated to draw air into inlet 16 where it is warmed. The warmed air rises within duct 14 and exits through openings 10 to the top of the fire. Cap 34 projects radially inwardly over the openings 10 to form a lip that helps to direct air from openings 10 toward the middle of the fire. The warmed air assists the combustion and thus reduces the amount of smoke produced by the fire. In situations where the fire is producing an undesirable amount of smoke, adding fuel to the fire is suggested in order to increase the amount of heat available to warm the air in duct 14 . The spaced sidewalls 30 and 32 and the process of drawing cool air between the walls where it is warmed reduces the temperature of outer sidewall 32 . In some situations, outer sidewall 32 may be touched by the hand without danger even while inner sidewall 30 is too hot to touch without pain.
[0028] Main body 4 is provided in the form of a cylindrical cup with inner sidewall 30 forming a right angle with the bottom wall 40 of main body 4 . The height of main body 4 is about half of the diameter with the lip formed by cap 34 extending inwardly about a half inch to three inches. In one configuration, the height of main body 4 is one foot with the diameter being two feet. These dimensions have been found to provide desirable results with the air supplied through openings 10 being radially close enough to the center of the fire to reducing the amount of smoke produced by the fire.
[0029] Air inlets 42 are defined by bottom wall 40 . Inlets 42 are capped with shields 44 that have open ends 46 . Shields 44 help to prevent inlets 42 from becoming clogging. Shields 44 also prevent ashes and fire fuel from falling directly out of main body 4 . Shields 44 also prevent the cool air from under main body 4 from being pulled directly into the fire. The air is pulled under and along the heated shields 44 so that it is preheated before being used in the combustion.
[0030] A cooking grill 50 may be supported directly on rim 8 or on an upright pole 52 that also may support an arm 54 from which one may hang a kettle. Grill 50 can be rotated about pole 52 to remove the cooking surface from above the fire. The handle extends rearwardly from the cooking surface to allow the user to rotate the grill. A winch 56 may be provided to safely change the height of the kettle. Pole 52 may be secured to main body 4 . The winch cable is protected inside a tube that has two openings facing downwardly.
[0031] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described. Throughout the description and claims of this specification the words “comprise” and “include” as well as variations of those words, such as “comprises,” “includes,” “comprising,” and “including” are not intended to exclude additives, components, integers, or steps. | A device for containing a camp fire reduces the amount of smoke produced by the fire. The device reduces the amount of smoke by supplying air to the top of the fire to increase the combustion and thus reduce the smoke produced. In one configuration of the device, the air supplied to the top of the tire is heated prior to being introduced to the top of the fire. The disclosure also provides a configuration wherein the preheating of the air simultaneously cools the outer surface of the device. | 0 |
FIELD OF THE INVENTION
This invention relates to synchronous binary counters and, more particularly, to a counter which utilizes a pipeline arrangement of transistors to propagate a toggle signal from the least significant bit of the counter up to the most significant bit of the counter.
DESCRIPTION OF THE PRIOR ART
Synchronous binary counters are well known in the art and are utilized in a great number of digital circuits. In order to implement a high-speed synchronous counter, (i.e., a counter with a frequency above two megahertz) a look-ahead toggle signal technique is required in which the toggle signal for each counter stage is produced in response to the logical "ANDING" of all lower order counter stage bits. More particularly, the nth stage of a binary counter will receive a toggle signal and experience a 1-to-0 or a 0-to-1 transition, if and only if, bits 0 through n-1 are at a logical "1" state when the clock signal is applied to a particular stage. Similarly, for a down counter, logical "0's" are required to be present in all lower order counter stages in order to produce a toggle signal.
IN MOS technology, high speed synchronous binary counters are most often implemented utilizing a two-phase clock (here-after referred to as φ 1 and φ 2 . In this type of a binary counter a separate AND gate is required for each counter stage to provide the logical "ANDING" necessary to ensure that all lower order bits are in the logical "1" state before the toggle signal is produced for bit n. Utilizing an AND gate to sense the state of all lower order bits results in a heavy consumption of silicon area due to the number of AND gates required. For example, in a 10-state counter, eight logic gates, having 2 to 10 inputs, are required to implement a look-ahead toggle technique. In addition, the lower order stages must provide sufficient drive current to operate all higher order AND gates which results in a high fan-out requirement for the lower order stages. The high fan-out requirement results because each lower order stage must drive all higher order stages in a look-ahead counter, and therefore, all lower order stages must be buffered to boost their drive capability in order to insure that the AND gates which propagate the toggle signal are properly driven and transfer the toggle signal from the lower order stages to the higher order stages.
It is, therefore, an object of this invention to provide a high-speed synchronous binary counter which does not require a large number of AND gates in order to implement a look-ahead toggle signal technique.
It is a further object of this invention to provide a synchronous binary counter utilizing a look-ahead toggle signal technique that does not require buffering for the lower order stages.
It is a further and general object of this invention to provide a synchronous high-speed binary counter which consumes minimum silicon area while at the same time providing a look-ahead toggle signal technique to allow high-speed operation.
SUMMARY OF THE INVENTION
In accordance with the invention, a synchronous binary counter is provided which comprises a plurality of counter stages, each counter stage having a first output state and a second output state, and each counter stage experiencing a state change in response to a toggle signal applied thereto.
It is a feature of the invention that gating apparatus, connected between successive one's of the counter stages, is responsive to only the first state of the preceding counter stage for transferring a toggle signal applied to said preceding counter stage, to the next succeeding counter stage.
It is another feature of the invention that the gating apparatus is responsive to the second state of the preceding counter stage for blocking the transfer of the toggle signal from the preceding stage to the next succeeding counter stage.
It is a further feature of the invention that the gating apparatus, connected between successive stages, is responsive only to the state of the immediately preceding stage and does not require inputs from lower order stages, thereby allowing the gating apparatus to operate with minimum fan-out capability.
It is a further and general feature of the invention that utilizing gating apparatus in accordance with the instant invention allows the implementation of a high-speed synchronous binary counter which occupies a minimum amount of silicon area.
The foregoing and other objects and features of this invention will be more fully understood from the following description of an illustrative embodiment thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 illustrates a prior art synchronous binary counter; and
FIG. 2 illustrates a synchronous binary counter in accordance with the instant invention.
DETAILED DESCRIPTION
Refer to FIG. 1 wherein is illustrated a block diagram of a prior art synchronous binary counter. The counter consists of a number of counter stages, such as counter stages 100 through 103. Each counter stage is identical to counter stage 100 which contains three MOS inverters, such as inverters 104, 105 and 107, and two MOS transistors, such as transistors 106 and 108. A toggle signal φ 1 is applied to terminal 110 and from there to the gate of transistor 108 and to the input of inverter 109, and a clock signal φ 2 is applied to the gate of transistor 106. Each counter stage has two output states, a true output state Q, and a complementary output state Q, and each counter stage is designed to change state in response to a toggle signal and a clock signal applied thereto.
More particularly, assume that the output of inverter 107 is at a logical "1" level and the output of inverter 105 is at a logical "0" level. In response to toggle signal φ 1 , transistor 108 is enabled and transfers the logical "1" level present at the output of inverter 107 to the input of inverter 104, causing the output of inverter 104 to go to a logical "0" state. The subsequent application of clock signal φ 2 to the gate of transistor 106 enables this transistor and transfers the logical "0" state present on the output of inverter 104 to the input of inverter 105, thereby causing the output of inverter 105 to go into a logical "1" state. This, in turn, forces the output of the inverter 107 to a logical "0" state, thereby accomplishing the state change recited above in response to the application of the toggle signal φ 1 and the clock signal φ 2 .
For the counter illustrated in FIG. 1 to operate at high frequencies, (above two megahertz), it is necessary to utilize a look ahead technique for the propagation of the toggle signal from the first stage, stage 100, to subsequent higher order stages. Recall from what precedes that the toggle signal for each higher order stage should be applied thereto if the lower order stages are all in a logical "0" condition (the Q output being equal to a logical "1"). NOR gates 111, 112, and 113 will produce a logical "1" at their outputs if, and only if, all of the inputs to each gate are at a logical "0" condition. For example, assume that stage 100 is at a logical "1" state which results in the complementary output of stage 100 being at a logical "0" state. The application of the toggle signal to terminal 110 and from there to inverter 109 causes the toggle signal to be inverted, which applies a logical "0" to one input of gate 111. The remaining input of gate 111 is also at a logical "0" state as stage 100 has its Q output at a logical "1" state. Therefore, the output of gate 111 goes to a logical "1", which applies a toggle signal to stage 101 of the counter.
The sequence described above is also applicable to gate 112 which will produce a toggle signal if, and only if, stage 101 is in the true state, stage 100 is in a true state, and a toggle signal is applied to terminal 110. When these conditions are met a toggle signal is applied to stage 102 of the counter. It is clear from FIG. 1 that this same sequence is also applicable to each stage of the complete counter.
FIG. 1 illustrates the disadvantages inherent in such a prior art binary counter. The first disadvantage is that a large number of NOR gates are required, with each NOR gate requiring progressively higher numbers of inputs for use in the higher order stages of the counter. For example, NOR gate 113 requires n inputs, which, for a 20-stage counter, results in gate 113 requiring 20 inputs. Such a large number of inputs required for each gate and the large number of gates required results in a heavy consumption of silicon area when constructing a large binary counter or when putting a large number of binary counters on a single silicon chip. The second disadvantage illustrated in FIG. 1 is the fact that each lower order stage must drive all of the switching gates associated with all of the higher order stages. This requirement results in a high fan-out requirement for the lower order stages which, in turn, requires that each of the lower order stage outputs be buffered in order to boost their drive capability. This requires further active elements for each chip, which, in turn, consumes additional silicon area.
Refer to FIG. 2 wherein is illustrated the synchronous binary counter of the instant invention, which utilizes a pipeline technique for propagation of the toggle signals. The binary counter illustrated in FIG. 2 is similar to that described above in that the counter consists of a number of counter stages such as stages 200 through 203. Each stage, in turn, is identical to stage 200 and consists of inverters such as inverters 211, 212 and 204 and MOS transistors 205 and 210. Each stage has a true output (Q) and a complementary output (Q) wherein the true output of counter stage 200 is the output of inverter 211 and the complementary output of counter stage 200 is the output of inverter 204.
Each counter stage shown in FIG. 2 operates in essentially the same manner as do the counter stages in FIG. 1. Assume that the Q O output is at a logical "1" level, and that a toggle signal φ 1 is applied to terminal 206. In response to the toggle signal, transistor 205 is enabled and transfers the logical "1" output of inverter 204 to the input of inverter 212, thereby making the output of inverter 212 go to a logical "0" state. Subsequent thereto, clock signal φ 2 is applied to transistor 210, thereby enabling this transistor and applying the logical "0" at the output of inverter 212 to the input of inverter 211, which forces the output of inverter 211 to a logical "1". This, in turn, forces the output of inverter 204 to a logical "0", thereby changing the state of counter stage 200. Each of the counter stages 201 through 203 operate in an identical manner to that just described for counter stage 200.
Recall from what precedes that the prior art counter shown in FIG. 1 required a substantial number of logic gates, each having a plurality of inputs, in order to implement the look-ahead toggle signal technique. The counter of the instant invention does not require these logic gates and, therefore, provides many advantages over the prior art counter. More particularly, the toggle signal for the least significant bit of the counter (i.e. counter stage 200) is the φ 1 toggle signal applied to terminal 206. Assume that counter stage 200 is at a logical "0" state such that the Q 0 output of stage 200 is at a logical "0" level. The Q 0 output being at a logical "0" level turns transistor 207 OFF, thereby preventing the toggle signal applied to terminal 206 from propagating through to higher counter stages. At the same time, Q 0 is at a logical "1" level, thereby enabling transistor 208 which grounds junction 220, thereby insuring that the toggle signal is blocked from all successive stages. Therefore, transistor 207 in combination with transistor 208 prevents the propagation of the toggle signal to higher counter stages when the first counter stage is in a logical "0" state.
Assume now that counter stage 200 is in a logical "1" state, whereby the Q 0 output of counter stage 200 is at a logical "1". This level is applied to transistor 207 which turns this transistor ON. At the same time, the Q 0 output of stage 200 is at a logical "0" level, thereby turning transistor 208 OFF. In this situation, the φ 1 toggle signal is propagated through transistor 207, to junction 220, and is applied to the toggle input of stage 201, thereby allowing this counter stage to change logic state in response to the φ 2 pulse being applied thereto. (The φ 2 clock pulse occurs subsequent to the φ 1 toggle pulse). The φ 2 clock pulse is also applied to transistor 209, as indicated in FIG. 2, thereby turning this transistor ON and grounding junction 220. Transistors 209, 215, 218 and 219 are necessary to hold the toggle input of each counter stage at a logic "0" level while lower order bits are transitioning from one state to another. This requirement is necessary due to the fact that capacitive coupling between the stages could produce transient toggle signals at the time a lower order stage is changing state. Transistors 209, 215, 218 and 219 are also necessary to insure that there is no overlapping between the toggle signal φ 1 and the clock signal φ 2 .
The operation described above for counter stage 200 is equally applicable to counter stages 201 through 203. More particularly, when the Q 1 output of counter stage 201 is at a logical "0" level, transistor 213 is turned OFF and transistor 214 is turned ON due to the Q 1 output of stage 201 being at a logical "1" level. The combination of transistors 213 and 214 prevents the propagation of the toggle signal to higher order stages when stage 201 is in a logic "0" state. Alternatively, when the output of stage 201 is at a logic "1" level, the Q 1 output is high, thereby turning transistor 213 ON while transistor 214 is turned OFF. In this configuration the toggle signal applied to terminal 206, if it has been propagated through transistor 207 and junction 220, will also be propagated through transistor 213 and applied to the toggle input of stage 202. Similar to the operation described above, the occurrence of the φ 2 clock pulse subsequent to the toggle pulse will turn on transistor 215, thereby grounding the toggle input of stages 201 and 202 while the lower order stages are changing state to thereby prevent transient toggle signals resulting from capacitive coupling between stages.
The circuit configuration described in FIG. 2 provides many advantages over the prior art configuration shown in FIG. 1. More particularly this "pipeline" configuration allows each stage output to have identical loading characteristics regardless of the length of the counter as each stage is required to drive an identical number of transistors. In addition, the pipeline transistors 207, 208 and 209 are easily incorporated within the structure of the counter stages during fabrication and each single cell of the counter stage can be repeated as often as desired to obtain the required counter length. This is in contrast to the conventional counter shown in FIG. 1, wherein the loading of each output stage varies from stage to stage as a function of the counter length. Thus, in a prior art counter, in order to achieve optimum design each stage must be designed individually and moreover, as the loading requirements increase for higher order stages, the devices incorporated within each stage must become larger, thereby using more circuit area. In addition, since the prior art stages are not identical, it is impossible to merely repeat identical cells and each cell must be designed individually which is an important disadvantage in large scale integration fabrication techniques. Through utilization of the "pipeline"configuration described above it has been shown that the toggle signal can be propagated through a ten-stage counter within 50 nsec. As the toggle signal frequency must be half of the clock signal frequency, a propagation time of 50 nanoseconds for a ten-stage counter is equivalent to a ten megahertz operation.
Although a specific embodiment of this invention has been shown and described, it will be understood that various modifications may be made without departing from the spirit of this invention. | A synchronous binary counter includes a plurality of counter stages wherein each stage experiences a state change in response to the application of a toggle signal thereto. Gating apparatus is provided between successive ones of the counter stages and said gating apparatus is responsive to a first state of the preceding counter stage for transferring the toggle signal to successive ones of the counter stages and responsive to a second state of the preceding counter stage for blocking the transfer of the toggle signal. | 7 |
BACKGROUND OF THE INVENTION
My invention relates to security systems and particularly to security systems which combine the advantages of low cost reliable integrated circuits and a microcomputer to attain the advantages of cryptographic encoding at minimum expense and complication.
Security systems employing electro-mechanical bolts or locks, controlled by electrical circuits requiring a combination of electrical inputs for unlocking, are well known in the art. Many of these systems employ wired digital logic to insure that only a proper combination of inputs will operate the locking mechanism. Such systems are complex to design and manufacture and would require extensive physical wiring changes to change the combinations of inputs required to unlock the system.
Also, prior systems have relied on a single number value, generally encoded in binary form, such as an 8-bit combination which would provide the equivalent of decimal numbers from 0 to 256 (28). Such arrangements can be rather easily defeated, since it is relatively simple to build a circuit arrangement which will quickly generate a sequence of all of the possible combinations, and by supplying this sequence to the security systems input, the unlocking sequence will be quickly found. More secure systems rely on such binary coded numbers and/or a set or keyboard entered numbers which must be remembered by the user, such as with card entry systems. U.S. Pat. Nos. 3,821,704; 4,286,305 and Re. 29,846 are exemplary of such prior art.
OBJECTS OF THE INVENTION
Accordingly, it is a principal object of my invention to provide an improved security system which employs a microcomputer rather than hard wired logic.
Another object of my invention is to provide a security system which uses a microcomputer and crytographic principles to provide a security system which is highly immune to unauthorized operation.
A further object of the invention is to provide a security system of the type described which is easy to install and maintain, and economical to manufacture.
Still another object of the invention is to provide a system of the type described which by using a plurality of n-bit binary combinations greatly increases the security of the system.
Another object of the invention is to provide a security system of the type described in which a plurality of n-bit binary numbers are read in sequence from a key device, and the numbers as well as the sequence must be correct to render the system operative, eliminating the need for a key pad number entry.
A further object of the invention is to provide a security system of the type described in which tampering with the system by unauthorized persons will not only operate an alarm device, but will also render the system inoperative for a predetermined time.
Still another object of the invention is to provide a security system of the type described in which a coded key device is employed to unlock the system from outside the secured area, but only conventional push button need to be operated to unlock the system from inside the secured area.
A further object of the invention is to provide a security system of the type described in which the code contained in the key device can be modified or changed quickly by a computer system arranged to provide the new code to the key device.
Yet another object of the invention is to provide a security system of the type described in which automatic relocking of the system is provided if the door or other protected device is not opened or otherwise operated within a predetermined time interval.
Still another object of the invention is to provide a security system of the type described in which a microcomputer controls the system, and wherein it is not possible for unauthorized parties to gain access to the microcomputer program.
SUMMARY OF THE INVENTION
The present invention is a security system for permitting access to a secure area through a door, gate, turnstile or other controllable entry means, by means of an electronic key comprising a read-only memory enclosed in a suitable housing and having a plurality of electrical connections extending therefrom. Insertion of the key in a slot establishes electrical connections extending to the key. A microcomputer in the system checks that the key is of the proper type, and then energizes reading means to establish data transfer circuits from the read-only memory in the key to the data inputs of the microcomputer. A plurality of successive binary numbers are read out of the key and checked against pre-stored numbers in a read-only memory directly connected to the microcomputer. If the stored numbers correspond with the numbers of the key the security system will unlock the entry to the secured area, otherwise an alarm signal will be generated. The entry must be used within a predetermined time interval following the unlock signal, otherwise the unlock condition will be terminated and the system will automatically relock. If the entry is used properly the unlock condition will be maintained until the entry is manually restored to its secure condition, e.g., the door is closed by the user, after which the system is restored, and the locked condition is again effective. For operation from within the secure area, a manually operated circuit is employed, governed, for example, by a push button located within the secure area. A plurality of indicating devices, such as light-emitting diodes, are provided to inform users of the system of its status.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and other features of the invention and its advantages will become more fully understood from the following detailed description when considered with the accompanying drawings, in which:
FIG. 1 is a simplified schematic illustration of a security system in accordance with a first preferred embodiment of the invention,
FIG. 2 is a simplified schematic illustration of a security system in accordance with a second preferred embodiment of the invention,
FIGS. 3A, 3B and 3C, taken together in the order named, comprise a schematic block diagram of the electronic circuits and microcomputer employed in the invention,
FIG. 4 is a simplified flow chart illustrating the operation of the invention,
FIGS. 5A, 5B, 5C, and 5D, taken together in the order shown in FIG. 6, comprise a detailed flow chart illustrating the operation of the invention, and
FIG. 6 is an alignment diagram for FIGS. 5A through 5D.
Similar reference characters refer to similar parts in each of the several views.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 shows a highly diagrammatic view of the principal elements of a single station security system which embodies the present invention, Key device 1 comprises a housing portion 3 and an electrical connector portion 5. Within housing 3 there is a read-only memory device 7, which has its terminals electrically connected to the connector portion 5. The key device is constructed and arranged so that it can be carried about by the user in the same manner as conventional mechanical keys, and is relatively rugged and unharmed by conventional rough treatment, dirt, moisture, and the like.
Located near but exterior to the secure area is a key reader 9 including a front plate having a slot 11 therein, which is designed to receive the connector portion 5 of the key device 1. A plurality of indicator devices such as LED's L1, L2, and L3 are located on the front plate of the key reader, to be plainly visible to a user of the system. The key reader 9 establishes electrical connections between the electrical connector portion of key device 1, and the conductors in a connecting cable 13, which extends between the key reader and a control box or housing 15.
Housing 15 is located within the secure area, and contains the logic circuitry, certain of the timers, the microcomputer, and other electrical and electronic elements of the invention. Control switches 17 and 19 are mounted on the front panel of housing 15, as are a plurality of LED indicators L4 and L5. An electro-mechanical lock mechanism 21 is connected to the control housing 15 by a multi-conductor cable 23.
Lock mechanism 21 may comprise, for example an electric motor which by suitable gearing or otherwise, drives a bolt 25 between an extended position as shown and a retracted position. When the bolt 25 is fully extended, it prevents any access to the secure area. The position of the bolt is detected by suitable limit switches, to be later described. Also, the closed condition or open condition of the access device such as a door, is detected by one or more limit switches, which may be conveniently located in the lock housing 21.
Electrical power for operation of the system is supplied from a small plug-in type of power supply of the well-known type which can be plugged into a convenient 110-120 volt power outlet. Rectified direct current is supplied from supply 27 to the control box via cable 29.
FIG. 2 illustrates another embodiment of the invention particularly suited to control the access to a plurality of restricted volumes, such as enclosures for railway signal apparatus, cable TV junction boxes, etc. Three such enclosures are shown, and designated by reference characters E1, E2 and EN. Each of the enclosures has therein a suitable lock device 31, and a receiver 33, the latter having inputs from an associated key reader indicated symbolically by the slots 35. The key device 37 is greatly similar to the key device 1 of FIG. 1, except that it has an additional element 39, which comprises a housing having therein a small rechargeable battery for supplying operating power to the key. This embodiment also provides a master programming module 41 to provide appropriate coding for the receivers and the keys, and may include means for providing a limited charge to the key battery so that the key is only operable for a predetermined number of hours for each charge.
Referring now to FIGS. 3A, 3B and 3C, they should be arranged with FIG. 3A to the left of Figure 3B, and FIG. 3C to the right of FIG. 3B. The power supply circuits are shown at the top of FIG. 3A. The plug-in supply unit 27 is connected to the control housing 15 by the wires 43 and 45, being the positive and negative leads, respectively, with the negative being connected to the system ground, with a first filter capacitor C1 and an over-voltage protector MOV1 connected to the positive lead, which is then connected to the input of a first three-terminal voltage regulator 47, the output of which is connected to a filter capacitor C2, and via a resistor R1 to the LED indicator L4 which is used to indicate that charging power is being supplied to the unit. The series connected steering diodes D1, D2, and D3 insure that the charging current to battery B1 and the current to the operating circuitry are correctly poled. Switch SW1 governs the supply of direct current to the system. The LED indicator L5 shows whether or not the power is on. Filter capacitor C3 is connected to the input side of the voltage regulator 49.
From the input side of regulator 49, a wire W1 is indicated as leaving FIG. 3A. This convention will hereafter be used to identify wires running from one figure of the drawings to another, eliminating the need for matching the position of the lines on adjoining drawings. In other words, a reference character such as W1 will indicate the same conductor, wherever it occurs in the drawings. The voltage on wire W1 may be for example, 12 volts and the voltage at the output of regulator 49 and on wire W2 may be, for example, 5 volts.
Operation of switch SW2, the "OPEN" control, which is a push-button, initiates the operation of a triggered monostable circuit comprising a type 555 integrated circuit timer 51 and associated components connected in a well-known configuration. The output is initiated by the operation of the push button and continues for a predetermined time. The output is inverted and the resulting negative-going pulse is supplied to a line W3 to initiate an interrupt operation of the microcomputer.
An audible alarm 53 is provided to indicate the operation of the system under proper as well as improper conditions, and it is energized by a driver unit 55 which is driven in turn by an input circuit including a delayed sensor input jack 57. This jack normally grounds one input to the NOR gate 59 but when a proper input is provided to jack 57 from some type of external sensor, the output of the driver 55 will cause alarm 53 to sound. The second input to NOR gate 59 is a wire W4 which is an output from the microcomputer which is active under certain alarm conditions as will be later explained.
An output from NOR gate 59 is also supplied via capacitor C4 to a second 555 timer circuit, 61 which at the termination of its delay period supplies a pulse to yet another 555 circuit 63 which supplies an output to circuitry for governing external alarms, to be subsequently described.
A second alarm circuit which provides an immediate alarm rather than the delayed alarm described above, includes an input jack 65, similar to the jack 57 associated with the delayed sensor input. This jack is connected to one input of NOR gate 67. The second input of the NOR gate 67 is connected to ground at the key reader via a wire W5 and a normally-closed tamper switch 69 in the key reader. Improper use of the key reader or tampering with the device will cause switch 69 to open thereby removing the ground from the second input to NOR gate 67. The output of NOR gate 67 is supplied through the succeeding logic devices and a capacitor C5 to the trigger input of timer 63. It will be apparent to those skilled in the art that this arrangement will cause an output to appear at the output pin 3 of the timer 63 shortly after an alarm signal has been supplied from the NOR gate 67.
A plurality of external connection terminals are provided on the housing 15, preferably on the rear side thereof to accomodate external alarm devices, particularly those which require considerable operating power, e.g., an electric siren. As shown in FIG. 3A, the terminals provide connections to +12 V., +5 V., ground, and the normally-open, normally-closed, and common contact 71 of a relay having an operating coil or winding 73 bridged by a snubbing diode D4. The relay winding is energized by a circuit including a transistor driver 75, which has its base connected to the output pin 3 of timer 63 via resistor 77. When relay winding 73 is energized contact 71 transfers from its normally-closed to its normally-open contact, and opens and/or closes the external circuitry connected to the terminals NO, NC, and COM. The relay contacts may be selected to handle much larger amounts of power than the solid state logic circuits. There is also provided an external connection terminal designated EXT ALARM TRIGGER, which is directly connected to pin 3 of timer 63.
It is apparent from the foregoing that the present invention can supply both on-board and external alarms to indicate the condition of the system.
Referring now to FIG. 3B, there is shown a microcomputer 79 and a read-only memory 81, which are principal components of the present invention. The microcomputer is a single chip type, 8-bit EPROM microcomputer containing a CPU, on-chip clock, EPROM, bootstrap ROM, RAM, I/O, and a TIMER. A commercially available type is manufactured by Motorola, Inc., and is known as the MC68705U3. Complete technical information is contained in an Advance Information publication ADI-859 R1, copyright Motorola, Inc., 1981, which is incorporated herein by reference. The read-only memory is a type AM27S19, and is used to store the codes which are also stored in the key devices. The microcomputer and the ROM 81 have a plurality of pin connections, the identification numbers being shown within the rectangles indicated by reference characters 79 and 81. The location of the pin numbers is not necessarily indicative of their actual location on the DIP modules.
Power is supplied at +5 volts via wire W2, with by-pass capacitors C6 and C7 being connected to the +5 volt line adjacent the microcomputer and the ROM, the negative power pins on these modules being connected to the system ground and hence to the negative side of the 5 volt power supply. +5 volts is supplied to pin 16 of ROM 81 and pins 4 and 7 of microcomputer 79, and ground is connected to pins 8, 14 and 15 of the ROM and to pin 1 of the microcomputer. The resistor R4 connected between pins 5 and 6 of the microcomputer governs the frequency of the internal clock. A resistor R3 and a capacitor C6 are connected in series between +5 v. and ground, and their junction is connected to pin 2 of microcomputer 79. This arrangement acts as a power-up reset delay circuit for the microcomputer. The data input lines from the key reader to the inputs of the microcomputer are contained in a cable CBL1. The interrupt line W3 from FIG. 3A is connected to pin 3, and the line W7 from the key reader is also connected to pin 3 via capacitor C7, the line W7 normally being held at +5 volts via resistor R5. Lines W8, W9 and W10, connected to pins 30, 31, and 32 are input lines from limit switches located in the lock body and shown in FIG. 3C. Wires W11 and W12 are connected to output pins 29 and 28 by transistors 83 and 85, along with limiting resistors R6 and R7, and base input resistors R8 and R9. Pin 28 is also connected to wire W4, as shown in FIG. 3B. A switched voltage regulator has an input connected to W1, an output connected to W15, and a control line connected to pin 25 of the microcomputer.
The dead bolt actuator is driven by a reversible direct current motor, by outputs at pins 26 and 27 of the microcomputer. Pin 27, via a transistor 89, governs the supply of energy to the pole changing contacts 91, 92 of a relay having a winding 93, bridged by a diode D5, with an arc suppression diode D7 connected to the relay contacts. The output of pin 26, via transistor 95 governs the operation of the relay. Thus the output of pin 27 turns the motor on and off while the relay controlled by the output of pin 26 governs the direction of rotation of the motor. The operating power for the motor is delivered on wires W13 and W14, which have a "glitch" protector MOV2 connected across them.
Referring now to FIG. 3C, there is shown the circuitry associated with the key reader, the key device and the lock mechanism itself. The data input lines from the key reader to the microcomputer are included in a cable CBL1, as previously described. Tamper switch 69 is connected to the immediate sensor input by wire W5, also described previously. Wire W6 is the system ground connection. Wire W7 is the interrupt input to the microcomputer, which is grounded in the event of improper operation of the key reader.
The three LED indicators L1, L2, and L3, shown in FIG. 1 as being on the faceplate of the key reader, are connected as shown in FIG. 3C. The yellow LED L2 is an "ON" indicator, showing that the system is on and is connected between W1 and ground with a current limiting resistor R13 in series. The green LED L1 is connected between W1 and W11, and is turned on when the system has provided an unlock. The red LED L3 is the "ALARM" indicator and is connected to W1 and W12. It flashes when the key is inserted in the reader, and also goes on for alarm conditions.
The lock body 21 indicated in FIG. 3C by the dashed line rectangle includes the motor 99 which drives the linear actuator that extends and retracts the dead bolt 25. The motor may be of the DC permanent magnet type, and will rotate in one direction or the other depending on the relative polarity of the energy supplied to the motor over wires W13 and W14.
Also contained within lock body 21 are three switches 101, 103, and 105, one side of each switch being connected to the system ground connection W6, and the other side of switches 101, 103 and 105 being connected to wires W8, W9 and W10, respectively. These wires are connected to the input pins 30, 31, and 32 of the microcomputer, and are also connected to +5 volts through the pull-up resistors R10, R11 and R12, respectively.
Switch 101 is closed and grounds wire W8 when the deadbolt is fully retracted, switch 103 is closed when the dead bolt is fully extended, and grounds wire W9 at that time, and switch 105 is closed and grounds wire W10 when the door is fully closed.
Also shown diagrammatically in FIG. 3C is the key device 1. A re-programmable read-only memory of the same type as shown and described in connection with FIG. 3B is contained within the key device, with all of the pins brought out to a plurality of edge connector type contacts, well known in the printed circuit art. These ROM's have a capacity of 32 eight bit words, with 8 pins for the data lines, 5 pins for the address lines, one "ENABLE" line, one pin for the positive power (+5 volts) and a ground pin. These ROM's are programmed by burning out fusible links, and they can have additional programming by subsequent burning. It will be apparent that other types of microcomputers and read-only memories can be used, the necessary changes being made.
FIG. 4 is a diagrammatic view of a flow chart, showing, in simplified form, the various actions occurring during an unlocking operation of the system. Following the start-reset operation, a check is made of the condition of the bolt. There is then a wait for the operation of the key or the push button, after which the alarm is cut off. If the key did not cause the interrupt, the motor is turned on to retract the bolt. The program checks the condition of the bolt until it is fully retracted, at which time the motor is stopped, and the "ENTER" LED is turned on. After 7 seconds has elapsed, the door is checked to see if it is closed, and if so, the motor is started to relock the door, and a timer is started to check for mechanical tampering. If the door is still closed, the bolt is checked to see if it is fully extended, and if so the motor is stopped, as well as the timer and the "ENTER" light is turned off, followed by a return to the start or reset condition.
Considering now the branching and looping operations, if the key caused the interrupt, the program branches to a subroutine which checks first that there has been no tampering at the key slot, after which power is supplied to read the key, and then the power is turned off. The stored set of codes is then read out of the read-only memory associated with the microcomputer and compared with the codes read out of the key device. If there is a match, by both combination and sequence there is a return to the main program to open or unlock the system. If there is a mismatch the alarm sequence is invoked. The alarm sequence is also invoked if there is evidence of tampering at the key slot. Another sequence is involved when the motor is started to relock the bolt, in which a timer is running while the bolt is extending. If the timer times out before the bolt is fully extended the motor is stopped and a timer interrupt activates the alarm. It should be noted that in any alarm event, the program then returns to wait for the key or push button to be activated. Another program loop exists if in the main program a door still closed decision indicates that the door is not closed, whereupon the program returns to the lock open sequence. A check on the full extension of the bolt stops the motor and timer, turns on the "ENTER" LED and returns the program to the start-reset condition.
FIGS. 5A through 5D are preferably arranged as shown by FIG. 6, and taken together comprise a detailed flow chart of the subject invention. The connecting paths in these diagrams are indicated by small circles containing alphabet letters and indicate that the circles with like letters connect with one another.
Starting on FIG. 5A with the power ON and reset operation, the relevant ports of the microcomputer are cleared and the bolt is checked to see if it is fully retracted. If so, the "ENTER" light is turned ON and the program jumps directly to point "C" to wait until the door is once again closed. If the bolt is not fully retracted in this startup phase of the program, the motor is turned OFF and the system waits for an interrupt (key or pushbutton) to occur. When it does, any alarm currently in progress, if any, will be turned off. If the interrupt was not caused by the key, but by the pushbutton, the motor is turned ON to retract. The bolt is checked until full retraction occurs.
Continuing on FIG. 5C, via connecting point "C", the motor is then turned OFF and the "ENTER" LED is turned ON. After 7 seconds, the door is checked to see if it is closed. If the door is closed, and after a door switch debounce delay, the relock sequence occurs. The motor and relay are turned on and the timer started to determine if mechanical tampering is occurring. The bolt is checked to see if it has left the retracted limit switch. With the door closed and the bolt fully seated, the timer is masked followed by stopping the motor, turning off the relay, and turning OFF the "ENTER" LED. Via the connection point "A", the flow diagram returns to FIG. 5A to the beginning of the program following power-up and reset. In FIG. 5C, after the door closed check, if the decision is "NO", a branch occurs in which the motor is turned off, the timer is masked, and the relay is off to retract the bolt, whereupon the program is returned to the main program in FIG. 5A via the connection point "B".
In the main program the bolt is always closed (extended) and the door closed. This part of the program test that the door switch is never released when the bolt is extended. As this can only occur if the door is removed from its hinges or the door button was pushed by something other than the door and held until the bolt was fully extended, an alarm condition is called.
Continuing from point "G" in FIG. 5C, during the time that the bolt is in the process of extending, the door switch is also being continually checked to see if it was somehow released before the bolt is fully extended. If it was, the motor is stopped, reversed, the timer is masked and the program returns again to point "B" where it retracts the bolt and again waits for the door to close. This ensures that a deliberate attempt to lock the system is made.
A branch program starting at connection point "G" in FIG. 5C continues at that connection point in FIG. 5D, with the timer running while the bolt is extending. If time out does not occur before the bolt is fully out, then the program as normal is continued with no interrupt, otherwise a timer interrupt is generated, after which the motor and relay are turned off and the timer is masked, followed by activation of the alarm, which by connection point "D" returns to FIG. 5A and the wait for interrupt to occur.
In the main program, in FIG. 5A, if the response to the decision point checking whether or not there was a key-caused interrupt, if the answer is yes then the program branches via the connection point "E" to FIG. 5B to cause a short "beep" of the audible alarm. The key reading routine is invoked, first by checking for tampering and if there is any evidence of tampering, the program switches over to activate the alarm via connection point "H", FIGS. 5B to 5D. If there is no tampering, then the program goes on to power the key reader, set the appropriate registers in the microcomputer, read the key and store the key codes in the random-access memory. Also the value X which had been stored in RAM as the number of codes to be checked is decremented by one, then the program moves to FIG. 5D via connection point "I". If X does not equal zero, the key address is incremented by one, and the program loops back by way of connection point "J" in FIG. 5B, and continues until X=zero, on FIG. 5D. At this time, the power to the key is cut off and the address is reset, followed by readout of the stored codes from the ROM, and comparison of the key codes and the stored codes. If unequal an alarm sequence is invoked, but if equal, then the value X is decremented and then tested to see if it equals zero. If not equal to zero, the address is incremented and the program jumps back to read another stored code.
When X becomes zero, the program returns to the door unlocking sequence via connection point "F" in FIG. 5A.
Although the invention is useful for controlling access to secure areas by doors, gates etc., it obviously is applicable to any situation where a controlled function is to be governed only by authorized personnel who have been provided with a suitable key. It should also be apparent to those skilled in the art that it is not necessary that a separate housing be provided for the microcomputer and the auxiliary circuitry, but that these elements of the invention may readily be housed in a suitable sized lock housing, thereby eliminating the need for a separate control box.
From all of the foregoing, it will be apparent that my invention provides a new and improved security system which is relatively simple and economical to implement and which has a very high immunity to improper or unauthorized use, or to tampering.
Although I have herein shown and described only two preferred embodiments of my invention, it will be apparent to those skilled in the art to which the invention appertains, that various other changes and modifications may be made to the subject invention, without departing from the spirit and scope thereof, and therefore it is understood that all modifications, variations and equivalents within the spirit and scope of the subject invention are herein meant to be encompassed in the appended claims. | A security system includes a microcomputer with an auxiliary read-only memory and a key device including a similar read-only memory, each of the read-only memories containing corresponding pluralities of corresponding binary combination codes. Under the control of the microcomputer the codes are read and compared. If the combinations and the sequence do not compare, the system will not unlock and an alarm will be generated. The read-only memories are of the programmable type, so that changes in the combinations and sequences can be accomplished easily. A plurality of visual indicators and an audible alarm provide the user and personnel in the secure area with information concerning the status of the system. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to the general field of diesel internal combustion engines, and more particularly relates to an intake air throttling device for a diesel internal combustion engine which can provide good anti vibration and anti noise protection, both during idling operation and during stopping of the diesel internal combustion engine.
Typically the load on a diesel internal combustion engine, i.e. the power output produced thereby, is regulated by controlling the amount of fuel injected into the combustion chamber or chambers thereof, rather than, as is the case with a gasoline internal combustion engine incorporating a carburetor, by regulating the amount of intake air flow. Thus, when the diesel internal combustion engine is required to produce a considerably high power output, i.e. is required to operate in a medium or a high load operational condition, then a considerable amount of fuel is injected into each combustion chamber thereof at each of its compression strokes; and, on the other hand, when said diesel internal combustion engine is required to produce a low power output just sufficient to keep the engine itself operating, i.e. is required to operate in an idling operational condition, then a much smaller amount of fuel is injected into each combustion chamber thereof at each of its compression strokes.
In a simplest form of conventional prior art, the intake air passage of the diesel engine is left wide open at all times, and therefore enough intake air is available for even high load operation of the engine wherein the pulses of injected diesel fuel which are injected into the combustion chambers are of maximum amount; and, correspondingly, the amount of intake air sucked in to the combustion chambers during idling engine operation wherein the pulses of injected diesel fuel which are injected into the combustion chambers are of quite small amount is very excessive - but this need not present any insuperable problem, although in this case the engine operates in a very over lean operational mode.
However, a problem which often occurs with diesel engines, especially small diesel engines such as are being used more and more these days in automotive applications for passenger cars, is that noise and vibration during engine idling operation are excessive, and can produce user complaints, as well as deteriorating the service lift of such a diesel engine. Accordingly, some means of restricting the idling vibration and noise levels has become a desirable design goal.
In the prior art, a known method of thus improving engine idling operation of a diesel internal combustion engine has been to somewhat throttle the air intake passage of the engine during idling operation thereof, as by using a throttling valve or the like. This has been very useful for reducing noise and vibration during engine idling, and various systems have been proposed for control of such a throttling valve.
Another problem which has been remarked upon with regard to diesel internal combustion engines is that during stopping of the engine, i.e. when during operation of the engine the key switch or the like controlling said engine is switched to the OFF state from the ON state (or the like) and according to this supply of injected pulses of diesel fuel into the combustion chamber or chambers of the diesel engine is terminated, then considerable vibration and noise are liable to be caused. Again, this can produce user complaints, as well as deteriorating the service life of such a diesel engine. Accordingly, again, some means of restricting such stopping vibration and noise levels has become a desirable design goal.
In the prior art, a known method of thus improving engine stopping operation of a diesel internal combustion engine has been to totally close the air intake passage of the diesel internal combustion engine during stopping operation thereof. This is often done in large diesel engines by using a manually controlled throttling valve or the like, and has been very useful for reducing noise and vibration during engine stopping.
Meanwhile, of course if the air intake passage of the diesel internal combustion engine is to be restricted at any time it is important that at no time should the air intake passage be restricted to such an extent as to prevent the entry into the combustion chamber or chambers of the diesel internal combustion engine of sufficient air to completely combust all of the diesel fuel which is being injected into said combustion chamber or chambers. If undesirably the air supply to the combustion chamber or chambers should thus be over restricted, generation of an undesirably large quantity of diesel smoke will most likely occur, as well as the emission in the exhaust gases of the diesel internal combustion engine of an undesirably large quantity of noxious components.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide an intake air throttling device for a diesel internal combustion engine, which reduces engine noise during idling operation of said diesel internal combustion engine.
It is a further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which reduces engine vibration during idling operation of said diesel internal combustion engine.
It is a further primary object of the present invention to provide an intake air throttling device for a diesel internal combustion engine, which reduces engine noise during stopping of said diesel internal combustion engine.
It is a further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which reduces engine vibration during stopping of said diesel internal combustion engine.
It is a further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which attains both of the primary objects detailed above with a useful economy of parts, by using some of the same parts for achieving both objects.
It is a further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which runs no risk of unduly throttling the air intake system of the diesel internal combustion engine at any time.
It is a further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which runs no risk of generation of undue quantities of diesel smoke, during engine load bearing operation.
It is a further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which runs no risk of emission of undue quantities of noxious components in the exhaust gases of the diesel internal combustion engine, during engine load bearing operation.
It is a further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which renders the diesel internal combustion engine quiet and comfortable to operate.
It is a yet further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which is of simple construction.
It is a yet further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which is cheap to manufacture.
It is a yet further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which is reliable during use.
It is a yet further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which does not incorporate any complicated control device such as a microcomputer or the like.
It is a yet further object of the present invention to provide such an intake air throttling device for a diesel internal combustion engine, which employs, for sensing the operational condition of the diesel internal combustion engine, a sensor or a combination of sensors or other information providing devices, which are in any event required to be provided to the diesel internal combustion engine for other purposes, thus achieving a useful economy by multiple functioning of said sensors or devices.
According to the present invention, these and other objects are accomplished by an intake air throttling system for a diesel internal combustion engine comprising an air intake passage, comprising: (a) a throttling valve mounted in said air intake passage so as to selectively throttle air flow therethrough, which can be positioned to at least a first position in which it substantially fully closes said air intake passage, a second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage, and a third position in which it does not throttle said air intake passage to any substantial extent; and (b) a control system which controls said throttling valve, and: which positions said throttling valve to said first position in which said throttling valve substantially fully closes said air intake passage, when said diesel internal combustion engine is put out of operation from being in operation; which positions said throttling valve to said second position in which said throttling valve partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage, when said diesel internal combustion engine is being operated in idling operational condition; and which positions said throttling valve to said third position in which said throttling valve does not throttle said air intake passage to any substantial extent, when said diesel internal combustion engine is being operated in non idling load bearing operational condition.
According to such a structure, during operation of the diesel internal combustion engine in its non idling load bearing operational condition the throttling valve is positioned by the control system to its said third position in which the air intake passage is not throttled to any substantial extent, and thereby the diesel internal combustion engine is allowed to inhale a proper large quantity of intake air appropriate to such load bearing operation, thus accordingly running no risk of over rich operation of said internal combustion engine. Further, during operation of the diesel internal combustion engine in its idling operational condition, the control system positions said throttling valve to its said second position in which said throttling valve partly throttles the air intake passage to a substantial extent but does not fully close said air intake passage, thus reducing vibration and noise during said engine idling operational condition. Yet further, during stopping of said diesel internal combustion engine, i.e. when said diesel internal combustion engine is put out of operation from being in operation, then the control system positions said throttling valve to said first position in which said throttling valve substantially fully closes said air intake passage, and this reduces the vibration during stopping of the diesel internal combustion engine to a large extent. Both of these beneficial effects are therefore provided by using the same intake throttling valve, which is an admirable economy of construction.
Further, according to a particular aspect of the present invention, these and other objects are more particularly and concretely accomplished by such an intake air throttling system for a diesel internal combustion engine as described above, wherein, when said diesel internal combustion engine transits from the idling non load bearing operational condition to the non idling load bearing operational condition, said control system relatively quickly moves said throttling valve from its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage to its said third position in which it does not throttle said air intake passage to any substantial extent; but, when said diesel internal combustion engine transits from the non idling load bearing operational condition to the idling non load bearing operational condition, said control system only relatively slowly moves said throttling valve from its said third position in which it does not throttle said air intake passage to any substantial extent to its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage.
According to such a structure, when said diesel internal combustion engine transits from the non idling load bearing operational condition to the idling non load bearing operational condition, i.e. when a vehicle incorporating said diesel internal combustion engine is decelerated to the idling condition, then because said throttling valve is only relatively slowly moved by said control system from its said third position in which it does not throttle said air intake passage to any substantial extent to its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage, thereby too rapid applying of said partial throttling action which could undesirably cause a large amount of exhaust smoke and high emission of undesirable components in the exhaust gases of the diesel internal combustion engine is rendered much less likely, due to the gradual applying of said partial throttling action. On the other hand, when said diesel internal combustion engine transits in the reverse sense from the idling non load bearing operational condition to the non idling load bearing operational condition, i.e. when a vehicle incorporating said diesel internal combustion engine is accelerated from the idling condition, then said control system relatively quickly moves said throttling valve from its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage to its said third position in which it does not throttle said air intake passage to any substantial exten, because at this time rapid supply of high volumes of intake air is appropriate in order to prevent the causing of the generation of a large amount of exhaust smoke and high emission of undesirable components in the exhaust gases of the diesel internal combustion engine.
Further, according to a particular aspect of the present invention, these and other objects are more particularly and concretely accomplished by such an intake air throttling system for a diesel internal combustion engine as described above, said diesel internal combustion engine comprising a key switch which is opened when said diesel internal combustion engine is not to be operated and which is closed when said diesel internal combustion engine is to be operated, and an accelerator linkage which controls the load on said diesel internal combustion engine; further comprising a switching system which is controlled by said accelerator linkage so as to furnish a first electrical signal indicative of whether said diesel internal combustion engine is operating in the idling non load bearing operational condition or in the load bearing non idling operational condition; said control system receiving said first electrical signal and also receiving supply of switched electrical power from said key switch as a second electrical signal, and based upon said first and second electrical signals controlling said throttling valve.
According to such a structure, said control system can easily and reliably be informed as to whether said diesel internal combustion engine is being idled or not, and as to whether said diesel internal combustion engine is being switched off or deactivated or not, according to said first and second electrical signals which come respectively from the aforesaid accelerator pedal switching system and from the aforesaid key switch. Since both the accelerator pedal switching system which detects whether the engine is being idled or not and also the key switch may have other applications in the construction and operation of the diesel internal combustion engine and its associated parts such as a transmission and an electrical system and so on, this makes for a good economy of parts.
Further, according to a particular aspect of the present invention, these and other objects are more particularly and concretely accomplished by such an intake air throttling system for a diesel internal combustion engine as proximately described above, wherein said control system comprises a double action diaphragm actuator which comprises a first and a second diaphragm chamber, a first electromagnetic pressure switching valve, and a second electromagnetic pressure switching valve; said double action diaphragm actuator positioning said throttling valve to its said first position in which it substantially fully closes said air intake passage, or its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage, or its said third position in which it does not throttle said air intake passage to any substantial extent, according to different combinations of supply of atmospheric pressure or vacuum to said first and second diaphragm chambers; selective supply of atmospheric pressure or vacuum to said first diaphragm chamber being controlled by said first electromagnetic pressure switching valve which is controlled based upon said first electrical signal, and selective supply of atmospheric pressure or vacuum to said second diaphragm chamber being controlled by said second electromagnetic pressure switching valve which is controlled based upon said second electrical signal; and wherein further said double action diaphragm actuator positions said throttling valve to its said first position in which it substantially fully closes said air intake passage when both said first diaphragm chamber is supplied with vacuum and also said second diaphragm chamber is supplied with vacuum; wherein said double action diaphragm actuator positions said throttling valve to its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage when said first diaphragm chamber is supplied with vacuum but when said second diaphragm chamber is not supplied with vacuum but is supplied with atmospheric air; and wherein said double action diaphragm actuator positions said throttling valve to its said third position in which it does not throttle said air intake passage to any substantial extent when when both said first diaphragm chamber is not supplied with vacuum but is supplied with atmospheric air and also said second diaphragm chamber is not supplied with vacuum but is supplied with atmospheric air.
According to such a structure, the control system may be of a simple and reliable construction, not necessarily incorporating any such device as a microcomputer or the like, and the throttling valve may be moved to and fro between its said first, second, and third positions so as to selectively throttle the intake passage of the diesel internal combustion engine by a reliable device such as the aforesaid diaphragm actuator, which is supplied with actuating vacuum by reliable and cheap devices such as the aforesaid first and second electromagnetic pressure switching valves.
Further, according to a yet more particular aspect of the present invention, these and other objects are more particularly and concretely accomplished by such an intake air throttling system for a diesel internal combustion engine as described above, further comprising a one way pressure transmission delay valve which is interposed between said first electromagnetic pressure switching valve and said first diaphragm chamber, and which permits the quick transmission of atmospheric air from said first electromagnetic pressure switching valve to said first diaphragm chamber, but which only permits the relatively slow transmission of vacuum from said first electromagnetic pressure switching valve to said first diaphragm chamber.
According to such a structure, the provision of this one way pressure transmission delay valve effectively implements the abovementioned desirable feature of the present invention of providing a somewhat delayed motion of the throttling valve, when said diesel internal combustion engine transits from the non idling load bearing operational condition to the idling non load bearing operational condition, i.e. when a vehicle incorporating said diesel internal combustion engine is decelerated to the idling condition, from its said third position in which it does not throttle said air intake passage to any substantial extent to its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage. This delayed motion is provided because of the length of time that it takes for air to pass through said one way pressure transmission delay valve from said first electromagnetic pressure switching valve to said first diaphragm chamber. The one way pressure transmission valve further is required to be a one way valve, in order to allow the aforesaid desirable quick motion of the throttling valve, when said diesel internal combustion engine transits from the idling non load bearing operational condition to the non idling load bearing operational condition, i.e. when a vehicle incorporating said diesel internal combustion engine is accelerated from the idling condition, from its said second position in which it partly throttles said air intake passage to a substantial extent but does not fully close said air intake passage to its said third position in which it does not throttle said air intake passage to any substantial extent.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be shown and described with reference to a preferred embodiment thereof, and with reference to the illustrative drawings. It should be clearly understood, however, that the description of the embodiment, and the drawings, are all of them given purely for the purposes of explanation and exemplification only, and are none of them intended to be limitative of the scope of the present invention in any way, since the scope of the present invention is to be defined solely by the legitimate and proper scope of the appended claims. In the drawings:
FIG. 1 is a sectional view of part of a diesel engine which is equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention;
FIG. 2 is a partly schematic view of said preferred embodiment of the diesel engine intake air throttling system according to the present invention, also showing a battery and a key switch for the diesel engine shown in FIG. 1, and showing in section part of the intake passage of said diesel engine;
FIG. 3 is a graph, in which percentage engine intake air throttling ratio is the abscissa and percentage variation in engine revolution speed is the ordinate, showing the performance of a diesel engine equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention with regard to variation of idling engine revolution speed, both at an average idling speed of 600 rpm, and at an average idling speed of 700 rpm;
FIG. 4 is a graph, in which percentage engine intake air throttling ratio is the abscissa and engine idling vibration is the ordinate, showing the performance of a diesel engine equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention with regard to idling engine vibration, both at an average idling speed of 600 rpm, and at an average idling speed of 700 rpm; and
FIG. 5 is a graph, in which time is the abscissa, and engine vibration is the ordinate, showing the performance of a diesel engine equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention with regard to engine vibration when the engine has been switched off and while its rotation is stopping, as contrasted to the performance of a diesel engine which is not equipped with any such intake air throttling system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described with reference to a preferred embodiment thereof, and with reference to the appended drawings. FIG. 1 is a sectional view through a diesel internal combustion engine, designated generally by the reference numeral 1, which is equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention, taken along the central axis of a cylinder bore 2 thereof.
A piston 3 reciprocates slidingly up and down in the figure in said cylinder bore 2, and above said piston 3 there is defined a combustion chamber 4 by said piston in cooperation with a cylinder head 100. In said cylinder head 100 there is formed a vortex chamber 5 which communicates to said combustion chamber 4, and in said vortex chamber 5 there is fitted a fuel injector 6. Intake air is supplied to said combustion chamber 4 through, in order from the atmosphere, an air intake tube 7, a valve housing 8 the function of which will be more particularly described later, an intake manifold 9 which is fixed to the outer surface of said cylinder head 100, and an intake port which is not shown in the figure because in fact it lies behind the fuel injector 6 and the vortex chamber 5, said intake port being controlled by an intake poppet valve which is not shown in the figure either, for the same reason. After this intake air has been mixed with diesel fuel injected through the fuel injector 6, and combustion has occurred in the combustion chamber 4, then the exhaust gases resulting from said combustion are exhausted from said combustion chamber 4 through an exhaust port 10 which is controlled by an exhaust poppet valve 12, and are vented through an exhaust manifold 11 which is also fixed to the outer surface of the cylinder head 100. This arrangement, with the exception of the interposition of the valve housing 8 in the intake air path as it passes into the combustion chamber 4, is per se well known and conventional.
In FIG. 2 the valve housing 8 can be seen in sectional view in more detail. This valve housing 8 is formed as a tube, and within the tubular interior thereof there is mounted a per se conventional butterfly valve 14. This butterfly valve 14 is fixed to a valve shaft 13 which is pivotally mounted across the center of the valve housing 8. The butterfly valve 14 can move to any position in the range between two extreme positions: a position shown by solid lines in the figure and denoted by "III", in which said butterfly valve 14 is fully open and does not significantly obstruct the passage of intake air through the tubular hole through the valve housing 8, and a position shown by double dotted lines in the figure and denoted by "II", in which said butterfly valve 14 is fully closed, and does not significantly allow the passage of any intake air through the tubular hole through the valve housing 8, totally blocking said tubular hole; and, in particular, said butterfly valve 14 can be positioned to an intermediate position between its said fully open position III and its said fully closed position II said position being shown by dashed lines in the figure and denoted by "I", in which said butterfly valve 14 is partly closed, and somewhat obstructs the passage of intake air through the tubular hole through the valve housing 8, without totally blocking said passage of intake air.
An end of the valve shaft 13 which projects to the outside of the valve housing 8 (although this detail cannot be seen in the figures) is fixedly coupled to the one end of a valve actuating lever 15, the other end of which is drivingly pivotally (and slidingly) coupled to the upper end in FIG. 2 of a valve actuating rod 17. The lower end of the valve actuating rod 17 extends into and is driven by a double action diaphragm device 16.
The double action diaphragm device 16 is of a per se well known sort, and has two diaphragm chambers, denoted in FIG. 2 by 18 and 19 respectively. The function of this diaphragm device 16 is as follows. When no negative pressure is introduced either into the first diaphragm chamber 18 or into the second diaphragm chamber 19 of the double action diaphragm device 16, then the valve rod 17 is so positioned thereby as to position the butterfly valve 14 to its said fully open position denoted by III in the figure and shown by solid lines, wherein it is fully open and does not significantly obstruct the passage of intake air through the tubular hole through the valve housing 8; when negative pressure is introduced into the first diaphragm chamber 18 of the double action diaphragm device 16, but no negative pressure is introduced into the second diaphragm chamber 19, then the valve rod 17 is so positioned thereby as to position the butterfly valve 14 to its said partly open position denoted by I in the figure and shown by dashed lines, wherein it is partly closed and somewhat obstructs the passage of intake air through the tubular hole through the valve housing 8 without totally blocking said passage of intake air; when negative pressure is introduced both into the first diaphragm chamber 18 and into the second diaphragm chamber 19 of the double action diaphragm device 16, then the valve rod 17 is so positioned thereby as to position the butterfly valve 14 to its said fully closed position denoted by II in the figure and shown by double dashed lines, wherein it is fully closed and does not significantly allow the passage of any intake air through the tubular hole through the valve housing 8, totally blocking said tubular hole; and the action when no negative pressure is introduced into the first diaphragm chamber 18 of the double action diaphragm device 16, but negative pressure is introduced into the second diaphragm chamber 19, need not be considered, since as will be seen later this state of affairs never occurs during the functioning of the shown preferred embodiment of the diesel engine intake air throttling system according to the present invention.
Now, the arrangements for selectively supplying actuating negative pressure to the first and second diaphragm chambers 18 and 19 will be explained.
A first electromagnetic vacuum switching valve and a second electromagnetic vacuum switching valve are provided, respectively for controlling supply of negative pressure to the first and the second diaphragm chambers 18 and 19, and these are denoted in FIG. 2 by the reference numerals 23 and 25 respectively. Each of these electromagnetic vacuum switching valves 23 and 25 is formed with three ports, denoted in the figure by "A", "B", and "C", and may comprise an electromagnetic coil, a solenoid element, and so forth, or may be formed in some other per se well known fashion. The functioning of each of these electromagnetic vacuum switching valves 23 and 25 is as follows: when it is not supplied with actuating electrical energy, then its ports A and B are communicated together, while its port C is not communicated to any other port; and, when it is supplied with actuating electrical energy, then its ports A and C are communicated together, while its port B is not communicated to any other port.
The ports C of both the first electromagnetic vacuum switching valve 23 and the second electromagnetic vacuum switching valve 25 are communicated to supply of air at atmospheric pressure. The ports B of both the first electromagnetic vacuum switching valve 23 and the second electromagnetic vacuum switching valve 25 are communicated to a vacuum storage tank 27 via a negative pressure conduit system 26. The vacuum storage tank 27, during normal operation of the diesel internal combustion engine 1, is kept filled with negative pressure (i.e. is exhausted to some extent of air) by a vacuum pump not shown in the figure which is operated from said diesel internal combustion engine 1, via a negative pressure conduit 28. Thus, during normal operation of the diesel internal combustion engine 1, the ports B of both the first electromagnetic vacuum switching valve 23 and the second electromagnetic vacuum switching valve 25 are continually supplied with a constant supply of negative pressure stored in said vacuum storage tank 27. Finally, the port A of the first electromagnetic vacuum switching valve 23 is communicated to the input port of the first diaphragm chamber 18 of the double action diaphragm device 16 via, in order, a negative pressure conduit 22, a negative pressure one way delay valve 21, and another negative pressure conduit 20, while the port A of the second electromagnetic vacuum switching valve 25 is communicated to the input port of the second diaphragm chamber 19 of the double action diaphragm device 16 via a negative pressure conduit 24. The negative pressure one way delay valve 21 is so constructed that it allows flow of negative pressure substantially freely in the right to left direction in the figure, i.e. it allows flow of negative pressure without offering any substantial interruption thereto from its port connected to the negative pressure conduit 20 to its port connected to the negative pressure conduit 22 - or in other words it allows flow of air substantially freely in the left to right direction in the figure, i.e. it allows flow of negative pressure without offering any substantial interruption thereto from its port connected to the negative pressure conduit 22 to its port connected to the negative pressure conduit 20; while on the other hand it only allows flow of negative pressure in the left to right direction in the figure, i.e. it only allows flow of negative pressure from its port connected to the negative pressure conduit 22 to its port connected to the negative pressure conduit 20, rather slowly with a certain delay time - or in other words it only allows flow of air in the right to left direction in the figure, i.e. it only allows flow of air from its port connected to the negative pressure conduit 20 to its port connected to the negative pressure conduit 22, rather slowly with a certain delay time. This negative pressure one way delay valve 21 may be constructed, as suggested in the figure, by combining a throttling orifice and a one way air valve.
The diesel internal combustion engine 1 is provided with a battery 29 which supplies electrical power to one side of a key switch 30. When the diesel internal combustion engine 1 is to be operated, the key switch 30 is turned to the ON condition; but, when the diesel internal combustion engine 1 is to be not operated, the key switch 30 is turned to the OFF condition. Electrical power taken from the other side of the key switch 30, as well of course as being used for other purposes to do with the diesel internal combustion engine 1, is fed directly to the coil or the like of the second electromagnetic vacuum switching valve 25 as a selective supply of actuating electrical energy, the other side of said coil or the like being connected to ground. Further, said electrical power taken from said other side of the key switch 30 is also fed both to one side of an accelerator pedal sensor switch 32, the other side of said accelerator pedal sensor switch 32 being connected through the electromagnetic coil of a relay 31 to ground, and to a switched input terminal of said relay 31, the switched output terminal of said relay 31 being connected directly to the coil or the like of the electromagnetic vacuum switching valve 23 so as to provide selective supply of actuating electrical energy thereto, the other side of said coil or the like being connected to ground. The accelerator pedal sensor switch 32 is so constructed and is so fitted to the linkage which leads from the accelerator pedal to control the diesel internal combustion engine 1 that said accelerator pedal switch is opened when said accelerator pedal is even slightly depressed by the foot of an engine operator, but is closed when said accelerator pedal is not so depressed at all. And the relay 31 is so constructed that the switched terminals thereof are communicated together when the electromagnetic coil thereof is not supplied with actuating electrical energy, but so that the switched terminals thereof are discommunicated from one another when the electromagnetic coil thereof is supplied with actuating electrical energy.
Thus, the second electromagnetic vacuum switching valve 25 is supplied with actuating electrical energy when and only when the key switch 30 is closed; while the first electromagnetic vacuum switching valve 23 is supplied with actuating electrical energy when and only when the key switch 30 is closed and in addition the accelerator pedal sensor switch 32 is open - i.e., when and only when the key switch 30 is closed and in addition the accelerator pedal which controls the diesel internal combustion engine 1 is at least slightly depressed by the foot of an engine operator.
By the way, the reason for the provision of the accelerator pedal sensor switch 32 as a switch which is closed when and only when the accelerator pedal is not depressed at all, and for the provision of the relay 31, rather than some reversed or simpler construction, is because in fact, although it is not so shown in the figure, this accelerator pedal sensor switch 32 may also be put to other uses in the operation of the diesel internal combustion engine 1 or of devices associated therewith in the vehicle in which it is fitted, such as a transmission, an electrical system, or the like.
Now, the operation of the shown preferred embodiment of the diesel engine intake air throttling system according to the present invention shown in FIGS. 1 and 2 will be explained.
First, when the diesel internal combustion engine 1 is operating in the non idling or load bearing engine operational condition, i.e. when said diesel internal combustion engine 1 is operating with the accelerator pedal which controls it at least somewhat depressed, then the accelerator pedal sensor switch 32 is open, and thus the switched terminals of the relay 31 are closed, and also of course the key switch 30 is closed, and thus both the first electromagnetic vacuum switching valve 23 and also the second electromagnetic vacuum switching valve 25 are supplied with actuating electrical energy. Accordingly, the switched port A of the first electromagnetic vacuum switching valve 23 is communicated to the atmospheric air port C thereof, and also the switched port A of the second electromagnetic vacuum switching valve 25 is communicated to the atmospheric air port C thereof, while the B ports of these valves are not communicated to any other ports. Therefore, both the first diaphragm chamber 18 of the double action diaphragm device 16 and also the second diaphragm chamber 19 thereof are supplied with air at atmospheric pressure, and accordingly as explained above the butterfly valve 14 is positioned by the action of said double action diaphragm device 16, via the valve actuating rod 17, the valve actuating lever 15, and the valve shaft 13 to its said fully open position denoted by III in FIG. 2 and shown by solid lines, wherein it is fully open and does not significantly obstruct the passage of intake air through the tubular hole through the valve housing 8. Thus, in this operational state, the diesel internal combustion engine 1 functions with no substantial obstacle being provided to the flow of intake air into its combustion chambers, which is appropriate for this current load bearing operational condition in which said diesel internal combustion engine 1 is operating with the accelerator pedal which controls it at least somewhat depressed.
However, when the diesel internal combustion engine 1 is operating in the idling or no load engine operational condition, i.e. when said diesel internal combustion engine 1 is operating with the accelerator pedal which controls it not even somewhat depressed, then the accelerator pedal sensor switch 32 is closed, and thus the switched terminals of the relay 31 are open, and also of course the key switch 30 is closed, and thus the first electromagnetic vacuum switching valve 23 is not supplied with actuating electrical energy, while on the other hand the second electromagnetic vacuum switching valve 25 is supplied with actuating electrical energy. Accordingly, the switched port A of the first electromagnetic vacuum switching valve 23 is communicated to the vacuum port B thereof, while the atmospheric port C of this first electromagnetic vacuum switching valve 23 is not communicated to any other port; and, on the other hand, the switched port A of the second electromagnetic vacuum switching valve 25 is communicated to the atmospheric air port C thereof, while the vacuum port B of this second electromagnetic vacuum switching valve 25 is not communicated to any other port. Therefore, the first diaphragm chamber 18 of the double action diaphragm device 16 is supplied with negative pressure (i.e., vacuum) which is stored up in the vacuum accumulation tank 27, via the conduit system 26, while on the other hand the second diaphragm chamber 19 of said double action diaphragm device 16 is supplied with air at atmospheric pressure, and accordingly as explained above the butterfly valve 14 is positioned by the action of said double action diaphragm device 16, via the valve actuating rod 17, the valve actuating lever 15, and the valve shaft 13 to its said partly open position denoted by I in FIG. 2 and shown by dashed lines, wherein it is partly closed and somewhat obstructs the passage of intake air through the tubular hole through the valve housing 8 without totally blocking said passage of intake air. Thus, in this operational state, the diesel internal combustion engine 1 functions with a considerable throttling action being provided to the flow of intake air into its combustion chambers, which is appropriate for this current idling non load bearing operational condition in which said diesel internal combustion engine 1 is operating with the accelerator pedal which controls it not even somewhat depressed. That is to say, by the provision of this certain degree of intake passage throttling action, drivability of the vehicle in idling condition is improved, and vibration and noise during idling are also substantially reduced. Further, as will be seen later, the wandering of the idling rotational speed of the diesel internal combustion engine 1, i.e. the percentage amount of change in its idling rotational speed which it is liable to suffer during a period of idling, is much reduced as compared with the case in which no intake throttling effect is provided for the intake air which is entering into the combustion chambers thereof.
In this connection, during the transition from the above described non idling or load bearing engine operational condition to the above described idling or no load engine operational condition, i.e. during deceleration of the diesel internal combustion engine 1, then when the accelerator pedal which controls the engine 1 is for example suddenly released and supply of electrical energy suddenly stops being made to the first electromagnetic vacuum switching valve 23 (while on the other hand the second electromagnetic vacuum switching valve 25 continues to be supplied with actuating electrical energy), and when thus the switched port A of said first electromagnetic vacuum switching valve 23 comes suddenly to be communicated with the vacuum port B of said first electromagnetic vacuum switching valve 23 from being communicated with the atmospheric port C thereof, and therefore when said switched port A comes suddenly to be supplied with negative pressure which is as mentioned above present at said vacuum port B of said first electromagnetic vacuum switching valve 23 as supplied from said negative pressure accumulation tank 27, then if the negative pressure one way delay valve 21 were not provided there would be a danger that this negative pressure now suddenly coming to be present at said switched port A of said first electromagnetic vacuum switching valve 23 would be immediately transmitted to the first diaphragm chamber 18 of the double action diaphragm device 16, and this would immediately and suddenly, as explained above, cause said double action diaphragm device 16 to position the butterfly valve 14, via the valve actuating rod 17, the valve actuating lever 15, and the valve shaft 13, to its said partly open position denoted by I in FIG. 2 and shown by dashed lines, wherein it is partly closed and somewhat obstructs the passage of intake air through the tubular hole through the valve housing 8 without totally blocking said passage of intake air. This would cause sudden excessive negative pressure to be produced in the intake passage downstream of said butterfly valve 14, which might well reduce the drivability of a vehicle incorporating the diesel internal combustion engine 1 at this time, and which accordingly is most undesirable. In other words, although in the steadily idling operational state the diesel internal combustion engine 1 will best function with a considerable throttling action being provided to the flow of intake air into its combustion chambers, as is appropriate for this idling non load bearing operational condition in which said diesel internal combustion engine 1 is operating with the accelerator pedal which controls it not even somewhat depressed, it is desirable not to apply this considerable throttling effect very suddenly when the engine is first to be put into the idling operational state, but rather to apply said considerable throttling effect quite gradually. This in fact is because, when the accelerator pedal which controls said diesel internal combustion engine 1 is suddently released, for a certain time the crankshaft or the like of said diesel internal combustion engine 1 will continue to rotate at a high rotational speed much above the idling rotational speed, at which high engine crankshaft rotational speed engine operational condition the provision of substantial intake system throttling action such as by the butterfly valve 14 is inappropriate; and only after a certain time will the rotational speed of said crankshaft of said diesel internal combustion engine 1 reach its idling rotational speed, at which idling rotational speed operational condition the provision of substantial intake system throttling action such as by the butterfly valve 14 is appropriate.
Accordingly, in order to prevent this difficulty, the negative pressure one way delay valve 21 is provided between the switched port A of the first electromagnetic vacuum switching valve 23 and the first diaphragm chamber 18 of the double action diaphragm actuator 16. Accordingly, when as described above during engine deceleration when the accelerator pedal which controls the diesel internal combustion engine 1 is suddenly released, and accordingly suddenly said switched port A of said first electromagnetic vacuum switching valve 23 is communicated to the vacuum port B thereof, the vacuum which thereby suddenly becomes present at said switched port A is not immediately transmitted to said first diaphragm chamber 18 of the double action diaphragm actuator 16, but rather said vacuum is gradually transmitted to said first diaphragm chamber 18, via said negative pressure one way delay valve 21. This prevents excessively high intake vacuum being produced in the intake passage downstream of said butterfly valve 14, and accordingly helps to promote the drivability of a vehicle incorporating the diesel internal combustion engine 1 at this time.
However, during the reverse transition to the above mentioned transition, i.e. during the transition from the above described non idling or load bearing engine operational condition to the above described idling or no load engine operational condition, at this time, i.e. during acceleration of the diesel internal combustion engine 1, then when the accelerator pedal which controls the engine 1 is for example suddenly depressed and supply of electrical energy suddenly starts to be made to the first electromagnetic vacuum switching valve 23 (while on the other hand the second electromagnetic vacuum switching valve 25 continues to be supplied with actuating electrical energy), and when thus the switched port A of said first electromagnetic vacuum switching valve 23 comes suddenly to be communicated with the atmospheric port C of said first electromagnetic vacuum switching valve 23 from being communicated with the vacuum port B thereof, and therefore when said switched port A comes suddenly to be no longer supplied with negative pressure which is as mentioned above present at said vacuum port B of said first electromagnetic vacuum switching valve 23 as supplied from said negative pressure accumulation tank 27, but instead is suddenly supplied with atmospheric pressure which is present at said atmospheric port C, then it is in fact desirable that immediately the butterfly valve 14 should move to its its said fully open position denoted by III in the figure and shown by solid lines, wherein it is fully open and does not significantly obstruct the passage of intake air through the tubular hole through the valve housing 8, in order for the diesel internal combustion engine 1 to receive a good supply of intake air for acceleration purposes. Accordingly, because the negative pressure one way delay valve 21 functions, as far as its delaying action is concerned, in one direction only, thus this atmospheric pressure now suddenly coming to be present at said switched port A of said first electromagnetic vacuum switching valve 23 is in fact as desirable immediately transmitted to the first diaphragm chamber 18 of the double action diaphragm device 16, and this immediately and suddenly causes said double action diaphragm device 16 to position the butterfly valve 14, via the valve actuating rod 17, the valve actuating lever 15, and the valve shaft 13, to its said said fully open position denoted by III in the figure and shown by solid lines, wherein it is fully open and does not significantly obstruct the passage of intake air through the tubular hole through the valve housing 8. Thus, the production of diesel smoke during acceleration of the vehicle incorporating the diesel internal combustion engine 1, due to shortage of intake air upon such acceleration, is prevented, although of course in line with the sudden depressing of the accelerator pedal which controls said diesel internal combustion engine 1 the amount of fuel supplied through the injectors thereof such as the injector 6 increases greatly.
In other words, in the load bearing operational state the diesel internal combustion engine 1 will best function with no considerable throttling action being provided to the flow of intake air into its combustion chambers, as is appropriate for this load bearing operational condition in which said diesel internal combustion engine 1 is operating with the accelerator pedal which controls it at least somewhat depressed, and it is desirable to remove the considerable throttling effect which was being provided in the engine idling operational condition quite suddenly when the engine is first to be put into the non idling or load bearing operational state, and not to remove said considerable throttling effect quite gradually. Accordingly, in order to provide this immediate transmission effect, the negative pressure one way delay valve 21 provided between the switched port A of the first electromagnetic vacuum switching valve 23 and the first diaphragm chamber 18 of the double action diaphragm actuator 16 is arranged to function as far as its delay action is concerned in one direction only. Accordingly, when as described above during engine acceleration when the accelerator pedal which controls the diesel internal combustion engine 1 is suddenly depressed, and accordingly suddenly said switched port A of said first electromagnetic vacuum switching valve 23 is communicated to the atmospheric port C thereof, the atmospheric pressure which thereby suddenly becomes present at said switched port A is immediately transmitted to said first diaphragm chamber 18 of the double action diaphragm actuator 16, via said negative pressure one way delay valve 21. This prevents smoke being generated due to lack of sufficient intake air during acceleration, and accordingly helps to promote the environmental acceptability of a vehicle incorporating the diesel internal combustion engine 1 at this time. The occurrence of diesel smoke is one of the principal problems confronting the acceptance of diesel engines in automotive vehicles, especially passenger cars, and accordingly smoke reduction is a highly desirable aim in the design of diesel engines.
Now, when from either of the above described engine operational conditions, i.e. either from the above described non idling or load bearing engine operational condition or from the above described idling or no load engine operational condition, the key switch 30 is opened so as to cease engine operation, then, irrespective of whether or not the accelerator pedal sensor switch 32 is open and of whether or not the switched terminals of the relay 31 are closed, both the first electromagnetic vacuum switching valve 23 and also the second electromagnetic vacuum switching valve 25 immediately and suddenly come not to be supplied with actuating electrical energy. Accordingly, the switched port A of the first electromagnetic vacuum switching valve 23 comes to be suddenly communicated to the vacuum port B thereof, and also the switched port A of the second electromagnetic vacuum switching valve 25 comes to be suddenly communicated to the vacuum air port B thereof, while the atmospheric air ports C of these valves come suddenly not to be communicated to any other ports. Therefore, both the first diaphragm chamber 18 of the double action diaphragm device 16 and also the second diaphragm chamber 19 thereof are supplied with negative pressure, although as explained above this negative pressure takes a little time to be transmitted to the first diaphragm chamber 18, if in fact the diesel internal combustion engine 1 was deactivated by switching off the key switch 30 from the non idling engine operational condition. In any event, when said negative pressure has been communicated to both the first diaphragm chamber 18 of the double action diaphragm device 16 and also the second diaphragm chamber 19 thereof, as explained above the butterfly valve 14 is positioned by the action of said double action diaphragm device 16, via the valve actuating rod 17, the valve actuating lever 15, and the valve shaft 13 to its said fully closed position denoted by II in the figure and shown by double dashed lines, wherein it is fully closed and does not significantly allow the passage of any intake air through the tubular hole through the valve housing 8, totally blocking said tubular hole. Thus, in this operational state, the diesel internal combustion engine 1 is not able to operate, because no substantial supply of intake air into the combustion chambers thereof is allowed, due to the closing of said butterfly valve 14. As previously mentioned and as will be seen hereinafter, this considerably reduces engine vibration and shutter when stopping the engine, and accordingly is highly advantageous.
Finally, if from the non engine operating engine condition it is desired to start the diesel internal combustion engine 1, then of course the key switch 30 is first turned on, and then the engine 1 is cranked to start it. As soon as the key switch 30 is turned on, the second electromagnetic vacuum switching valve 25 is supplied with actuating electrical energy. Accordingly, the switched port A of the second electromagnetic vacuum switching valve 25 is communicated to the atmospheric air port C thereof, while the vacuum port B of this valve is not communicated to any other port. Therefore, at least the second diaphragm chamber 19 of the double action diaphragm device 16 supplied with air at atmospheric pressure, and accordingly as explained above the butterfly valve 14 is at least positioned to its said partly open position denoted by I in the figure and shown by dashed lines, wherein it is only partly closed and only somewhat obstructs the passage of intake air through the tubular hole through the valve housing 8 without totally blocking said passage of intake air. In fact, either if the supply of negative pressure from the negative pressure accumulation tank 27 is inadequate or effectively non existent at this time, or if the accelerator pedal which controls the diesel internal combustion engine 1 is even slightly depressed (either due to depression by the operator of the engine or because the fuel amount is increased due to cold starting conditions) thus opening the accelerator pedal sensor switch 32 and thus connecting together the switched terminals of the relay 31 and supplying the second electromagnetic vacuum switching valve 25 with actuating electrical energy thus communicating the switched port A thereof with the atmospheric port C thereof, then also the first diaphragm chamber 19 of the double action diaphragm device 16 will be supplied with air at atmospheric pressure, and accordingly as explained above the butterfly valve 14 will in fact be positioned to its said fully open position denoted by III in the figure and shown by solid lines, wherein it is fully open and does not significantly obstruct the passage of intake air through the tubular hole through the valve housing 8. In either case, quite sufficient intake air will be available for starting of the diesel internal combustion engine 1 at this time; the amount of throttling action that will be present if in fact the butterfly valve 14 is positioned to its said partly open position denoted by I in the figure and shown by dashed lines will not cause any significant problems with regard to starting said diesel internal combustion engine 1, because the revolution speed of the crankshaft of a diesel internal combustion engine during starting thereof is naturally low, and therefore the flow of intake air through the intake system during starting is also relatively low, and accordingly no substantial negative pressure will be generated in the intake passage downstream of the butterfly valve 14 at this time, even if said butterfly valve 14 is partly closed.
In FIG. 3, which is a graph in which percentage engine intake air throttling ratio is the abscissa and percentage variation in engine idling revolution speed is the ordinate, showing the performance of a diesel engine equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention with regard to variation of idling engine revolution speed, it can be seen that the percentage variation in engine revolution speed during idling operational condition reduces steadily, the higher is the percentage engine intake air throttling ratio. However, it should be noted that if the percentage engine intake air throttling ratio is too high, then bad fuel economy and engine smoke will occur, and this causes excess pollution; therefore, it is desirable from this point of view to keep the percentage engine intake air throttling ratio between about 10% and about 30%. In FIG. 3, the upper line relates to idling operational condition at 600 rpm of the diesel internal combustion engine, and the lower line relates to idling operational condition at 700 rpm thereof. The lines shown in the graph of FIG. 3 have been determined by a process of experiment.
In FIG. 4, which is a graph in which percentage engine intake air throttling ratio is the abscissa and engine idling vibration is the ordinate, showing the performance of a diesel engine equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention with regard to idling engine vibration, it can be seen that the engine vibration during idling operational condition reduces steadily, the higher is the percentage engine intake air throttling ratio. However, for the reasons outlined above it is desirable to keep the percentage engine intake air throttling ratio between about 10% and about 30%. In FIG. 4, the upper line relates to idling operational condition at 700 rpm of the diesel internal combustion engine, and the lower line relates to idling operational condition at 600 rpm thereof. The lines shown in the graph of FIG. 4, again, have been determined by a process of experiment.
In FIG. 5, which is a graph in which time is the abscissa, and engine vibration is the ordinate, showing by the dashed line the performance of a diesel engine equipped with said preferred embodiment of the diesel engine intake air throttling system according to the present invention with regard to engine vibration when the engine has been switched off and while its rotation is stopping, in which stopping the butterfly valve 14 is as described above completely closed, as contrasted to the performance, shown by the solid line, of a diesel engine which is not equipped with any such intake air throttling system, in which stopping the engine intake air is not particularly throttled, it can be seen that generally according to the present invention the engine vibrates much less while stopping, and also that the peak of engine vibration when stopping is very significantly reduced. Thus drivability and comfort for the driver during operation of a vehicle incorporating said diesel engine are much improved, according to the present invention.
Although the present invention has been shown and described with reference to a preferred embodiment thereof, and in terms of the illustrative drawings, it should not be considered as limited thereby. Various possible modifications, omissions, and alterations could be conceived of by one skilled in the art to the form and the content of any particular embodiment, without departing from the scope of the present invention. Therefore it is desired that the scope of the present invention, and of the protection sought to be granted by Letters Patent, should be defined not by any of the perhaps purely fortuitous details of the shown embodiment, or of the drawings, but solely by the scope of the appended claims, which follow. | An intake air throttling system for a diesel engine comprising an air intake passage. The system includes a throttling valve mounted in the air intake passage so as to selectively throttle air flow through it. This throttling valve can be positioned to at least a first position in which it substantially fully closes the air intake passage, a second position in which it partly throttles the air intake passage to a substantial extent but does not fully close it, and a third position in which it does not throttle the air intake passage to any substantial extent. The throttling valve is controlled by a control system, which positions it to the first position when the engine is being stopped, which positions it to the second position when the engine is being idled, and which positions it to the third position when the engine is being operated in non idling load bearing operational condition. Thereby, when the engine is being stopped, the cutoff of intake air reduces stopping vibration considerably, while when the engine is being idled the partial but substantial throttling of intake air reduces idling vibration and reduces wandering of engine idling speed; and both these effects are accomplished by the use of one throttling valve. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to marking material-spraying anti-theft devices, and, more particularly to anti-theft systems which spray a marking material such as a dye or odorant on a thief who opens a particular closure in a protected article.
Conventionally, marking material-spraying anti-theft devices are activated by a timing means, such as in dye grenades for adding to bags of money during bank robberies. Additionally, it is known to use hand-held devices, which are activated by a victim, to spray dye on a thief. None of these devices is useful as a safe, effective method for identifying a thief after a mugging or purse-snatching. Devices with timers are useful only when they can be activated by a victim before a thief absconds with the stolen article. Such timer devices are problematic because the victim may not have a chance to activate such a device, and in doing so, the victim risks retaliation by an alert thief. Hand-held spray devices also invite retaliation by the thief because the thief must be present when such devices are used.
For the foregoing reasons, there is a need for a marking material-spraying anti-theft device which can be used to mark a thief and the stolen goods after the thief has left the victim, and the victim is thus out of danger. There is also a need for a marking material-spraying anti-theft device which is automatic, and does not require dangerous action by the victim during a robbery to be effective.
SUMMARY OF THE INVENTION
There is provided, in accordance with the invention, an improved marking material-spraying anti-theft device that does not possess the shortcomings of the prior art, and offers the advantages of being safe for the victims to use because it operates automatically. The device has a closure, which is preferably a part of the protected article, i.e. a wallet, purse, etc. The owner knows not to open the closure because doing so actuates an activator which causes marking material to spray out of the protected article. Since a thief is likely to search the stolen protected article for valuables after leaving the victim, the victim does not risk retaliation by a thief who is marked with the dye.
More particularly, the marking material-spraying anti-theft device of the present invention comprises a container which may contain means for directing the marking material spray toward the thief. This means for directing the marking material may comprise one, or preferably several, aperture sections designed to break open when sufficient pressure develops within the container. A marking material is positioned within the container such that when an overpressure inside the container causes the aperture sections to break, the marking material sprays out of the broken aperture sections.
Upon activation, an overpressure generating means, such as an explosive or compressed gas vessel, supplies the necessary overpressure. The force exerted by the overpressure then breaks open the aperture sections, and sprays out the marking material. An activating means triggers the overpressure generating means when a thief opens a closure within the article while searching for valuables.
The overpressure generating means must be powerful enough to force the dye to spray out of the container onto the thief. However, it must not be powerful enough to rupture the container in places other than the weaker aperture sections. At least one of the aperture sections should be positioned to direct the spraying dye through the now-opened closure towards the thief.
The present invention may be employed to advantage in personal carriers such as wallets, purses, briefcases, handbags, personal computer carrying cases or other articles which have compartments for receiving items of value.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side elevational view of a protected wallet according to the invention with parts broken away to show an anti-theft device.
FIG. 2 is a diagrammatic top view of the wallet of FIG. 1, and illustrates the aperture sections for directing the marking material.
FIG. 3 is a diagrammatic side elevational view of the wallet of FIG. 1, after detonation.
FIG. 4 is a diagrammatic side elevational view of a further embodiment of the anti-theft device according to the invention.
FIG. 5 is a diagrammatic side elevational view of one embodiment of a closure that, when opened, triggers activation.
FIG. 6 is a schematic circuit diagram of one embodiment of an activating means.
FIGS. 7(a), 7(b) and 7(c) are schematic circuit diagrams of three embodiments of a switch. FIG. 7(a) shows the switch as a combination of several subswitches connected in series. FIG. 7(b) shows the switch as a combination of several subswitches connected in parallel. FIG. 7(c) shows the switch as a combination of several subswitches connected in series and in parallel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a container 10 has a flexible bladder 11 containing a marking material in the form of a dye 15. The container 10 is shown situated in a compartment or pocket 14 of a wallet 12, which has a closure 35. The wallet has a first compartment 13 used in the ordinary way to contain, e.g., currency as indicated. The composition of the container 10 in the wallet's second compartment 14 is not important so long as it is strong enough to only break at one or more weaker aperture sections 17 when the explosive 19, detonates. The shape of the container 10 is also unimportant so long as the weaker aperture sections 17 can be located such that dye material 15 spraying from the container 10 (as shown in FIG. 3) will be directed toward a person activating the device.
Moreover, while a flexible container 10 with a flexible interior bladder 11 is contemplated in FIG. 1, it will be recognized that various alternative arrangements may suffice, such as a rigid container shaped to fit the protected item and/or an inflexible piston driven by an explosive or compressed air to force the marking material from the container.
In one preferred embodiment of the invention, a detonating circuit 45 is electrically connected with the explosive 19. A flexible bladder 11 divides the container into (i) a first container section 16 containing the dye 15; and (ii) a second container section 18 containing the explosive 19. The first container section 16 which contains the dye 15, also defines the weaker aperture sections 17. These weaker aperture sections 17 may be formed by stretching or heating a thermoplastic material, forming the container 10 so that it is considerably weaker at the aperture sections 17.
As seen in FIG. 2, looking down on the top of the container 10, one or more of the weaker aperture sections 17 may be located as shown. These aperture sections 17 are not necessarily circular; their shape is unimportant so long as they direct the dye 15 to spray out towards the thief upon activation. One or more aperture sections 17 may also be located in other parts of the container 10 to direct some of the dye to spray out in other directions, e.g. onto the valuable contents of the wallet.
In an alternative embodiment of the invention, shown in FIG. 4, the dye 25 is contained in one or more passages 23 found in the container 20. These dye-filled passages 23 engage the explosive material 29. The explosive material 29 is positioned within, or proximate to the passages 23, such that detonation forces the dye 25 to spray out of a series of weaker aperture sections 27 similar to those previously described. The passages 23 may be formed by heat sealing together two sheets of thermoplastic material in the pattern shown to form heat seals at the walls 31 and 33. The aperture sections form the ends of the passages 23. The passages and the location of the aperture sections direct the marking material to spray out at a thief opening a closure 35.
The weaker aperture sections 17 or 27 of both the first and second embodiments shown in FIG. 1 and FIG. 4 respectively, may be of the same material as the walls of the container 10 or 20, weakened by stretching or heating, or they may be separable patches or the like of the same or different material forming closures to holes in the container.
In FIG. 6 a preferred embodiment of a circuit 45 is shown which can be used as an activating means to detonate the explosive 19 or 29 when the closure 35 is opened. This particular circuit comprises a five volt battery 47, an optional 100 μf capacitor 49 (shown in broken lines in FIG. 6), a ZVN4210A-ND transistor 51, a resistive detonating element 55, a 22MΩ or greater resistor 53, and a closure incorporating a switch 41. The switch 41 may actually comprise several sub-switches 43 connected in series, or in parallel, or both, as shown in FIGS. 7(a), 7(b) and 7(c).
The circuit 45, shown in FIG. 6, is but one of many circuits which would work satisfactorily in the present invention. The important feature of the circuit is that it must send enough current through the resistive detonating element 55 to detonate the explosive 19 when the closure 35 is opened.
In FIG. 5 the closure 35 is used for triggering the invention. The closure 35 has one or more electrical leads 37. These electrical leads 37 and the closure 35 form the switch 41 which connects to circuit 45 of FIG. 6.
In the embodiments of the invention shown, opening the closure 35 opens the switch 41, which causes the circuit 45 to detonate the explosive 19 or 29. Alternatively, it will be apparent that one may make an embodiment of the invention where opening the closure 35 would close a switch 41, and cause a different circuit to detonate an explosive or release a compressed gas.
In the circuit 45 shown, opening the closure 35, physically breaks electrical contact between both ends of the electrical leads 37. The electrical leads 37 may comprise separable contacts 39. These separable contacts 39 are physically separated when the closure 35 is opened, thus breaking electrical contact. The separable contacts 39 may be magnetic, and may themselves serve as the means for maintaining the closure closed. It is also possible that the electrical leads 37 could be designed spanning the closure 35 without separable contacts 39 to simply break when the closure is opened.
The degree to which the closure 35 must be opened to activate the explosive 19 may be chosen in a number of ways. This can be accomplished by changing the positions where the electrical leads 37 or subswitches 43 separate upon opening the closure 35. Also, series-connected switches arranged along the length of a closure as in FIG. 7(b) will permit activation by just opening of a single switch in just one portion of the closure. Switches arranged along the length of a closure, but connected in parallel as in FIG. 7(a), will require the closure to be opened more fully to open each switch and activate the explosive. Various combinations, such as that of FIG. 7(c), are possible as well.
In operation, referring again to the embodiment of the invention pictured in FIG. 1, when a thief opens the closure 35 of FIG. 5, electrical current ceases flowing through the electrical leads 37. The cessation of current through the electrical leads 37 causes the circuit 45 to redirect current through the resistive detonating element 55.
As happens in the activation of an automobile air bag, the energized resistive detonating element 55 then heats to detonate the explosive 19. This creates an explosively expanding gas 113, shown in FIG. 3. The explosively expanding gas 113 creates an overpressure in the container 10, which is transmitted to the flexible bladder 11. This overpressure causes the weaker aperture sections 17 to rupture. The pressure exerted on the compressed flexible bladder 11 causes the dye 15 to spray from the ruptured aperture sections 17 onto the thief who opened the closure 35.
The alternative embodiment of the invention shown in FIG. 4 operates in much the same way as the above-described embodiment shown in FIGS. 1 and 3, except that upon detonation of the explosive 29, by the circuit 45, the explosively expanding gas 113 (shown in FIG. 3), enters the passages 23. The pressure from the gas 113 forces the dye 25 to push against the weaker aperture sections 27 with enough force to cause them to rupture and spray out the dye 25 as in the embodiment of FIG. 3.
In both alternative embodiments of the invention, the container 10 or 20 may be so dimensioned as to fit within a wallet, purse, briefcase, handbag, personal computer carrier or the like.
The explosive 19 or 29 may be an azide or another suitable explosive. The explosive 19 or 29 may be replaced by any means for generating an overpressure. The dye 15 or 25 may be a liquid or a powder, and may also contain odiferous material. Alternatively, if desired, an odorant alone may replace the dye 15 or 25 as the marking material. The closure 35 is preferably held closed by synthetic materials that adhere when pressed together, which are commonly sold under the trademark "Velcro." However, the closure 35 may use any sort of fastener.
The separable contacts 39 are not essential, so long as the electrical conducting path across the switch 41 is broken when the closure 35 is opened. A circuit such as the one shown in FIG. 6 may incorporate a delay provision such as the capacitor 58 (indicated in broken lines in FIG. 6) to provide a slight delay between opening the closure 35 and detonating the explosive 19 or 29. Such a delay could help prevent accidental misfiring. Alternatively, if the closure were changed such that opening the closure would close a switch, a circuit could detonate the explosive when the switch was closed. Also, the circuit 45 may be located either inside the container as shown in FIG. 1, or outside the container as shown in FIG. 4.
Many other variations and modifications of the invention will be apparent to those skilled in the art without departing from the spirit and scope of the invention. The above-described embodiments are, therefore, intended to be merely exemplary, and all such variations and modifications are intended to be included within the scope of the invention defined in the appended claims. | A marking material-spraying mechanism is incorporated into a protected article, such as a wallet, handbag, laptop computer case, or briefcase. When a thief who has stolen the protected article opens a closure within the article the mechanism operates to spray the marking material on the thief. The mechanism is automatic, and does not require activation during a robbery. | 4 |
FIELD OF THE INVENTION
The invention relates generally to systems for use in the trenchless removal of underground pipe, and more particularly, to systems which use hydraulic cylinders as the cable puling device.
BACKGROUND OF THE INVENTION
The underground location of water and sewer lines, as well as electrical conduits, makes their replacement difficult. This is particularly so where additional infrastructure has been developed around or on the previously built underground lines or conduits. Often such lines were installed via open trenches years ago and now they cannot be easily re-excavated. Over the years, new developments, such as roads, parking lots, buildings, or landscaping have been placed over the surface of the old lines, thus making re-excavation impossible or unacceptably costly.
Numerous methods have been developed over the years to address the problem of how to replace worn out water and sewer lines without excavating the lines. Typically, such methods will replace the older iron or steel lines with a new line made from a flexible plastic material. One such method, of which this invention is an improvement, is called pipe bursting.
Pipe bursting methods for replacing old, typically metal, water, sewer, or electrical conduit lines make use of a conical shaped mole that is pulled through an existing pipe. The mole is shaped such that it is smaller than the inside diameter of the old pipe at one end of the mole and larger than the inside diameter of the pipe at the other end of the mole, and thus, the mole causes the original pipe to be burst or fractured upon the mole being pulled through the pipe. The original pipe is burst outward radially. Typically, attached to the back of the mole is a length of flexible replacement piping which is drawn into the space formerly occupied by the burst pipe and therefore takes the place of the original. Thus, the new pipe replaces the old pipe without excavating along the entire length of the pipe being replaced. Excavation is required typically only at the ends of the pipe to be replaced.
The basic components of prior art pipe bursting systems include a mole, a length of cable engageable to the mole, a cable pulling device, and a mounting structure for supporting the cable pulling device against an opening through which the mole is to be pulled. In order to pull a mole through an iron pipe, pulling force on the order of 15-75 tons may be required. To provide sufficient pulling force, many prior art pipe bursting processes have used winches of various types. U.S. Pat. No. 5,328,297 to Handford is one example of such a device. However, winches of sufficient size to generate 75 tons of pulling force typically weigh several tons themselves and are frequently mounted on trucks or are attached to other large excavation devices. In some applications, space limitations prevent the use of a winch as the source of pulling force.
Due to the relatively large size of a winch suitable for pulling a mole through an iron or steel pipe, efforts have been made to find smaller devices capable of generating the necessary pulling force. These devices typically make use of the high force that can be generated by relatively compact hydraulic cylinders. Such devices are exemplified by U.S. Pat. No. 6,305,880 to Carter et al (“the Carter patent”). The Carter patent uses a pair of single acting hydraulic cylinders as the cable pulling device. The cylinders are are sufficiently small that the puller, along with a pulling frame, can be used by one or two operators and represents an improvement in the art over a winch based system.
The pulling device of the Carter patent however, nevertheless suffers from certain drawbacks. One drawback of the Carter device is that because the device uses single acting hydraulic cylinders, it has a relatively slow cycle time. Another drawback of the Carter device is that to prevent the cable from rebounding back into the pipe to be burst, the device requires additional hardware to hold the pulling cable stationary while the hydraulic cylinders make their return stroke.
Accordingly, there persists a need in the in art of trenchless pipe replacement for an improved cable pulling device that does not suffer the aforementioned drawbacks. Preferably, such a device would be smaller than the prior art winch-type devices, yet have a substantially faster cycle time than prior art hydraulic devices. A faster acting device would be more cost efficient for contractors and thus would reduce the time and cost of trenchless pipe replacement work.
SUMMARY OF THE INVENTION
The present invention comprises an improved cable puller for the trenchless replacement of underground pipes including water, sewer, and electrical conduits. The cable puller of the present invention improves upon prior art hydraulic cable pullers. Unlike the single-acting pullers of the prior art which pull only on their outward stroke and do little, or no, useful work on their inward or recovery stoke, the present invention cable puller pulls continuously on the cable on both the device's outward and inward strokes and therefore doubles the speed at which a mole may be pulled through a pipe to be burst. Moreover, because the device pulls the cable on both its inward and outward strokes, the present invention puller has no need for a mechanism to hold the cable stationary during the return stroke as is required by the prior art. Such a device however, may be provided with the present invention puller for added safety.
The present invention double acting cable puller comprises a cylinder body which houses four hydraulic cylinders. The cylinder body has a forward end and an aft end. One pair of hydraulic cylinders operates in tandem on the forward end of the cylinder body and another pair of cylinders operates in tandem on the opposite, aft end of the cylinder body. Each of the hydraulic cylinders houses one double acting piston and piston rod, and each cylinder has its own inlet and outlet ports for hydraulic fluid. For each set of paired forward and aft cylinders, the cylinder rods are attached to a puller, and each puller has a set of jaws for engaging the pulling cable.
In operation the present invention cable puller is securely attached to a pulling base designed for use with the puller. During phase I in the operation cycle, pressurized hydraulic fluid is directed into each of the paired cylinders so that pressure bears on the outward faces of the pistons (the faces opposite the rods) causing both the forward and aft pullers to travel outward away from the cylinder body until the cylinders' maximum length of travel has been reached. During this phase, the aft puller's jaws engages the cable so that the cable is displaced (i.e. the mole is pulled through the pipe to be burst) as the aft puller travels away from the cylinder body. During this phase, the forward puller's jaws are not engaged with the cable and therefore the cable simply passes freely through the forward jaws.
During phase II of the present invention cable puller's operation, pressurized hydraulic fluid is redirected into the cylinders so pressure bears upon the outward faces (i.e. the faces on the same side as the rods) so that both pullers travel inward towards the cylinder body. During this phase, the two pullers have alternated tasks: the forward puller's jaws are now engaged the cable and now pull the cable through the pipe to be burst, while the aft puller's jaws have released the cable, allowing cable to pass freely between them. The cycle repeats continuously until the mole is pulled through the length of pipe to be burst.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a typical prior art system for trenchless pipe replacement using hydraulic cylinders as the force for pulling a mole attached to a cable through a pipe to be burst.
FIG. 2 shows the cable puller assembly of the present invention mounted on a pulling base configured to receive the cable puller.
FIG. 3 shows the cable puller assembly of the present invention, removed from the pulling base, with the pullers shown in their retracted position.
FIG. 4 shows the cable puller assembly of FIG. 3 with the pullers in their extended position.
FIG. 5 shows an exploded view of the cable puller assembly of the present invention.
FIG. 6 shows an exploded view of a puller of a cable puller of the cable puller assembly of the present invention.
FIG. 7 shows a perspective view of the cable puller assembly of the present invention, indicating the direction of cable movement when the pullers are in their extended position and beginning a retraction stroke.
FIG. 8 shows a perspective view of the cable puller assembly of the present invention, indicating the direction of cable movement when the pullers are in their retracted position and beginning an extension stroke.
FIG. 9 shows the present invention cable puller installed in an excavation, pulling a mole and new replacement pipe through a pipe to be burst.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 , it has long been known in the art that an old pipe 1 , i.e. water, sewer, or electrical conduit, can be replaced by pulling a mole 2 via a cable 3 through the pipe to be burst 1 , and thereby bursting the pipe in a radially outward direction. Typically, a length of flexible plastic pipe 4 is drawn through the burst pipe 1 and thereby takes the place of the burst pipe 1 . Prior art systems require a means for generating the pulling force on the cable 1 and this means has typically been supplied by winches (not shown) or by a hydraulic cylinder-based cable puller 5 . Hydraulic cylinder-based cable pulling systems further require a pulling frame 6 that faces an opening in the pipe to be burst 1 through which the cable 3 may be drawn. Such systems further require a source of pressurized hydraulic fluid 7 and at least one operator 8 . As noted in the background section, prior art systems pull the cable only on their outward stroke.
Referring to FIG. 2 , the present invention improves upon the prior art by providing a double-acting hydraulic cable puller 10 , where both the inward and outward strokes of the cable puller, pull the cable 3 through the pipe to be burst 1 . With reference to FIG. 2 , the double acting cable puller 10 of the present invention is shown attached to a pulling base 12 . For purposes of description, the puller 10 has a forward end and an aft end as indicated in FIG. 2 , a right hand side and a left hand side as indicated in FIG. 3 .
Referring now to FIGS. 3-5 , the cable puller of the present invention comprises a cylinder body 12 which houses four hydraulic cylinders, two opposed cylinders 24 and 26 are located in a right hand pressure tube 14 and two opposed cylinders 20 and 22 are in a left hand pressure tube 16 . Each of the pressure tubes 14 and 16 features an internal wall 18 (see FIG. 5 ) in the center of the tubes. The internal wall 18 functions to split each tube ( 14 , 16 ) into the opposed, independently acting hydraulic cylinders. Therefore, pressure tube 14 on the left hand side includes opposed hydraulic cylinders 20 and 22 , while pressure tube 16 on the right hand side includes opposed hydraulic cylinders 24 and 26 .
Referring now to FIGS. 4 and 5 , the forward hydraulic cylinders 20 and 26 feature pistons 28 , piston rods 30 , seals 32 and end caps 34 . Each rod 30 features an end portion 40 which extends beyond the end cap 34 . The end portions 40 of the piston rods 30 are internally threaded to accept cap screws 37 . The end portion 40 of each piston 30 mates in a slip fit within holes 42 bored through a forward puller 36 . Included in the bores 42 of the forward puller 36 are steps 44 (see FIG. 6 ) which allow the piston rods 30 to be drawn up tightly, or rigidly attached to, the aft puller 36 via the cap screws 37 .
With continued reference to FIGS. 4 and 5 , similar to the forward hydraulic cylinders 20 and 26 of the present invention cable puller 10 , the aft hydraulic cylinders 22 and 24 also feature pistons 46 , piston rods 48 , seals 50 and end caps 52 . Each rod 48 also features an end portion 54 which extends beyond the end cap 52 . The end portions 54 of the piston rods 48 are internally threaded to accept cap screws 60 . The end portion 54 of each piston rod 48 mates in a slip fit within holes 58 bored through an aft puller 56 . Included in the bores 58 of the aft puller 56 are steps 44 (see FIG. 6 ) which allow the piston rods 48 to be drawn up tightly, or rigidly attached to, the aft puller 57 via the cap screws 60 .
With continued reference to FIGS. 3 through 5 , the forward hydraulic cylinders 20 and 26 are larger and have a shorter stroke than the aft cylinders 22 and 24 . This is necessary so that the forward and aft pullers 36 and 56 will reach their maximum points of extension and retraction at the same time. The forward and aft pullers can only reach their maximum points of extension and retraction at the same time if both the forward pair of cylinders and the aft pair of cylinders receive an equal volume of hydraulic fluid on their forward and return strokes. Consequently, the pistons 28 , rods 30 , seals 32 and end caps 34 of the forward hydraulic cylinders 20 and 26 are larger than the corresponding pistons 46 , rods 48 , seals 50 and end caps 52 of the aft hydraulic cylinders 22 and 24 , in order to accomplish this goal.
As noted, two double-acting forward, 20 and 26 , and aft 22 and 24 , pairs of cylinders are responsible for the actuation of the cable puller 10 . The forward cylinders ( 20 and 26 ) control the forward puller 36 , while the aft pair of cylinders ( 22 and 24 ) control the aft puller 56 . Pressurized hydraulic fluid is forced into each of the forward ( 20 and 26 ) and aft ( 22 and 24 ) cylinder pairs on the appropriate side of their pistons to cause simultaneous extension or retraction of the forward and aft pullers 36 and 56 . To cause the cylinders to extend, fluid is forced against the outward piston faces 29 (i.e. the faces opposite the rods). To cause the cylinders to retract, fluid is forced against the inward piston faces 31 (i.e. the faces on the same side as the rods).
An operational constraint is that each of the forward ( 22 and 26 ) and aft ( 22 and 24 ) cylinder pairs must receive an equal volume of fluid. Receiving an equal volume of fluid is required because the cylinder pairs are opposed, i.e. one pair will receive fluid against the open-face side 29 of their pistons while at the same time the other pair will receive fluid against the side of their pistons to which the cylinder rod attaches 31 . Essentially, during any given phase in the cable puller's operation, one pair of cylinders will have its volume consumed by fluid only, and the other pair will have its volume consumed both by fluid and the cylinder's rods. This constraint dictates that the cylinder pairs must be dimensionally different. Specifically, the cylinder pairs must differ in cylinder diameter, rod diameter, and travel distance. For any particular size of cable puller, the above parameters must be adjusted to achieve an equal volume of fluid in each cylinder pair.
Referring now to FIGS. 3-5 and particularly FIG. 6 , the pullers 36 and 56 of the present invention cable puller 10 will be described. The pullers are identical in function and are essentially identical in physical structure with the exception that bores 42 and 58 of the forward and aft pullers are sized differently to correspond to the differently sized piston rods to which they mate. That is, the bores 42 of the forward puller 36 are sized to mate with the rods 30 of the forward cylinders 20 and 26 , while the bores 58 of the aft puller 48 are sized to mate with the rods 48 of the aft cylinders 22 and 24 , the rods of the forward and after cylinders being of different sizes. In all other respects, the forward and aft pullers are identical.
Each of the forward and aft pullers feature sliding jaws 62 . Each jaw 62 includes serrations 72 . The serrations 72 are designed to grasp or clamp onto the pulling cable 3 (see FIG. 1 ). Each jaw 62 has a V-shaped surface 74 . The V-shaped surface of the jaws 62 slidably mate with V-shaped surfaces 76 of the centrally located V-section 78 on the puller 36 , 56 . The sliding interaction of V-shaped surfaces 74 of the jaws 62 with the mating V-shaped surfaces on the puller 36 , 56 are such that when the puller moves in a direction opposite to that of the narrow portion of the V-section 78 , the jaws 62 clamp down on the cable 3 and pull the cable in the direction of the puller. Likewise, when the puller 36 , 56 moves in the same direction of the narrow portion of the V-section 78 , the jaws do not clamp down on the cable, but rather remain loose and thereby, the cable passes freely through the jaws.
To allow for easy insertion of the pulling cable 3 , each puller has a cable access door 64 which is hinged to the puller(s) 36 , 56 . The hinge is fixedly held in place on one side by a hinge pin 68 which includes a groove 80 . To retain the hinge pin 68 in place, a roll pin 66 passes through groove 80 in pin 68 and passes partially into a hole 82 formed into the puller(s) 35 , 56 . On an opposite side, the cable access door is held in place by a ball-lock-pin 70 . The ball-lock pin 70 allows the cable door to be readily opened to accept a pulling cable, and just as easily closed. This feature of the present invention cable puller 10 is desirable because it creates a closed cable path through the puller and therefore increases the puller's safety over prior art devices which may allow a cable under tension to slip out of the puller in the event an operator were to lose control of the device.
Ball-lock-pin 70 actuated cable doors 64 equipped with cable jaws 62 are located on both the forward 36 and aft 56 cable pullers. Optionally, a stationary puller 84 is may be located on the cylinder body 12 . The optional stationary puller is a safety mechanism and only activates to prevent cable rebound in the event one of the puller assemblies 36 , 56 fails.
Operation of the Cable Puller of the Present Invention
With reference to FIG. 9 , prior to beginning operation, if necessary, excavations are made at each end of the pipe to be burst 1 . A pulling cable 3 is then run the full length the pipe to be burst 1 . A mole 2 having an eyelet or other means for cable attachment at one end, of which many prior art designs exist, is connected at the eyelet end to the pulling cable 3 . Replacement piping 4 is attached to the other end of the mole 2 . The present invention cable puller 10 is than attached a pulling base 11 specifically designed for use with the new puller. The new cable puller 10 is then connected to a source of pressurized hydraulic fluid 7 . (Sources of pressurized hydraulic fluid are well known to those of skill in the art.) The ball-lock-pins 70 are pulled which allows the cable doors 64 to be opened and the cable to be pulled to be inserted into the present invention cable puller 10 . (See FIGS. 5-8 .)
Referring to FIGS. 3-4 and 7 - 8 , during phase I in the operation cycle, pressurized hydraulic fluid is directed into the forward ( 20 and 26 ) and aft ( 22 and 24 ) cylinders so that both pullers travel outwardly away from the cylinder body 12 until the cylinders' maximum travel point has been reached. (See FIGS. 4 and 7 .) During this phase, aft puller's 56 jaw set 62 engages the cable 3 so that the cable is displaced (i.e. pulled through the pipe to be burst) as the aft puller 56 travels away from the cylinder body 12 . At this time, the forward puller's 36 jaws are not engaged with the cable 3 and therefore the cable simply passes freely through the forward puller's jaws 62 .
During phase II of the cable puller's 10 operation, pressurized hydraulic fluid is redirected into the cylinders ( 20 and 26 ) and ( 22 and 24 ) so that both pullers ( 36 and 56 ) travel inwardly towards the cylinder body 12 . (See FIGS. 3 and 8 .) During this phase the two pullers have alternated tasks, the forward puller's jaws have engaged the cable and now pull the cable 3 through the pipe to be burst 1 , while the aft puller's jaws have released the cable and cable passes freely between them. The cycle repeats continuously until the mole 2 is pulled through the length of pipe to be burst 1 .
The foregoing detailed description and appended drawings are intended as a description of the presently preferred embodiment of the invention and are not intended to represent the only forms in which the present invention may be constructed and/or utilized. Those skilled in the art will understand that modifications and alternative embodiments of the present invention, which do not depart from the spirit and scope of the foregoing specification and drawings, and of the claims appended below, are possible and practical. It is intended that the claims cover all such modifications and alternative embodiments. | The present invention comprises an improved cable puller assembly for use in the trenchless replacement of underground pipes including water, sewer and electrical conduits. The improved cable puller assembly utilizes a cylinder body comprising four double acting hydraulic cylinders set up in pairs of two, i.e. two forward cylinders and two aft cylinders. The cable pullers are configured to move inwardly and outwardly from the cylinder body and feature the ability to pull a cable through a pipe on both their inward and outward strokes. | 7 |
RELATED APPLICATION
[0001] This application is a divisional of pending U.S. patent application Ser. No. 11/379,492 filed on Apr. 20, 2006, the content of which is expressly incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The invention relates to silicon power semiconductor devices and, more particularly, to a device having improved edge termination.
BACKGROUND
[0003] Protection of device edges is an essential aspect of the design of high voltage semiconductor devices such as MOSFETs, IGBTs, MCTs, bipolar transistors, thyristors, and diodes. The edge protection, or edge termination structure, must perform the function of distributing the applied voltage over a wider region on the surface of the device than it occupies within the silicon substrate, hereby ensuring that the electric field at the surface is low enough to prevent arcing outside the silicon substrate or avalanche breakdown within the substrate near its surface.
[0004] Various edge termination techniques have been developed, including, for example, field plate (FP), described in F. Conti and M. Conti, “Surface breakdown in silicon planar diodes equipped with field plate,” Solid State Electronics, Vol. 15, pp 93-105, the disclosure of which is incorporated herein by reference. Another edge termination approach is field limiting rings (FLR), described in Kao and Wolley, “High voltage planar p-n junctions,” Proc. IEEE, 1965, Vol. 55, pp. 1409-1414, the disclosure of which is incorporated herein by reference. Further edge termination structures utilized junction termination extension (JTE), described in V. A. K. Temple, “Junction termination extension, a new technique for increasing avalanche breakdown voltage and controlling surface electric field in p-n junction,” IEEE International Electron Devices Meeting Digest, 1977 Abstract 20.4, pp 423-426 and variable lateral doping concentration (VLD), described in R. Stengl et al., “Variation of lateral doping as a field terminator for high-voltage power devices”, IEEE Trans. Electron Devices, 1986, Vol. ED-33, No. 3, pp 426-428, the disclosures of which are incorporated herein by reference.
[0005] Typically, a planar diffusion technique is used to produce a P-N junction diode, which yields a cylindrical junction. Because of the curvature at the edge of the junction it produces a greater electric field than an ideal planar junction. As a result, the breakdown voltage of a cylindrical junction diode is substantially lower than that of an ideal planar junction diode. Edge termination techniques are used to reduce the concentration of the electric field in a cylindrical junction diode.
[0006] U.S. Pat. No. 6,215,168 B1 to Brush et al., the disclosure of which is incorporated herein by reference, describes a semiconductor die that comprises a heavily doped silicon substrate and an upper layer comprising doped silicon of a first conductivity type disposed in the substrate. The upper layer includes an active region that comprises a well region of a second, opposite conductivity type and an edge termination zone comprising a junction termination extension (JTE) region that includes portions extending away from and extending beneath the well region. The JTE region is of varying dopant density, the dopant density being maximum at the point beneath the junction at the upper surface of the upper layer of the JTE region with the well region. The dopant density of the JTE region decreases in both lateral directions from its maximum point.
[0007] Finding an improved way to reduce the electric field at the junction of the active area and the JTE region of a power semiconductor device, the JTE region having a laterally constant or varying (VLD) dopant density, and thereby increasing its breakdown voltage remains a highly desirable goal.
SUMMARY
[0008] One embodiment is directed to a semiconductor device comprising a doped semiconductor substrate and an upper layer comprising doped semiconductor material of a first conductivity type disposed on the substrate. The upper layer comprises an upper surface and includes an active region with a well region of a second, opposite conductivity type and an edge termination zone that comprises a junction termination extension (JTE) region of the second conductivity type. The JTE region comprises portions extending away from the well region. A number of field limiting rings of the second conductivity type are disposed at the upper surface in the junction termination extension region.
[0009] Another embodiment is directed to a semiconductor device comprising a doped semiconductor substrate and an upper layer of semiconductor material of a first conductivity type disposed on said semiconductor substrate, said upper layer having an upper surface and including an active region that comprises a well region of a second, opposite conductivity type and an edge termination zone that comprises a first junction termination extension (JTE) region of the second conductivity type, said region comprising portions extending away from said well region, and a second junction termination extension (JTE) region of the second conductivity type extending away from said well region disposed in the first junction termination extension region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A shows a cross-sectional view of a semiconductor die including a JTE region as an edge termination structure according to a first embodiment of the invention.
[0011] FIG. 1B shows a cross-sectional view of a semiconductor die including a JTE region as an edge termination structure according to a second embodiment of the invention.
[0012] FIG. 2 shows a graph of the current-voltage-characteristic under reverse bias of a power semiconductor device with the die of FIG. 1 .
[0013] FIG. 3 shows a detail of the graph of FIG. 2 .
DETAILED DESCRIPTION
[0014] FIG. 1A schematically depicts a semiconductor die 100 according to a first embodiment of the present invention. The semiconductor die 100 comprises an N-doped upper layer 101 which includes an active region well 102 , which can be e.g. a p-emitter of a diode or a p-body of an IGBT, and a JTE region 103 , which are both p-doped. The upper layer 101 further comprises a number of p-doped field limiting rings 109 , 110 and 111 in the JTE region 103 . A metal contact 104 and a dielectric layer 105 overlie, respectively, the active region 102 and the JTE region 103 with the field limiting rings 109 . The JTE-region 103 extends deeper into the upper layer in the direction perpendicular to the upper surface than the field limiting rings 109 .
[0015] It is recognized that the conductivity types of the dopants in layer 101 , well 102 , JTE region 103 , and field limiting rings 109 , 110 and III, N, P, P, and P, respectively, can also be of the opposite conductivity types, i.e., P, N, N and N, respectively.
[0016] The active region 102 and the field limiting rings 109 are preferably heavily doped with a dopant concentration of the order of 10 18 cm −3 or above, while the JTE region 103 is typically doped with a concentration of the order of 10 15 cm −3 . In one embodiment of the invention, the field limiting rings 109 , 110 and 111 comprise substantially the same dopant density. In another embodiment of the invention, the dopant density of the field limiting rings increases from a maximum value of the innermost field limiting ring 109 closest to the well region 102 to a minimum value of the furthermost field limiting ring 111 . The field limiting rings preferably comprise substantially the same width.
[0017] From a point of maximum dopant density 107 , that lies substantially directly beneath the junction of JTE region 103 with active region 102 at the upper surface of upper layer 101 , the dopant density of the JTE region 103 preferably decreases in both lateral directions, forming a variation of lateral doping (VLD) region. The VLD edge termination is therefore a special case of a JTE structure.
[0018] The JTE region 103 and the field limiting rings 109 , 110 and 111 of die 100 are preferably formed by implanting varying amounts of dopant according to known procedures described in, for example, U.S. Pat. Nos. 4,927,772, 4,667,393, and 4,648,174. The JTE region 103 and the field limiting rings can also comprise epitaxial layers, as described in U.S. Pat. No. 5,712,502.
[0019] In the case of an avalanche breakdown, the concentration of p-holes compensates the charge of the ionized dopants in the JTE region, thereby reducing the maximum electrical field strength in the area of the junction termination. If the p-hole concentration in the case of an avalanche breakdown exceeds the dopant concentration of the JTE region 103 , this mechanism no longer works and the breakdown may jump to the edge of the active region 102 .
[0020] The field limiting rings however have a dopant concentration that exceeds the concentration of p-holes in the case of a breakdown. They can therefore built up a spacecharge region that partly compensates the influence of the curved junction on the electric field and therefore increases the breakdown voltage of the semiconductor device even in the case of high leakage current densities.
[0021] FIG. 1B schematically depicts a semiconductor die 100 according to a second embodiment of the present invention. The semiconductor die 100 comprises an N-doped upper layer 101 which includes an active region well 102 , which can be e.g. a p-emitter of a diode or a p-body of an IGBT, and a first JTE region 103 , which are both p-doped. The upper layer 101 further comprises a second JTE region 112 in the first JTE region 103 . A metal contact 104 and a dielectric layer 105 overlie, respectively, the active region 102 and the first and second JTE region 103 and 112 .
[0022] It is recognized that the conductivity types of the dopants in layer 101 , well 102 , first JTE region 103 , and second JTE region 112 , N, P, P, and P, respectively, can also be of the opposite conductivity types, i.e., P, N, N and N, respectively.
[0023] The lateral extension of the second JTE region on the upper surface is 20 to 200 μm, depending on the desired voltage class of the device.
[0024] The first JTE region 103 is typically doped with a dose of the order 10 12 cm −2 to 5·10 12 cm −2 , while the second JTE region is doped with a dose of the order of 10 13 cm −2 to 10 15 cm −2 . The first JTE region 103 and the second JTE region 112 can be of constant or varying lateral dopant density.
[0025] FIG. 2 depicts a computer simulation of the current-voltage-characteristic under reverse bias of a power semiconductor device with field limiting rings 109 in addition to a JTE region 103 . The characteristic shows a sharp voltage drop at the point 201 of an avalanche breakdown.
[0026] FIG. 3 shows a detail of FIG. 2 , which illustrates the influence of the number of field limiting rings 109 in the JTE region 103 on the current-voltage-characteristic. The first characteristic 302 is the characteristic of a die 100 which comprises a JTE region 103 but no field limiting rings 109 . The second, third and fourth characteristic 303 , 304 , and 305 respectively, are the characteristics of a die 100 with a JTE junction and additional three, four or five field limiting rings 109 , respectively.
[0027] The point 201 indicating a breakdown jumping of the position of the edge of the JTE to the edge of the active region is shifted to higher currents and higher voltages by employing the field limiting rings. The improvement can be achieved with a constant as well as with a varying lateral doping.
[0028] The die 100 with the edge termination according to the invention is preferably used in an IGBT-, Schottky-diode or a pin-diode semiconductor device.
[0029] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention, which is defined by the following claims.
REFERENCE NUMBERS
[0000]
100 device
101 upper layer
102 active region
103 JTE region
104 metal contact
105 dielectric layer
107 point of maximum dopant density
109 field limiting ring
110 innermost field limiting ring
111 furthermost field limiting ring
112 second JTE region
201 point of avalanche breakdown
302 first characteristic
303 second characteristic
304 third characteristic
305 fourth characteristic | A semiconductor device has a heavily doped substrate and an upper layer with doped silicon of a first conductivity type disposed on the substrate, the upper layer having an upper surface and including an active region that comprises a well region of a second, opposite conductivity type. An edge termination zone has a junction termination extension (JTE) region of the second conductivity type, the region having portions extending away from the well region and a number of field limiting rings of the second conductivity type disposed at the upper surface in the junction termination extension region. | 7 |
This is a continuation of copending application Ser. No. 07/763,355 filed Sep. 20, 1991 now U.S. Pat. No. 5,181,556 granted Jan. 26, 1993.
FIELD OF THE INVENTION
This invention relates to the art of processing thin substrates such as those for magnetic disks in high vacuum systems where control of substrate temperature is difficult to achieve. More particularly, the invention relates to a system for cooling substrates in an evacuated environment for purposes such as preparation for a subsequent coating, exit to the atmosphere, or protection against excessive temperature increases.
BACKGROUND OF THE INVENTION
Thin substrates, such as those used for magnetic disks, require high vacuum processing. This processing generally involves heating of the substrate to a desired temperature and applying different coatings by sputtering or similar physical vapor deposition processes. The high vacuum processes facilitate very high purity coating depositions and the achievement of a variety of properties that are controlled by such parameters as background pressure, coating rate, and substrate temperature. Illustrative is the substrate handling and processing system disclosed in co-pending application Ser. No. 07/763,183, filed Sep. 20, 1991 now U.S. Pat. No. 5,215,420.
Control of substrate temperature in an evacuated environment (i.e. vacuum) is an essential, but difficult task. Typically, heating of a substrate is done by radiation transfer from such devices as quartz lamps. However, normal heat conduction processes work very poorly in the vacuum environment. The atmosphere is not present to supply an ambient environment around the heat sink.
During substrate (or disk) processing, it is also often desirable to lower the substrate temperature. For example, controlled cooling of the substrate may be necessary to achieve a predetermined temperature for a serial coating step, such as chromium, cobalt alloy or carbon layers with magnetic disks. In this instance, the properties of the high hardness, abrasion resistant carbon coatings are enhanced when deposited onto a substrate which is at a relatively low temperature.
Further, cooling of substrates or disks by exposure to the atmosphere while still hot may severely limit the usefulness of such substrates or disks for particular applications. Additionally, uncontrolled cooling and/or cooling in atmosphere could adversely effect coating quality by virtue of the diffusion of different coatings at elevated temperature.
Several prior art techniques have been employed in an attempt to cool the relatively thin substrates during processing. Illustrative is the apparatus disclosed in U.S. Pat. No. 4,909,314. The system disclosed in the noted patent includes a heat exchanging body which is designed and configured to be in contact with the article to be cooled. The system also employs a relatively low conductivity gas, such as argon, to facilitate the heat exchange between the article and the heat exchanging body.
The main disadvantage of such a system is that the act of touching such a relatively thin substrate may do harm to one or more surfaces that have to be maintained in pristine condition. Further, the low mass and the need to handle the substrates only at the edges make them difficult to conductively couple with a heat sink.
Accordingly, it is an object of the invention to provide an improved method for substrate cooling in a vacuum environment which could be employed between process starting steps and not harm the substrate surface of coatings already deposited.
It is a further object of the invention to provide a system for cooling a substrate in a vacuum environment with an enhanced cooling rate so that commercially viable processes could be effected.
SUMMARY OF THE INVENTION
The disclosed system for cooling a substrate in an evacuated environment eliminates the disadvantages and shortcomings associated with the prior art techniques. The disclosed system employs conduction/convection heat transfer in a specialized process chamber to cool thin substrates rapidly without any contact to either surface. A cooling chamber is provided with stationary heat sinks spaced a predetermined distance apart, between which the substrate is positioned. A high thermal conductivity gas is then introduced, filling the entire chamber to the desired operating pressure. The substrate is then cooled to a given temperature, depending on the heat sink temperature, original substrate temperature, gas thermal conductivity, pressure, and spacing between the substrate and heat sinks.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages will become apparent from the following and more particular description of the preferred embodiment of the invention, as illustrated in the accompanying drawings, in which like referenced characters generally referred to the parts or elements throughout the views, in which:
FIG. 1 is a cross-sectional view of the substrate cooling system within the substrate processing chamber according to the invention;
FIG. 2 is a graph illustrating the thermal conductivity versus pressure for helium; and
FIGS. 3 through 8 are graphs illustrating the cool down rates of substrates under varying processing conditions according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, the disclosed system for cooling a substrate in an evacuated environment substantially reduces or eliminates the disadvantages and shortcomings associated with the prior art techniques. According to the invention, a cooling chamber is provided with a pair of stationary heat sinks having substantially planar parallel facing surfaces. Once the substrate is operatively positioned between the heat sinks, with its respective outer surfaces adjacent to and substantially parallel with the facing surfaces of the heat sinks, a high thermal conductivity gas is introduced into the cooling chamber to facilitate the heat transfer from the substrate to the heat sinks. A highly important technical advantage of the invention is that the contiguous surfaces of the heat sinks are maintained at a predetermined close spacing with the substrate to achieve a substantial conductive/convective heat transfer and eliminating the risk of any damage to the extremely sensitive surface of the substrate or disk by heat sink contact.
Gas conduction cooling can be viewed with a simple model as per the following: ##EQU1## where
ΔE=Energy removed from the disk
Δt=time increment
K=gas thermal conductivity
Δφ=temperature difference between substrate and heat sink
L=spacing between substrate and heat sink
For most gases, the thermal conductivity K is constant at pressures of one atmosphere and higher, with little or no dependency on the pressure. As the pressure falls below an atmosphere, the conductivity is reduced. The conductivity of the various gases is related to their molecular weight, with the lightest gases, such as helium and hydrogen, being the best conductors. FIG. 2 graphically illustrates the conductivity versus pressure for helium, as determined by recent experiments.
In designing a processing station to give the highest substrate cooling rate, it is important to choose a gas such as helium or hydrogen for best conductivity. Further, it is necessary to maintain the heat sinks at the lowest practical temperature to provide the highest temperature difference between the sinks and the substrate. It is also desirable to maintain the spacing between the heat sinks and the substrate at a practical minimum such that the substrates can be easily and readily positioned in and out of the processing station as the substrate is sequentially processed in a vacuum system such as disclosed in co-pending application Ser. No. 07/763,183, filed Sep. 20, 1991 now U.S. Pat. No. 5,215,420. This is a compromise spacing where undesirable contact with the substrate surfaces is avoided, but heat transfer from the substrate to the heat sinks is maximized.
Finally, the gas pressure of the processing station must be controlled to optimize conductivity at the highest practical value consistent with the vacuum system operation. This is typically done by throttling the gas flow to a high vacuum pump such that a small (total) gas flow gives a greatly elevated pressure.
FIG. 1 is a simplified sectional view of one embodiment of the present invention. In the preferred embodiment of the invention, the substrate cooling station 1 is operatively secured to the main vacuum chamber housing 21 by conventional mounting means, such as the plurality of bolts shown in phantom, and is effectively sealed thereto by virtue of O-ring seal 22.
The substrate cooling station 1 generally comprises two heat sink spacers 2 mounted on a pair of heat sinks 3. The heat sink spacers 2 are employed to conveniently set and maintain the critical spacing between the substrate 10 and the heat sinks 3. To maintain the temperature of heat sinks 3 at a suitably low value, conduits 4 and 5 passing into and through the heat sinks 3 are provided to allow a conventional coolant to be flowed into and out of the heat sinks 3, thereby maintaining the temperature of the heat sinks 3 at the desired level.
Temperature of the heat sinks 3 is monitored by virtue of a pair of conventional temperature sensors 6, operatively mounted on each heat sink 3, and a pair of conventional temperature sensor vacuum feedthroughs 7 operatively positioned in the processing chamber 1 housing. The temperature sensors 6 and feedthroughs 7 are operatively connected by leads 8, 9.
In the preferred embodiment, the heat sinks 3 have a generally planar surface and are generally positioned parallel one to the other. The heat sink spacers 2 are tightly mounted to the heat sinks 3 to ensure that they are both at the same temperature. The surfaces of the heat sink spacers 2 are closely spaced to achieve a substantial convective/conductive heat transfer from the substrate 10 to the heat sinks 3, but not in contact with the substrate 10 when positioned therein, eliminating any risk of damage to the delicate substrate 10 surfaces. The term substantial convective/conductive heat transfer, as used herein, means a convective/conduction heat transfer in excess of 500% of the optimum heat transfer from the substrate 10 to the heat sinks 3 by radiation alone.
An input gas conduit 21 is provided to introduce the high thermal conductivity gas, such as helium, directly into the processing chamber 20. The introduction of helium gas increases the rate of cooling by increasing the rate of heat transfer from the substrate 10 to the heat sinks 3.
In the preferred embodiment of the invention, the heat sinks 3 comprise a high conductivity material such as copper, and are capable of cryogenic operation at approximately -130° C. Each of the heat sink spacers 2 are also maintained at a predetermined distance from the respective substrate 10 surface between 0.05 and 0.25 inches, preferably 0.09 inches.
In the preferred embodiment, helium gas is employed as the conductive medium. The helium gas is introduced into the processing chamber by conduit 21 and pumped through a very small orifice or throttle plate (not shown) to a conventional high vacuum cryopump 23 mounted near the base of the processing station 1.
The substrate 10 is moved into and out of the processing station, and loosely supported therein, on a substrate holder 11, such as that disclosed in co-pending application U.S. Ser. No. 1/763,183, filed Sep. 20, 1991 now U.S. Pat. No. 5,215,420, whereby neither of the two coated surfaces of the substrate are touched by any part of the apparatus.
The substrate cooling station 1 may also include a pair of external handles 25 to facilitate removal and installation of the cooling station 1.
According to the method of the present invention, to effect cooling of the substrate 10, each of the heat sinks 3 is prepositioned (i.e. spaced) between 0.05 and 0.25 inches, preferably 0.09 inches from the substrate 10. The heat sinks 3 are then cooled to between -50° C. and -200° C., preferably -130° C. by conventional cryogenic refrigeration.
The substrate 10 is then positioned in the processing chamber 20 by the substrate holder 11 such that the respective outer surfaces of the substrate 10 are adjacent to and substantially parallel with the facing surfaces of the heat sink spacers 2. A high thermal conductivity gas, such as helium or hydrogen is introduced into the processing chamber 20 while the heat sinks 3 are at their operating temperatures to increase the rate of heat transfer from the substrate 10 to the heat sinks 3. The gas flow is introduced and maintained at a pressure significantly above that of the processing chamber 20, yet substantially below that of the atmosphere. In the preferred embodiment the gas pressure is maintained at approximately 1 to 100 Torr, preferably 10 Torr. To stop the substrate 10 cooling, the gas flow is stopped and the throttle plate orifice (not shown) is opened.
Another method which may be used to cool the substrate 10 is to completely close off the high vacuum pumping port (not shown) and admit enough gas for effective conduction. This involves only an initial gas flow which is then stopped when the operating pressure is reached. To stop the cooling, the high vacuum valve is then opened and the relatively small net amount of gas is pumped away, restoring high vacuum in the processing chamber 20.
After cooling the substrate 10 to a predetermined temperature, the substrate 10 is removed from the processing chamber 10 by the substrate holder 11.
The controls and examples which follow illustrate the superior performance of the invention. The controls and examples are for illustrative purposes only and are not meant to limit the scope of the claims in any way.
CONTROLS AND EXAMPLES
A 95 mm. dia.×0.050" thk. un-coated (except for electroless nickel) aluminum disk was employed for the following experimental analysis. The disk was placed in a V-block and preheated to 300° C. The disk was equipped with a conventional thermocouple to closely monitor the disk temperature. The spacing between disk and each heat sink spacer was maintained at 0.225".
In the first experiment, the cooling rate was measured without conductive helium present. This experiment thus measured the cooling rate due to radiation only and is shown in FIG. 4.
Similar cooldown experiments were then repeated at various helium pressures, as shown in FIGS. 4, 5, 6 and 7, with the heat sink temperature maintained at 21° C. using cooling water. FIG. 8 illustrates the enhanced cooling rate which was achieved using cryogenic heat sinks at -130° C. The results of the above experiments are summarized in Table 1.
TABLE 1______________________________________ Time to Reach 150° C. From 300° C. InitialPressure Heat Sink Temp °C. Temp.______________________________________High vacuum 21° C. 625 sec.44.4 mtorr 21° C. 315 sec.84.0 21° C. 227 sec.125.8 21° C. 195 sec.251 23° C. 120 sec.242 -130° C. 62 sec.______________________________________
The foregoing examples have set forth a substrate cooling system which effectively cools a substrate or disk during processing without any risk of damage to the delicate surfaces of the substrate or disk. This is accomplished by positioning a pair of heat sinks at a predetermined spacing such that the substrate or disk may be easily and readily positioned between the sinks, but close enough in spacing to achieve a substantial conductive/convective heat transfer from the substrate to the heat sinks with the aid of a high conductivity gas.
While the embodiments of the substrate cooling apparatus and methods have been disclosed with reference to specific structures, one of ordinary skill can make various changes and modifications to the invention to adapt it to various uses and conditions. As such, these changes and modifications and properly, equitably, and intended to be, within the full range of equivalents of the following claims. | A method and apparatus are disclosed using a combination of convection and conduction cooling to cool an article in an evacuated environment. A processing chamber is used which includes at least one heat sink. A flat surface of the article to be cooled is positioned within the chamber in a spaced apart facing parallel relationship to a facing surface of the heat sink. High conductivity gases are admitted into the chamber to accomplish cooling of the article. | 8 |
RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 11/053,526, filed on Feb. 7, 2005, which is incorporated herein by reference for all purposes and which claims priority to Provisional Application Ser. No. 60/543,588 filed on Feb. 9, 2004, Provisional Application Ser. No. 60/550,631 filed on Mar. 4, 2004 and Provisional Application Ser. No. 60/553,040 filed on Mar. 12, 2004, which are incorporated herein by reference for all purposes.
BACKGROUND
[0002] The disclosed method and apparatus relates generally to methods and apparatus for the treatment of respiratory, blood or other body cavity infections in humans and/or animals, and/or inanimate object disinfection. It has been known for almost 100 years that ultraviolet light in the 248-253.7 nm wavelength range, the so called deep or far ultraviolet (also known as UVC), is lethal in small doses of short time duration, meaning power level per area exposed over time, to most bacteria, viruses, fungi and molds. An approximate band that is useful in the applications of the disclosure of this patent is the band from about 200 nm to 320 nm. DNA deactivation appears to be somewhat more likely or more efficient in the shorter wavelength part of this range, from about 200 nm to 250 nm. Antibiotics delivered orally or by intravenous methods are somewhat effective at eradicating certain pathogens in the lung tissue where the circulatory system is able to deliver the drug. However, the larger airways of the lungs (and certain other body or organ cavities) are not particularly accessible via the circulatory system. Further, the larger airways of the respiratory system (trachea and major bronchi) are the predominant producers of mucous which create a protein rich environment for pathogen growth that is physically distant from vascular access.
[0003] The overall disclosure herein is using computer controlled, fiber-coupled laser delivery of treatment specific wavelength, intensity and duration of UV irradiation to control bacterial, fungal, viral, and mold infections in bodily cavities, fluids and external applications. The method of treatment is focused on DNA breakdown beyond repair by natural DNA repair mechanisms of the pathogen, with less than damaging doses to tissues being treated, thus avoiding mutagenicity and carcinogenicity. The minimal intensity and duration and exposure area of any given surface of tissue to be treated is to be pre-determined by tissue and pathogen testing to optimize the therapeutic ratio. External applications include specifically Trichophyton Rubrum (toenail fungus) through the nail and Pseudomonas Aeruginosa infections in burns and elsewhere.
[0004] The disclosure herein is, additionally, for a surgically installed inline arterial blood treatment device that allows for outpatient and in-home application of computer controlled, preprogrammed therapies of UV germicidal irradiation via a fiber optic connection external to the patient's body. With a simple fiber optic connector, the computer controlled, fiber optic coupled laser UV light source delivers the desired wavelength, intensity and duration needed to deactivate pathogens (bacterial, viral and others) in blood as it traverses through the device. The method of treatment is focused on DNA breakdown beyond repair by natural DNA repair mechanisms of the pathogen, with less than damaging doses to tissues being treated, thus avoiding mutagenicity and carcinogenicity. Further, as blood cells do not reproduce but rather are generated in bone marrow, their need for DNA to reproduce is unimportant while the pathogens attached to the blood cells are then unable to replicate thereby reducing further colonization of new blood cells.
[0005] Further still, the disclosure herein is for using perflourocarbons and other possible partial liquid ventilation substances, doped with optically appropriate compounds to reflect and refract UV light delivered via Ultraviolet Video Bronchoscopic Devices to allow UV germicidal irradiation of remote and difficult to reach spaces within the respiratory system. The method of treatment is focused on DNA breakdown beyond repair by natural DNA repair mechanisms of the pathogen, with less than damaging doses to tissues being treated, thus avoiding mutagenicity and carcinogenicity. Additionally, these perflourocarbons and other possible partial liquid ventilation substances can be used as a means of transport of retrovirus vectors to deliver gene therapies to difficult to reach areas within the respiratory system thereby enabling an effective therapeutic outcome previously not possible.
[0006] When used in a lung treatment application, the disclosure incorporates a fiber optic coupled, computer controlled light source or laser emitting UVC via a video bronchoscope or other suitable device for insertion into a patient's lungs. The computer controller is capable of determining the frequency or wavelength of light and the power of the light applied as indicated by the patient's condition and size, tissue being treated, amount of mucous present and pathogen type. Almost all viruses, bacteria and fungi are killed by 253.7 nm wavelength of UVC but other wavelengths are probably even more beneficial and efficient. The disclosure provides for methods for the pulmonologist or other medical professional to apply the treatment in a systematic manner such that all areas of potential pathogen colonization are exposed to the predetermined duration, intensity and wavelength of UVC light. The method also specifies that the pulmonologist or other appropriate medical professional, using a video bronchoscope monitor, can control the instrument placement into the distal end of each of the third generation major bronchial branches. The computer controller can then be set to deliver the desired wavelength, duration and intensity of UVC as the instrument is withdrawn smoothly and slowly enough to evenly expose the infected airway region. Withdrawal can be by hand or by suitable mechanical or electromechanical devices. For example, an electromechanical withdrawal device can be devised using an exposure power level versus time function built into the monitor or other hardware of the apparatus so the practitioner can be more certain that the withdrawal was at the right or optimal speed. Once the instrument is withdrawn to the proximal end of the branch where it meets the next higher generation bronchial branch, the light source is turned off. In practice, one way to implement this is to provide the light source with a shutter on the fiber coupling and/or the PC controller which would be able to control the light without powering off the light source. Next, the instrument is inserted into the next higher third generation bronchial branch to the distal extent accessible and this process is repeated for all 18 of the segmental bronchi airways, followed by similar treatment of the right and left main bronchi and finally the trachea as the procedure is completed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a video bronchoscope capable of reaching the distal end of all 18 of the segmental bronchi in pediatric or adult patients.
[0008] FIG. 2 illustrates the disclosed apparatus shown as a modification to or accessory for a video bronchoscope where either one of the fiber optic light sources normally used to provide light for video bronchoscopy is setup for UVC delivery (in combination with or instead of visible light while UVC is being delivered) or the accessory channel is used for the fiber optic delivery of the UVC light to the desired location. Additionally, the light source and computer controller are depicted.
[0009] FIG. 3 illustrates the major airways of the human respiratory system 300 that are of primary interest to the disclosure of this patent for lung disease applications.
[0010] FIG. 4 is a more detailed illustration of the major airways of the human respiratory system, specifically illustrating the peripheral bronchi.
[0011] FIG. 5 illustrates red blood cells treatable by one embodiment of the disclosure.
[0012] FIG. 6 illustrates a device for blood treatment using an embodiment of the patent.
[0013] FIG. 7 illustrates a second device for blood treatment using the teachings of the patent.
[0014] FIG. 8 illustrates an additional embodiment for bodily fluid treatment.
SUMMARY OF THE INVENTION
[0015] The disclosed method and apparatus provides useful methods and apparatus for the treatment of respiratory, or other, pathogen infections using ultraviolet light germicidal irradiation (UVGI) as a germicidal agent and can be used in combination with traditional antibiotic and other drug therapies. The smaller airways and lung tissues are better suited to infection treatment using antibiotics due to their inherent vascular accessibility. The combination of drugs and UVGI of the larger airways provides more complete pathogen eradication with greatly reduced risk of re-infection or at least longer durations of reduced symptoms while pathogen colonies regenerate between treatments. In addition to respiratory therapy, the disclosed method and apparatus can also be used in the treatment of blood infections, and other body cavity infections in humans and/or animals, and/or inanimate object disinfection.
DETAILED DESCRIPTION
[0016] The disclosure generally pertains to methods and apparatus for the reduction and/or elimination of pathogens causing infection in human and animal respiratory systems and other body cavities. The disclosure is applicable to the disinfection of difficult to reach and access areas of inanimate objects as well. Further, the disclosed method and apparatus is applicable to heart-lung and blood transfusion systems for pathogen and/or chemical antigen deactivation in blood by exposing the blood cells to UVC at such a wavelength and intensity and duration as to deactivate the antigen. This can be accomplished via a UVC venous system wherein multiple simultaneous UVC tubes are used to exposure a large volume of blood simultaneously. The disclosure utilizes apparatus comprised of a computer controllable UVGI light-source fiber optically delivering the light to desired areas via an accessory for or modification to existing video bronchoscopes. The computer can control the duration, intensity and wavelength(s) of light being delivered during treatments. The disclosure includes methods for treatments of infected areas in a systematic manner that assures maximum pathogen kill ratios with minimal risk of tissue damage. The disclosed method and apparatus is designed to work in conjunction with antibiotic drug therapies wherein the drugs perform the primary function of disinfecting small airways and tissue that are vascular and accessible via the circulatory system. The disclosure provides the methods and apparatus to disinfect larger airways where greater mucous quantities are produced that creates an opportune environment for pathogen colonization and where the circulatory system does a poor job of delivery of intravenous or orally administered antibiotics. By reducing or eliminating the pathogen culture populations in the larger airways, likelihood of re-infection of the smaller airways and lung tissue is greatly reduced.
[0017] FIG. 1 shows a typical video bronchoscope 100 that can be modified or accessorized with the disclosed apparatus.
[0018] The disclosure is directed to methods and apparatus for the reduction and/or elimination of pathogens causing infection in human and animal respiratory systems and other body cavities. The method and apparatus can be used to treat infections occurring in patients having, for example, cystic fibrosis. The disclosure is also applicable to the disinfection of difficult to reach and access areas of inanimate objects as well.
[0019] Continuing with a description of an application for lung therapy, FIG. 2 illustrates the block diagram of the apparatus of the disclosure. The video bronchoscope 215 is navigated by watching a monitor, attached in a well known manner and viewable by the medical professional operating the protocol, to visually guide the instrument to the desired area of the bronchial tree. This instrument is capable of reaching the distal end of each of the 18 segmental bronchi in the third generation of the bronchial tree in pediatric and adult patients. The computer laser controller 200 is used to set the duration, wavelength(s) and intensity of ultraviolet light to be applied. The wavelengths, duration and intensity of light to be used are predetermined based upon pathogen type(s) being killed, quantity and quality of mucous in infected airway area, size of patient, length of time allocated to overall procedure to be conducted and other factors. Other factors include the type of tissue being treated and its susceptibility to light induced damage and whether a “kill” or “cidal,” or a DNA deactivation or “-static” is desired. In some cases just deactivating DNA would be very valuable. The methods of treatment include protocols for the laboratory identification of pathogen(s) present and how they respond to different wavelengths of ultraviolet to determine optimal kill ratio with minimal risk of damage to respiratory system structures and tissue. The computer controller is connected to an appropriate fiber optic coupled light source or laser 205 functioning as a light source. Such fiber optic coupled lasers operating in the desired range are now available commercially. The light source has one or more computer controllable wavelengths, intensities and a shutter that can open and close to control duration of ultraviolet exposure. The light source 205 is in turn connected to a fiber optic cable 210 that is inserted into the open channel of the video bronchoscope 215 or is modified to utilize the visible light fiber optic system of the video bronchoscope that illuminates the viewing area for capture by the camera (often a charge coupled device camera) at the distal end of the video bronchoscope. The distal end of the fiber optic cable has a specially designed diffuser that illuminates a hemispherical area with approximately even distribution of light energy on all areas illuminated. The disclosure provides for treatment protocols including autoclaving and other sterilization procedures, for example UV sterilization, necessary to insure that infections are not spread from one patient to another. As mentioned above, FIG. 2 illustrates for lung therapy applications a device for computer controlled ultraviolet germicidal irradiation UVGI light source for fiber optically delivering the light to desired areas via an accessory for or modification to existing video bronchoscopes. The computer can control the duration, intensity and wavelength(s) of light being delivered during treatments. The disclosure includes methods for treatments of infected areas in a systematic manner that assures maximum pathogen kill ratios with minimal risk of tissue damage. The disclosed method and apparatus can work in conjunction with antibiotic drug therapies. One example is lung applications wherein the drugs perform the primary function of disinfecting small airways and tissue that are vascular and accessible via the circulatory system. In lung applications the disclosure provides the methods and apparatus to disinfect larger airways where greater mucous quantities are produced that creates an opportune environment for pathogen colonization and where the circulatory system does a poor job of delivery of intravenous or orally administered antibiotics. By reducing or eliminating the pathogen culture populations in the larger airways, likelihood of re-infection of the smaller airways and lung tissue is greatly reduced.
[0020] The disclosed method and apparatus provides treatment protocols including systematic process of delivery of uniform exposure of UVGI needed as predetermined during laboratory analysis of pathogen(s) cultured. FIG. 3 depicts the disclosure in a lung therapy application. As seen in FIG. 3 , the proximal three generations of airways in the human respiratory system bronchial tree terminating in the 18 segmental bronchi. The basic treatment protocol begins by-instrument insertion into the distal end of the lower most segmental bronchi of the left lung 301 of the appropriately monitored and anesthetized patient. Once the distal end of this branch of the bronchial tree is in view on the monitor of the video bronchoscope, the predetermined settings for the UVGI light source are used to begin the exposure process. Next the physician or other appropriate medical professional performing the procedure withdraws the instrument at a predetermined rate as visually tracked on the monitor of the video bronchoscope until the intersection of the left main bronchus 320 is observed by seeing the proximal opening of the next lower most segmental bronchi of the left lung 302 . The procedure is again performed for each subsequent next higher branch of the segmental bronchi in each lobe. Once the uppermost segmental bronchi branch of each lobe is treated ( 303 in the case of the left lower lobe), the main bronchus is then treated similarly perhaps using a different set of parameters of wavelength(s), duration and intensities to accommodate changes in cultures, airway size, or other known attributes, until the proximal opening of the lowest segmental bronchi branch ( 304 in the case of moving to the upper lobe of the left lung) of the next higher lobe becomes visible. At this point the procedure methodically begins over for each subsequent lobe, working from the bottom of the left lower lobe through the top of the left upper lobe 308 and then through the left main bronchus 320 to the junction of the trachea 330 . Next the procedure continues starting with the lower most segmental bronchi of the lower lobe of the right lung 309 through the upper most segmental bronchi of the upper lobe of the right lung 318 . Next the right main bronchus 321 is treated until the confluence of the trachea 330 . Finally, the trachea is treated with appropriate predetermined settings applicable for known parameters of any particular patient's respiratory infection. While this procedure has been described the protocol beginning with the lower left segmental bronchi because it is the most distal, it will be appreciated by one of ordinary skill in the art that the protocol can begin with the right main bronchus. Also, it could be for specific airway regions of any of the five lobes only, and could also treat smaller airways down to the sixth generation airway as labeled in FIG. 4 to the fifth generation.
[0021] Use of perflourocarbons can provide additional applications for this patent. Perflourocarbons are used for “liquid ventilation” (LV) or “partial liquid ventilation” (PLV) of the lungs. These are fluids that can be taken into the lungs and the lungs can actually breathe the fluid. This gives rise to three additional applications for the present patent.
[0022] The first is an adaptation of the Video Bronchoscopic Germicidal Irradiation (“VBGI”) described above with respect to the device of FIG. 2 . The liquid ventilation solution could be used directly or doped with an appropriate, additive such that UV light introduced through it by the device of FIG. 2 would reflect and refract into areas not accessible by the VBGI alone.
[0023] That is, the utilization of appropriately doped perflourocarbons or other so-called liquid ventilation (LV) or partial liquid ventilation (PLV) fluids in the lungs of humans and animals to reflect and refract UVC light will provide access to more surface area of the affected lung tissue being treated. With the lungs inflated with doped PLV (DPLV), the weight and pressure exerted on the lung tissue from the inside of the airway causes opening of airways and increases accessibility to otherwise inaccessible airways. Additionally, UV light being administered via the previously disclosed VBGI, can be more effective using DPLV that provides a liquid pathway for UV light to eradicate pathogens deeper in the lung bronchial tree illustrated in FIG. 4 than accessible by the previously disclosed bronchoscopic method alone.
[0024] The actual introduction of the liquid ventilation solution into the lungs or other appropriate body part can be done by today's well-known methods. For lung treatment, these methods include filling the lungs with the fluid. As the patient breathes, the fluid is used up and can be “topped off” continually or from time to time either manually or by use of a float valve. The introduction of the UV would be by VBGI perhaps requiring a different lens at the end of the bronchoscope device of FIG. 2 than would be used without the use of the solution. This may be a remotely controllable variable lens for different parts of the path in the lungs to control where the UV is being directed. Visible light can be used as a guide for this process. For example, depending on the refractivity of the liquid one may need to have a wide-angle lens to diffuse and disperse the UV light rather than focus the UV light.
[0025] Secondly, one can use the liquid ventilation solution with antibiotics to kill pathogens. Since one of the main reasons for the earlier disclosed apparatus and method is that aerosolized antibiotics generally do not reach the lungs effectively, this liquid ventilation delivery approach can improve the effectiveness of antibiotics. That is, by adding antibiotics that would normally be aerosolized and administered via breathing treatments to PLV, the antibiotics can be far more effective. These aerosolized antibiotics are usually inhibited from effectively functioning due to limited accessibility to pathogen-infected areas of the respiratory system. However, adding antibiotics to the above liquid ventilation delivery approach would improve their effectiveness.
[0026] The third application provides access to all or nearly all parts of the lung for retrovirus inoculation of gene transplant therapy. At present, advances in cystic fibrosis lung gene therapy are difficult due to lack of a delivery mechanism that is capable of reaching enough of the lung surface area to make a meaningful difference. By adding the “corrected gene” DNA carrying retrovirus to PLV fluids and then ventilating the patient using the fluid as disclosed above, the gene therapy would be able to treat a significant portion of the respiratory system surface area. It is commonly thought that greater than 10% of the respiratory surface area must be treated to achieve a meaningful change in respiratory function using gene therapy. By modifying the gene therapy procedure to use PLV, both greater effectiveness can be achieved and less frequent treatments are required.
[0027] Another application of the disclosure can be for treatment of blood diseases. Referring to FIG. 5 , there is illustrated a number of red blood cells and their donut shape. It is well know that most pathogens (viral, bacterial, fungal and chemical, as examples) adhere to the outside of the donut shape of the cell at least initially. It is also well known that most of these pathogens can be eradicated or deactivated by the application of UV light in the wavelength range of approximately 200 nm to 320 nm. The teachings of the disclosure can be applied to treating blood cells via a device similar to that illustrated in FIG. 6 . In that device a UV light source, which could be a bulb or a tube such as a mercury tube, is wrapped with a quartz coil that exposes blood cells passing though it to UV light.
[0028] FIG. 7 illustrates another embodiment useful in treating blood diseases. In the device illustrated in that figure, a tube through which blood flows is connected to a flanged or other suitably shaped area where it flattens out and quartz or other suitable material window is fitted with a fiber optic UV light source such as the fiber coupled laser discussed above. The devices of FIG. 6 or FIG. 6 can be shrouded to prevent UV exposure outside the desired exposure areas. The coil in FIG. 6 and the flattened bridge device in FIG. 7 can be disposable, or can be autoclavable for subsequent use. Either device can be fitted inline to heart-lung machines or other suitable apparatus for blood treatment of a patient external to the patient's body. Since the DNA of blood cells is not used for replication or reproduction inasmuch as blood is made in the marrow of bones, the UV light that damages DNA will deactivate the pathogen DNA with little or no harmful effect on the blood cell's functionality. The UV irradiated blood can then be passed back into the patient's body where the deactivated pathogens are not able to replicate, and they can eventually be removed via the patient's immune system.
[0029] FIG. 8 illustrates an additional embodiment for bodily fluid treatment. This is a small, permanent or temporary, surgically installed, inline arterial (or other bodily tube for bodily fluid other than blood) germicidal irradiation blood or other bodily fluid treatment device 801 . It could have its UV light source external to the body, which would be connected via a fiber optic coupling 800 as needed during periodic treatment. Treatment could be in-home, in hospital or as an outpatient in a doctor's office or other suitable office or center. This could be used for treatment against HIV/AIDS, leukemia and/or other blood borne (or other bodily fluid borne) pathogens.
[0030] As seen in FIG. 8 , there could be a permanent or temporary surgical connection to UV device 801 between parts of an artery, vein or other bodily fluid conducting tube 802 ( a ), 802 ( b ). The device 801 can be constructed so as to have internal baffling (not shown) or other turbulence-inducing construction. The internal baffling can cause fluid flow through the device to become turbulent therefore exposing more surface area of the fluid passing through the device to UV as desired. The connection of the device 801 with artery or vein or other bodily fluid conducting tissue can be permanent or temporary and is surgically implanted in connecting relationship between two sections of the artery, vein or other tissue. The device is preferably constructed with inert plastic. It can be made such that connective tissue, such as artery, vein or other, as appropriate, is not exposed to UV. That is, the device itself acts to contain essentially all the UV light and exposes only the fluid passing through it to UV, as explained with respect to an earlier embodiment. The device can have a remote or external UV light source connected via fiber optic or other suitable coupling 800 for the period of the treatments depending upon the pathogen, patient health, an other criteria. The external light source 803 can be a fiber coupled UV laser, as described above, or other appropriate UV light source. Sometimes the connection of the external light source to the patient is called a button, which refers to the patient's connection point to the external light source. What is required is the connection to the external light source, here preferably a fiber optic connection, and a good mechanical connection surgically to the patient's tissue at the connection site to keep the fiber optic cable connected to the UV treatment chamber 801 within the patient from pulling out or entangling with other structures in the patient's anatomy. In operation, the fluid would pass through the device or treatment chamber 801 to allow UV light to irradiate the fluid flowing through the device at appropriate periods. Digital or analog control means, well known in the art, can be used to control the frequency, time period and intensity of the UV light as it is exposed to the fluid flowing through the device 801 .
[0031] While the foregoing description has been with reference to particular embodiments, it will be appreciated that these are only illustrative and that changes may be made to those embodiments without departing from the principles of the invention, the scope of which is defined by the spirit and scope of this overall description. | Method and apparatus for using computer controlled, fiber-coupled laser delivery of treatment specific wavelength, intensity and duration of UV irradiation to control bacterial, fungal, viral and mold infections in bodily cavities, fluids and external applications. The method of treatment is focused on DNA breakdown beyond repair by natural DNA repair mechanisms of the pathogen, with less than damaging doses to tissues being treated, thus avoiding mutagenicity and carcinogenicity. The minimal intensity and duration and exposure area of any given surface of tissue to be treated is to be pre-determined by tissue and pathogen testing to optimize the therapeutic ratio. External applications include specifically Trichophyton Rubrum (toenail fungus) through the nail and Pseudomonas Aeruginosa infections in burns and elsewhere. | 0 |
FIELD OF THE INVENTION
This invention is in the field of percutaneous transluminal arterial catheters which are designed for the purpose of surgical excision of atheromas which typically consist of plaque deposits that cause narrowing (stenosis) of an artery. The cutting out of atheromas has been given the name "atherectomy".
BACKGROUND OF THE INVENTION
Atherosclerotic arterial disease is the leading cause of morbidity and mortality in the United States and most other developed countries. Atherosclerosis is a chronic disease process characterized by lipid deposits and fibrosis of the intima, irregularly distributed in large and medium sized arteries. The disease is progressive and most often becomes clinically manifest in the middle-aged and elderly. When severe, the atheroschlerotic plaque causes a reduction of the cross-sectional area of the arterial lumen, with and without thrombosis. Resultant ischemic manifestations include: angina pectoris, myocardial infarction, stroke, intermittent claudication, gangrene of the lower extremities and renovascular hypertension.
The current management of atherosclerotic disease includes preventative therapy aimed at minimizing known major risk factors such as hypertension, smoking, hypercholesterolemia and diabetes mellitus.
Coronary artery bypass grafting (CABG), carotid endarterectomy and bypass grafting (autogenous vein or synthetic graft) of the iliac, femoral and renal arteries are all well established surgical methods of palliative therapy. Although these procedures are often effective in relieving ischemia, each of these represents a major surgical operation with significant associated morbidity, mortality and expense. CABG, for example, requires the opening of the chest cavity (thoracotomy) and use of cardiopulmonary bypass, with not uncommon postoperative complications including postpericardotomy syndrome, Non-A Non-B hepatitis, stroke and a mortality of approximately one percent (1%) at most medical centers.
Percutaneous transluminal angioplasty (PTA) by means of a balloon catheter is a relatively new ("non-surgical") procedure with proven efficacy in relief of atheroschlerotic obstruction of the coronary, renal and peripheral circulations. The technique involves the percutaneous passage (under local anesthesia) of a specialized balloon-tipped catheter through the site of arterial narrowing, and inflation of the balloon to reduce obstruction. This is always done in conjunction with angiographic visualization of the vessel being treated. When successful, this procedure results in a reduction of the arterial stenosis and a decrease in the transstenotic pressure gradient. The mechanism of action is felt to consist of some combination of plaque compression, intimal splitting and medial/adventitial stretching. Healing of the balloon-damaged plaque may involve fibrosis and retraction of the split intimal elements, with further luminal enlargement in the weeks to months following the procedure.
The safety and efficacy of PTA is a function of the vessel being treated, patient selection, and the expertise of the physician performing the procedure. Primary angiographic success, defined as 20% or greater reduction of stenosis, is now achieved in approximately 80-90% of attempts in carefully selected patients at experienced centers. The obvious advantage of PTA, compared to surgical palliative therapy, is that it does not require major surgery or general anesthesia with the associated sequelae.
Despite its proven efficacy in the palliation of obstructive atherosclerotic disease, PTA, as it is currently performed, has several important technical limitations. These limitations are particularly true in the application of PTA to the coronary circulation.
Even in the most skilled hands, dilation of an arterial obstruction is currently not achievable in approximately 20% of attempts. The most common cause of failed PTA is the inability to pass either the guide wire or dilating catheter through the site of a tight or eccentric stenosis. This problem is even more common in attempts to dilate the difficult to access right and circumflex coronary arteries. Although technical advances, such as steerable catheters, have reduced the frequency of unsuccessful attempts, inability to cross a tight, eccentric or fully closed stenosis remains a major limitation of PTA.
Attempts at balloon or guide wire passage in vessels which are tightly stenotic may lead to arterial dissection and/or acute occlusion necessitating emergency vascular surgery. This major complication occurs in 6-8% of attempts at coronary angioplasty.
Inability to dilate an obstruction, even after proper balloon positioning and inflation is a second common mode of PTA failure. This problem is most frequently encountered in older plaques which are densely fibrotic and/or calcified.
Restenosis of the obstructed arterial segment following successful PTA is a major problem with the current technique. This problem is more common following PTA of a coronary obstruction (30-35% at one year) than in the peripheral circulation (10-15% at two years). Pharmacologic attempts to reduce the incidence of restenosis have been largely unsuccessful.
Distal embolization of atherosclerotic plaque following balloon PTA occurs in approximately 5% of patients undergoing PTA of lower extremity or renal arteries. Although these emboli are usually clinically insignificant in these vascular territories, such embolization could be catastrophic in the cerebral circulation. For this reason, balloon PTA is considered to be contraindicated for the treatment of obstructive lesions in the arteries of the aortic arch, such as the carotid artery.
In U.S. Pat. No. 4,207,874 (dated June 17, 1980) D. S. J. Choy describes a means for using a laser beam to tunnel through an arterial occlusion by vaporization of the obstruction. The difficulty with Choy's invention is that that there is insufficient means to prevent simultaneous destruction of the arterial wall. For example, the Choy invention shows an intense laser beam directed in the forward direction without significant beam attenuation in that direction. If the artery were to curve and the arterial wall was exposed to the laser beam, the wall could also be vaporized which could be catastrophic for the patient. Although the Choy invention describes a means for direct visualization of the obstructed region, it does not describe a centering means or a guide wire following means in order to guarantee that the laser beam does not illuminate part of the arterial wall. Furthermore, the Choy invention may completely obstruct a partially obstructed artery thereby cutting off blood flow to distal tissues for a significant time period. The result is ischemia which could cause irreparable damage to heart or brain tissue. Furthermore, if laser oblation was used in the carotid arteries, the resulting gas bubble formation would undoubtedly cause some cerebral ischemia resulting in permanent brain damage.
In U.S. Pat. No. 4,273,128 (date June 16, 1981) B. G. Lary describes a "Coronary Cutting and Dilating Instrument" used for opening a coronary stenosis that is restricting blood flow. The device described by Lary could not be used in a completely or nearly completely occluded artery because its "blunt ovoid tip" could not pass through a completely occluded vessel. Furthermore, the Lary invention does not have any means to prevent its cutting blade from cutting through the arterial wall as well as occluding the stenotic material. Furthermore, there is no means taught in the Lary patent for centering the cutting blade within the arterial walls. Thus, if the probe wire 13 (of FIG. 10) of the Lary invention guides the knife through a highly eccentric lumen within the stenotic plaque its knife blade would surely cut through the arterial wall which would have serious adverse effects for the patient.
In a prior patient application Ser. No. 874,140 filed on June 13, 1986, by Robert E. and Tim A. Fischell which is entitled "A Guide Wire Following Tunnelling Catheter System for Transluminal Arterial Angioplasty" there is described a means for removing stenotic plaque by advancing a tunneling catheter through a guiding catheter and around a guide wire. In that prior invention, the cutting is done by advancing the cutting catheter in a forward (anterograde) direction. A potential difficulty in such a procedure is the inability to exert enough forward force to cut through a hard calcified plaque. Furthermore, if the tunneling catheter is advanced too far in the forward direction, it could cut the arterial wall. Even with the use of cutting (as opposed to fracturing the plaque which occurs with balloon dilation) there would still be the possibility of some particulate matter flowing into the bloodstream which could result in some distal ischemia.
It is the goal of the present invention to eliminate the numerous shortcomings of the prior art in order to provide a device which can safely tunnel a clean hole through virtually any arterial stenosis without the possibility of cutting the arterial wall or creating gas bubbles, or causing the release of particulate matter into the bloodstream.
SUMMARY OF THE INVENTION
The Pullback Atherectomy Catheter (PAC) described herein operates by first penetrating the stenotic plaque in a forward direction with a conically pointed metal tip and then pulling the tip back in a retrograde direction (which tip includes a cylindrical cutting edge) to shave off a cylindrical layer of the plaque. Thus, the force required to perform the cutting is exerted by pulling back on the catheter (a retrograde motion) as opposed to the prior art devices which all cut with a forward (anterograde) motion. Sequentially larger diameter tips are progressively used to enlarge the lumen of the stenotic plaque. PAC devices would typically be guided to the stenosis by a guide wire that is first passed through the narrowed lumen. Each of the sequentially larger tips is first advanced within a guiding catheter through the stenotic plaque, then it is pulled back through the plaque to shave off plaque and finally it is withdrawn from the body. Each tip includes a chamber designed to collect the shaved off plaque thus preventing it from entering the bloodstream. Since it is virtually impossible with this technique to cause the release of particulate matter into the bloodstream, the PAC is particularly well suited for treatment of the carotid arteries.
As described in the prior application Ser. No. 874,140, which is incorporated herein by reference, one could enhance the cutting action by rotating the blade, or by applying a high energy ultrasonic vibration to the cutting edge or possibly by the application of an electrocautery current applied at the cutting edge. For PAC these means for cutting enhancement would be applied during pullback.
Thus an object of the present invention is to safely remove stenotic plaque material by first advancing the PAC tip through the stenotic lumen and then to shave off stenotic plaque by pulling back the sharpened cylindrical edge at the center of the tip through the stenosis.
Another object of the present invention is to collect the shaved off plaque into a plaque collection chamber within the tip and then remove the entire PAC including the plaque from the body.
Still another object of the present invention is to enhance the cutting action of the sharpened cylindrical edge by rotating it during pullback.
Still another object of the present invention is to utilize ultrasonic vibration of the cylindrical cutting edge to facilitate its ability to cut through the plaque.
Still another object of the present invention is to utilize an electrocautery electric current at the cylindrical cutting edge of the PAC tip to enhance its ability to cut through the plaque.
Still another object of the present invention is to use sequentially larger diameter tips each sequentially pulled back through the stenotic plaque to progressively enlarge the lumen of the stenosis.
Still another object of the present invention is to first use the PAC to bore a tunnel into the plaque and then use balloon angioplasty to further enlarge the lumen of the stenotic plaque.
Still another object of the present invention is to use the PAC system to remove plaque deposited at a branch point of an artery, i.e., to open an ostial stenosis.
Still another object of the present invention is to use the PAC to remove thrombotic tissue from an artery.
Still another object of the present invention is to apply this technique to any stenotic or occluded artery including the coronary arteries, the carotid artery, the renal, iliac or hepatic arteries and the arteries of the arms and legs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the distal portion of the Pullback Atherectomy Catheter System.
FIG. 2 is a cross-sectional view of the proximal portion of the Pullback Atherectomy Catheter System.
FIG. 3 is a cross-sectional view of the carotid artery showing the Pullback Atherectomy Catheter System in place just proximal to a stenotic plaque.
FIG. 4 is an enlarged cross-sectional view showing the Pullback Atherectomy Catheter being pulled back through the stenotic plaque.
FIg. 5 shows the cross section of the stenotic plaque in the carotid artery after atherectomy has been completed.
FIG. 6 shows the cross section of the Pullback Atherectomy Catheter System after the PAC tip has been advanced through an ostial stenosis in the renal artery.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-sectional view of the distal end of the Pullback Atherectomy Catheter (PAC) System, which system consists of the PAC 20 guiding catheter 10 and guide wire 50. The guiding catheter 10 which is percutaneously or intraoperatively advanced through the arterial system has at its distal end a rigid end piece 12 joined to a plastic cylinder 14. The proximal end of the guiding catheter 10 extends outside the body. The rigid end 12 would typically be made from a metal such as steel so that it would accurately maintain its circular cross section, and the plastic cylinder 14 typically would be PVC or a similarly strong plastic material. They would typically be joined with a tight press fit or adhesive.
Contained within the guiding catheter 10 is the Pullback Atherectomy Catheter (PAC) 20 whose catheter cylinder 22 extends to outside the body at its proximal end. The PAC 20 has a metal tip 21 that is shaped so as to be easily advanced through an arterial stenosis and then to shave off the plaque material is it is pulled back through that stenosis. The metal tip 21 has at its center a guiding cylinder 24 whose outer diameter is approximately the same dimension as the interior diameter of the narrowed lumen in the stenosis. The purpose of the guiding cylinder 24 is to prevent cocking of the cutting edge 38 of the tip 21 as it is pulled back through the stenosis. The back end of the tip 21 is rigidly joined to the cylinder 22 by means of a back flange 23 and an indentation 25 of the tip 21 that are adhesively or mechanically joined respectively to the larger internal diameter 27 and smaller internal diameter 29 of the plastic cylinder 22. This construction (as shown in FIG. 1) precludes the possibility that the tip 21 will slip off the cylinder 22 during the atherectomy procedure.
As shown in FIG. 1, a connecting cylinder 26 connects the guiding cylinder 24 to the most distal portion of the tip 21. A rounded point 28 allows ready entry of the tip 21 into the stenotic lumen whose diameter "d" is approximately equal to the outer diameter of the guiding cylinder 24. Going backward from the point 28, is a conical surface 32 which has a comparatively steep slope. At a distance just slightly less than the stenotic lumen diameter "d", the shape of the tip 21 changes to a conical surface 34 which has a very shallow slope. The purpose of this shallow slope is to allow a decreased forward force when pushing the tip 21 through the stenotic lumen. The purpose of the comparatively steep slope of the conical surface 32 is to provide a shorter length for the tip 21 so that it can more easily pass through a curved arterial lumen. It should be understood, however, that one could use a single conical surface at the front of the tip 21, especially for tips that have a very small diameter. For example, the smallest outer diameter of the cutting cylinder 36 of the tip 21 might be 1.0 mm (40 mils). For that small a diameter, only a single, comparatively shallow slope of the conical surface would be needed because, for that small diameter, the length of the tip 21 would be quite short enough to pass through even a highly curved arterial lumen.
Returning again to FIG. 1, the cutting cylinder 36 has a sharpened edge 38. The purpose of the sharpened edge 38 is to shave off plaque material as the tip 21 is pulled backward just as a wood plane would shave a piece of wood. The thickness of the cutting cylinder 36 would typically be between 2 and 5 mils. The difference in diameter between the outer diameter of the guiding cylinder 24 and the diameter of the cutting edge 38 would typically be between 0.25 mm and 2 mm, (i.e. between 10 and 80 mils). At a typical diameter difference of 0.5 mm, a radial shaving of 0.25 mm (10 mils) thickness would be shaved off as the tip 21 is pulled back through the stenosis. Thus, a succession of PACs 20 whose tips 21 would have sequentially increasing diameters would be needed to increase the diameter of the stenotic lumen from, let us say, a minimum of 1.0 mm diameter to a maximum of let us say 5.0 mm. Each of these stages in the atherectomy procedure might increase the luminal diameter of the stenotic plaque by approximately 0.5 mm. By using staged tips 21 of successively increasing diameter, the thrust required to force the conical surface 34 in a forward direction through the stenotic lumen is always kept to a very low value. The reasons why this force can be kept very small are as follows:
(1) the lumen does not have to be enlarged very much in each stage (typically only 0.5 mm in diameter),
(2) the slope of the conical surface is very shallow,
(3) the conical surface 34 is polished so that it is very smooth, and
(4) the blood acts as a lubricant between the polished metal conical surface 34 and the plaque which, when combined with the polished finish of the metal, results in a very low coefficient of friction.
It should be noted that coating the exterior surface of the tip 21 with Teflon could further reduce the force required to push the PAC 20 through the stenosis.
Returning again to FIG. 1, the volume enclosed by the interior surface of the cutting cylinder 36, the outer surface of the connecting cylinder 26, the most distal surface 24a of the guiding cylinder 24 and the interior conical surface 30 forms a plaque collection chamber 40. As the plaque is shaved from the interior surface of the stenotic lumen, it is collected in the chamber 40 and is removed from the body when the PAC 20 is removed from the body.
At the center of the catheter cylinder 22 and the tip 21 of the PAC 20 is a passageway 42 through which a guide wire 50 can be inserted. The guide wire 50 is used to first penetrate the narrow stenotic lumen and is then used to guide the tip 21 through that same lumen. If a radial hole (not shown in FIG. 1) was made in the connecting cylinder 26, the application of a suction through the passageway 42 could be used to assist in keeping the shaved plaque within the chamber 40.
The passageway 42 can also be used for injecting angiographic dye to the site of the stenosis and for flushing out that passageway 42 with saline solution.
Returning again to FIG. 1, the distance "L" would typically be just slightly longer than the length of the stenosis where it is in contact with the tip 21. The length of the cutting cylinder 36 would typically be between 1/2L and 2L in length. Typical values of L would be between 5 and 20 mm.
The material of the tip 21 would typically be any steel which could be sharpened to a very sharp edge. Thus steels such as those used for razor blades or surgical scalpels would be best suited for this purpose.
FIG. 2 is a cross-sectional view of the proximal end of the PAC 20 which lies outside the body, typically near the patients thigh where the PAC 20 is percutaneously inserted through the femoral artery. The guiding catheter 10 whose interior surface is typically sealed against the outer surface of the catheter cylinder 22 is also typically equipped with a means for injecting liquids such as angiographic dye and/or saline flushing solution. These capabilities are well known in the art of percutaneous transluminal angioplasty, so they have not been illustrated herein. The catheter cylinder 22 is typically adhesively joined to a metal or plastic handle 40 as is shown in FIG. 2. The metal used for the handle might be stainless steel and the plastic might be acetal or PVC or a similar material. The guide wire 50 is sealed into the handle 40 by an elastomer seal 48 which may typically be made of silicon rubber. The handle includes an inlet port 44 whose interior passageway 46 is in fluid communication with the passageway 42. Angiographic dye or a rinsing saline solution that is injected into the passageway 46, would then go through the passageway 42 and would finally emerge from the distal end of the tip 21. If there was a radial hole in the connecting cylinder 26 of FIG. 1 that allowed fluid communication between the passageway 42 and the plaque collection chamber 40, then the application of a suction to the passageway 46 would result in a suction in the plaque collection chamber 40. Such a suction would be enhanced if the passageway 42 was made to be a tight sliding fit around the guide wire 50 at the extreme distal end of tip 21. An ultrasonic vibratory energy source U, if applied at the distal end of the handle 40 as shown in FIG. 2, could assist in the cutting action of the plaque as the cutting edge 38 (of FIG. 1) is pulled back through the stenosis. Such a vibratory source U would undoubtedly also be effective if applied at the proximal end of the handle 40.
FIG. 3 shows typical plaque deposits in the carotid arteries. This plaque P is typically deposited in the external carotid artery EC, the internal carotid artery IC and the common carotid artery CC as is generally illustrated in FIG. 3. The internal carotid IC provides blood to the brain. An important object of the PAC System is to restore adequate blood flow without a surgical procedure.
FIG. 3 shows a guiding catheter 10 that has been percutaneously inserted typically through the femoral artery and subsequently advanced to be just proximal to the stenosis in the internal carotid artery IC. The physician would then advance a guide wire 50 through the center of the PAC 20 (of FIGS. 1 and 2) and then would advance that assembly until its distal end was positioned as shown in FIG. 3. The catheter cylinder 22 would then be thrust forward causing the tip 21 to be pushed through the stenotic lumen until the cutting edge 38 was just forward of the stenotic lumen (as is shown in FIG. 6 for the renal artery). By means of the handle 40 of the PAC 20 (see FIG. 2) the tip 21 would then be pulled back through the stenosis (as shown in FIG. 4) and a cylindrical section of plaque would be removed.
FIG. 4 is an enlarged cross-sectional view of the tip 21 of the PAC 20 as it is pulled back through the plaque P which forms a stenosis. We see in FIG. 4 that the sharpened edge 38 has shaved off a plaque shaving S and is depositing that shaving S into the plaque collection chamber 40. If necessary, the volume of the chamber 40 could be enlarged by hollowing out the guiding cylinder 24 or by making a longer cutting cylinder 36.
The tip 21 is first pulled back completely into the guiding catheter 10, and then it is completely removed from the body with the plaque securely contained within the plaque collection chamber 40. Thus the plaque should be able to be removed without causing particulate matter to be placed in the bloodstream.
For the first used and smallest diameter tip 21, the guiding cylinder 24 would be approximately equal to or slightly larger than the interior diameter of the stenotic lumen. Once that smallest tip 21 was successfully pulled back through the stenosis, the next larger diameter tip 21 would be used. Typically the sequentially larger diameter of the tip 21 would have the diameter of its guiding cylinder 24 equal to the outer diameter of the cutting cylinder 36 of the prior tip 21. Three to six sequentially larger diameter tips 21 might be used to expand the narrowed passageway in the stenosis from as little as 1 mm in diameter to as much as 5 mm. The largest tip 21 would have an outer diameter of its cutting cylinder 36 that just fits within the interior diameter of the guiding catheter 10.
FIG. 5 shows the enlarged passageway EP that has been formed in the stenosis after the largest tip 21 was pulled back and after the guide wire 50 and the guiding catheter 10 were removed from the body.
Although this procedure was described specifically for the carotid artery, it is readily applicable to any stenosis of an artery in the body. For example the PAC System could be used to open stenoses in the coronary, iliac, renal or hepatic arteries or in any other peripheral artery in the arms or legs or elsewhere. The PAC System could also be used to remove deposits in by-pass vein grafts and to remove thrombus from arteries or veins. The PAC System might ideally be applied for removing both thrombus and plaque from a coronary artery in the early treatment of myocardial infarction.
A particular stenosis that is not readily opened by balloon angioplasty is one that is at the branch point of an artery. This particular type of narrowing is called an ostial stenosis. One such arterial stenosis, illustrated in FIG. 6, shows the lumen of the aorta A joining to the lumen of the renal artery RA with plaque deposits P that form an ostial stenosis. Also shown in FIG. 6 is the PAC tip 21 after it has been advanced through the stenosis just prior to pullback. Here we see the outer diameter of the guiding cylinder 24 being just equal to (or slightly larger than) the diameter of the lumen of the stenosis. Prior to achieving the position shown in FIG. 6, the guide wire 50 was advanced through the narrowed passageway in the lumen. Furthermore, the tip 21 and the catheter cylinder 22 were both advanced percutaneously within the guiding catheter 10 to the position shown in FIG. 6. The distal end 11 of the guiding catheter 10 would have a preformed shape as shown in cross section in FIG. 6 so as to enhance the entry and pullback of the tip 21 into and out of the ostial stenosis. Again sequentially larger diameter tips 21 would be used until a sufficiently large luminal diameter would be formed to allow adequate blood flow to the kidney.
Wherever in the body the PAC System is used, the tip 21 can be pushed through and pulled back from the stenosis in a matter of 5 to 30 seconds. Although blood flow to a distal organ (such as the brain or kidney) would be stopped during that time period, even the longest time period of 30 seconds would not result in damage to any tissue due to ischemia.
As described in the referenced prior application Ser. No. 874,140, the handle 40 (of FIG. 2) could be rotated during the cutting process to enhance the cutting action of the cutting edge 38 of FIGS. 1 and 4. Also, if the entire tip except for the cutting edge 38 was electrically insulted (e.g., with Teflon) then an electrocautery current applied to the tip (as described in the above referenced patent application) would enhance the cutting action of the cutting edge 38 as the tip 21 is pulled back through the stenosis. To accomplish this, the catheter cylinder 22 must contain an electrical conductor that would electrically connect the tip 21 to a metal handle 40. Then one end of an electrocautery current generator would be electrically attached to the handle 40. A grounding plate attached to the patient would be joined to the ground terminal of the electrocautery generator.
Another method to enhance the cutting action during pullback would be to provide the cutting edge 38 with a serrated edge similar to that which is used for bread knives. Then when the tip 21 is rotated as it is pulled back, there would be a more effective cutting of the plaque.
Although the present invention has only described the removal of plaque or thrombus from human arteries, the PAC could also be used to remove other stenotic or occluding tissue from ducts such as the ureters or the fallopian tubes. The PAC might also be useful in cleaning vessels of various animals.
Although percutaneous PAC procedures are for the most part described herein, large tip diameters could be used intraoperatively by surgical incision into a major artery.
One possible additional use of the PAC System might be as a precursor to balloon dilation. A balloon catheter angioplasty procedure could be used to further enlarge a stenotic lumen after the smallest diameter PAC tip 21 had provided an initial luminal enlargement.
Various other modifications, adaptations, and alternative designs are, of course, possible in light of the above teachings. Therefore, it should be understood at this time that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | An atherectomy apparatus and method is disclosed for the purpose of surgical excision of atheromas which typically consist of plaque deposits that cause narrowing (stenosis) of an artery. The apparatus, called a pullback atherectomy catheter, cuts and collects obstructive material into a collection chamber as the catheter is pulled back through obstructive material within a human vessel such as an artery. | 0 |
CLAIM FOR PRIORITY
[0001] This application is a national stage application of PCT/EP2006/061076, filed Mar. 28, 2006, which claims the benefit of priority to U.S. Application Ser. No. 60/666,392, filed Mar. 30, 2005, the contents of which are hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to a method and an arrangement for the storage and playback of TV programs, and in particular, to a method and arrangement for operating a network PVR.
BACKGROUND OF THE INVENTION
[0003] After decades of tape-based analog video recorders being the only means whereby home users could record and conveniently store programs screened on antenna, cable or satellite TV, with the availability of fast and at the same time inexpensive video processors and high-performance video codecs such as, say, MPEG2 (1994) and MPEG4 (1998) a number of mainly hard-disk-based digital machines providing not only straight video recording but also a number of convenience features have become available in recent years.
[0004] The term personal video recorder (PVR), or sometimes digital video recorder (DVR), is frequently used for this new generation of devices. While these modern machines can of course be used like conventional VCRs for simple recording and subsequent playback of programs, they are capable of much more than that. For example, a frequently used feature of a PVR is what is referred to as time shifting, whereby the user can begin replaying a program even while it is still recording. Thanks to the high-performance hardware of a modern PVR, the picture quality achieved is superior to that of a conventional VHS or S-VHS tape machine.
[0005] Time-shifted viewing also allows the user to “pause” a program initially being viewed live, e.g. to take a telephone call, and to resume playback later, it appearing to the user that he has actually paused the live screening and continued it later. In the background, however, pressing of the “Pause” button by the user has caused the user's PVR to record the current program, and pressing the “Pause” button again results, on the one hand, in the recorded program continuing to be recorded and, on the other, allows it to played back already.
[0006] Another very popular feature of a PVR is the ability to skip lengthy sections in a recording with minimal delay. Often this is used during playback to skip blocks of commercials contained in the recorded program. A number of services have become established around this capability which facilitate locating the boundaries of the blocks of commercials, e.g. by storing the start and end of a block as points in time relative to the beginning of a program as a recording index, thereby enabling the commercials to be automatically skipped during playback.
[0007] In addition to specially adapted entertainment electronics, multimedia PCs with suitable software are also increasingly being used as PVRs (known as home theater PCs, HTPCs). Technically there is virtually no difference between a specialized PVR and a PC PVR; both have a large (disk) memory, sufficient processor power and suitable video codecs.
[0008] By means of configurable software or firmware, both platform variants are able to offer the user additional functions, such as program search, thematically geared to his favorite programs. The common feature of both platform variants is that recording takes place locally on the user's premises and the quantity of recordable programs is limited by the local disk memory. It is therefore often possible to transfer recorded programs from the device's internal memory to writable media such as re(writable) CDs or DVDs. However, this involves a time and a cost factor and, not least, the price of a PVR is also considerable. And even PVRs suffer from the problem that recording several programs simultaneously also requires a plurality of PVRs. More expensive multi-tuner machines solve this problem only to a limited extent, as there will always be fewer tuners than TV stations and, in addition, PVR hardware that is of sufficiently high performance for one channel reveals its limitations when required to record a plurality of channels simultaneously.
[0009] To be able to offer users all the advantages of a PVR without them having to invest in a PVR, the white paper titled “Network PVR: Everything on Demand”, Jay Schiller, nCube Corporation, proposes a network PVR whereby storage, encoding logic and codecs are held available in the cable network by a provider. The user gets a unit with which he can select programs to be stored and can retrieve stored programs which are then transmitted to the user in real time by means of a broadband connection. Such a device can be much less powerful than a PVR or an HTPC. At the same time the user can rent virtually unlimited storage space on the PVR server, while the operator of the PVR server only needs to keep one copy of each program which is then distributed as required to those users who have stored that program in their (virtual) store.
[0010] In one alternative, a network PVR of this kind can be designed so as to eliminate “programming” of the network PVR by the user, instead of which the user has access to all the shows in its program bouquet of, say, the last 4 weeks.
[0011] In both cases, however, the user must decide separately for each program whether he would like to program it or to select from the pool of all recorded programs those programs of interest to him for playback. Where there is a great broadcaster offering, however, this is very laborious and time-consuming.
SUMMARY OF THE INVENTION
[0012] The invention discloses a method and an arrangement for storing and playing back TV programs which make it easier for the user to play back interesting TV programs or other video content.
[0013] In one embodiment of the invention, there is an arrangement for storing and playing back TV programs which includes a PVR server having a receiving device for receiving a plurality of digitally encoded TV channels, a supplying device for supplying a plurality of user terminals, and a recording device for recording TV programs to be stored, at least one user terminal having a selecting device for selecting TV programs to be stored and a transmitting device for transmitting the selection to the PVR server, and a playback device for playing back the recorded TV programs selected for storage by the user terminal as a continuous TV program on the user terminal.
[0014] In another embodiment of the invention, there is a method for the storage and playback of TV programs, including, reception of a plurality of digitally encoded TV channels by a PVR server which supplies a plurality of user terminals and records TV programs to be stored, selection by a user terminal of TV programs to be stored and transmission of the selection to the PVR server, and playback of the recorded TV programs selected for storage by the user terminal as a continuous TV program on the user terminal.
[0015] The selection of interesting TV programs is advantageously made easier for the user in that the user specifies a selection on his user terminal and can then play back the recorded programs as a continuous, personal TV program, the personal program then requiring no further user interaction in order to run. The selection can also include simultaneously broadcast programs which are then scheduled for playback in an order chosen by the user or by the PVR server. The user can of course skip programs or parts thereof during playback if these are of no interest to him in an individual case or generally. User preferences can be formed from the regular skipping of programs or parts thereof, for example such that only the first 30 minutes of a specific, regularly broadcast program are of interest to the user.
[0016] The user can select the programs by using an electronic program guide (EPG). In this case a single selection can, for example, automatically schedule for recording all episodes of a series, all news programs of a specific channel or the program broadcast regularly at a specific time on one channel (e.g. the weekly changing film that is always broadcast in the same timeslot).
[0017] The programs can also be selected by the user's specifying preferences, for example the mains news of all regional broadcasters; all films/series featuring a particular actor or having a particular director; and/or all reports, documentaries and/or films on a particular subject. The preferences can, as indicated above, be determined and/or updated at least partly automatically by analysis of which of the programs played back as a personal TV program are skipped by the user. A requirement for this is that for example the PVR server can determine, for each broadcast program, metadata permitting a synchronization with the user preferences from the videotext of the broadcasting stations or from the internet or by inputs by operating personnel of the PVR server.
[0018] Finally, the selection of the programs can be made by a user group whose members know of one another, for example, that they have similar interests in terms of the choice of TV programs. One or more users within the user group can recommend a program for recording, and all the other users are then requested to approve this recommendation or reject it. If, for example, the majority of the votes cast is in favor of the recording, the program is recorded for all the users and subsequently played back within their personal TV program. It can also be provided in addition that personal preferences are managed for each user of the user group so that a program rejected by a user will not appear in that user's personal TV program and/or that a program desired by a user against the majority rejection will be included in that user's personal TV program.
[0019] In a further embodiment it can be determined on the basis of further details which programs a user selects for his personal TV program and which he actually views. On the basis of the consumer behavior determined in this way, offerings from an on-demand video archive VoD (VoD=Video on Demand) can then be made selectively to the user; it is also possible to match the pricing structure thereto by, for example, offering films that are likely to be of particular interest to a user (e.g. the third part of a trilogy) at a higher price and films in which he has shown no interest to date (e.g. the first part of a different trilogy) at a lower price or free of charge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Preferred exemplary embodiments of the present invention are explained in greater detail below with reference to a drawing.
[0021] FIG. 1 shows an exemplary arrangement of a network or server and user terminals in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 shows an arrangement 100 including a network PVR or PVR server 102 and user terminals 104 A . . . 104 N supplied by same. The PVR server 102 receives digitally encoded TV channels from an encoder 120 . The encoder in turn receives the TV channels from a receiver 122 which receives suitable TV signals via terrestrial antenna 124 and/or satellite antenna 126 and/or TV cable 128 . In this arrangement, the encoder 120 and the receiver 122 can be designed as a single unit. The encoder 120 uses a codec such as MPEG2 or MPEG4 or codecs derived therefrom to convert the TV signals initially present in analog form into an efficient digital data format. If a TV channel is already present as a digital data stream, e.g. as digital video broadcast DVB, (received terrestrially as DVB-T, via cable as DVB-C or via satellite as DVB-S), the encoder 120 can forward this data stream unmodified to the PVR server 102 or modify it prior to forwarding, e.g. by matching the bandwidth of the data stream to the bandwidth of the connection to the user terminals 104 .
[0023] The PVR server 102 is linked to a mass storage device 108 such as a hard disk drive array or HDD array. Numerous methods of creating redundant hard disk mass storage arrays which can still deliver the stored data in full in the event of the failure of individual hard disks are well known in the technology. The use of such a redundant array, e.g. a redundant array of independent disks (RAID), is advantageous in relation to the present invention, since a PVR server 102 and the attached mass storage device 108 stores all or at least a large portion of the data of the TV recordings of a large number of users.
[0024] The user terminals 104 are connected to the PVR server 102 via the TV cable network or via a DSL link, for example. Modern codecs permit an acceptable video quality and transmission rates of a few hundred kbit/s or more. With the bandwidths of several Mbit/s technically possible via DSL links, two or more parallel video streams (for different playback devices in the user's household) or a single high-quality video stream are conceivable.
[0025] The user terminals 104 can be equipped with or linked to local memory 110 which is implemented for example as a conventional hard disk and/or as flash memory and/or as RAM. Special forms such as micro hard drives available in flash memory card format are of course also conceivable, flash memory having the advantage that data can be stored independently of the presence of a supply voltage while at the same time enabling particularly quiet user terminals 104 to be created, as flash memory has no rotating or other mechanical parts.
[0026] In such an arrangement the memory 110 can be permanently connected to the user terminal 104 or be embodied as a replaceable medium. The memory 110 of the user terminals 104 is subject to less stringent requirements than the mass storage device 108 in terms of redundancy and failsafe operation.
[0027] The user terminal or CPE 104 can be a set-top box which is connected to a video playback device 116 . Alternatively, the user terminal 104 can be integrated in the video playback device 116 . The video playback device 116 can be a conventional TV. Alternatively, it can be a monitor which does not have a TV tuner of its own. The user terminal 104 has a user interface 106 allowing the user for example to manage his archive of recorded TV programs. This user interface can, as is usual in the set-top box field, be implemented such that the user makes inputs via a remote control and outputs are displayed to him on the video playback device 116 .
[0028] According to an exemplary embodiment of the present invention, the user interface 106 serves to display an EPG and enable the user to navigate therein. As already explained above, the EPG-based selection of programs can include not only individual programs but also, for example, all episodes of a series, all news broadcasts of a particular channel or even the program broadcast weekly or daily in the same timeslot.
[0029] Alternatively, or in addition, it is possible to specify preferences by the user interface 106 , for example the main news of all regional broadcasters; all films/series featuring a particular actor or having a particular director; and/or all reports, documentaries and/or films on a particular subject. The preferences can be determined and/or updated at least partly automatically by analysis of which of the programs played back as a personal TV program are skipped by the user or which programs/program type he consistently programs in addition. A requirement for selecting programs on the basis of user preferences for recording by the PVR server 102 is that, for example, the PVR server can determine, for each broadcast program, metadata permitting a synchronization with the user preferences from the videotext of the broadcasting stations or from the internet or by inputs by operating personnel of the PVR server.
[0030] In a further alternative, the operator of the PVR server offering users the option of setting up and managing user groups 140 (or this is done by the operator of the PVR server). For this purpose, a database 132 can be provided in which the user groups and the user terminals belonging to the respective user groups are recorded. The user groups are preferably set up and managed by the user interface 106 , for example by a user's “inviting” further users and the latter confirming the invitation. If a user is to be removed from the user group 140 , this can be effected for example by means of a majority decision of the other users—likewise supported by the user interface 106 .
[0031] The members of such a user group 140 who know of one another, for example, that they have similar interests in terms of the choice of TV programs, select programs based on one of more users within the user group recommending a program for recording and all the other users then being requested to approve this recommendation or reject it. If, for example, the majority of the votes cast is in favor of the recording, the program is recorded for all users and subsequently played back within their personal TV program.
[0032] Advantageously, a user who belongs to a user group that accurately reflects his own interests can rely exclusively on the selection of the other users for the choice of “his” personal program. With sufficiently large groups the user does not need to contribute actively to the selection for this purpose; depending on user group, his inactivity can be interpreted in the voting as abstention or approval.
[0033] It can be provided in addition to manage personal preferences for each user of the user group 140 so that a program rejected by a user or always skipped during playback will not appear in that user's personal TV program and/or that a program desired by a user against the majority rejection will be included in that user's personal TV program.
[0034] The inputs of a user or the users of a user group are sent to the PVR server 102 which generates data records identifying all the TV programs to be recorded from the data received (individual program, program groups, user preferences, votes of the users of a user group 140 ). The corresponding TV programs are earmarked for recording by means of a scheduler. A first database 130 , e.g. a user database, manages in this way the programs earmarked by a user for recording and checks the user's authorizations, e.g. whether the user has subscribed to the corresponding TV channel.
[0035] When a TV program is transmitted, the PVR server 102 checks in conjunction with the database 130 whether a user (a single user suffices) has earmarked that program for recording. If this is the case, recording is performed, the data arising from the recording being able to be stored completely in the mass storage array 108 of the PVR server or subdivided into a local and a central part and stored accordingly in the memory 110 of the user terminal 104 or in the mass storage device 108 . If the program has been programmed for recording on a plurality of user terminals 104 , either a common copy can be provided, all or the central portion of which is stored in the mass storage array 108 of the PVR server 102 , or a separate copy is created for each user terminal. For each user terminal which had earmarked the program for recording, address information relating to the common or separate copy, e.g. a filename or other index information, is then stored in the first database 130 . A user-related entry of this kind can contain further information about the program in the form of metadata such as an expiration date or the positions of any blocks of commercials in order to enable same to be skipped.
[0036] If the recording data is subdivided into central and local data, the local data is accordingly sent to the user terminals 104 on which the program is to be included in the personal TV program, the subdivision of the data being implementable in such a way that at least the central data stream, on its own, no longer supplies a decodable video signal (picture and sound). When the two volumes of data (from the memory 110 of the user terminal 104 and the mass storage device 108 ) are combined can the program be played back in its entirety.
[0037] To initiate playback, a user accesses, via user interface 106 on the user terminal 104 , his personal TV program which is sent from the database 130 to the user terminal 104 for display on the screen 116 . In this case TV programs can also be viewed in real time, i.e. the PVR server 102 forwards the video data received from the encoder 120 to the user terminal(s) 104 whose personal TV program includes the corresponding program. A parallel storage of the video data can also be provided here in order to enable the users to “pause” the program.
[0038] If the recording data has been subdivided into central and local data, the parts of the recording stored in the memory 110 of the selecting user terminal 104 and in the mass storage device 108 can be combined in the PVR server 102 . For this purpose, the data stored in the user terminal is first transmitted to the PVR server and combined there. The completed video data is then transmitted to the user terminal 104 for playback as a real-time data stream.
[0039] Alternatively, the parts of the recording stored in the memory 110 of the selecting user terminal 104 and in the mass storage device 108 can be combined in real time in the user terminal 104 . In response to appropriate user input, by means of the PVR server 102 the incomplete video data is transmitted as a near-real-time data stream from the mass storage device 108 to the user terminal 104 where it is supplemented by the data stored in the user terminal 104 and played back. Near-real-time data stream, in this context, means that, depending on the selected subdivision of data between local memory 110 and mass storage device 108 , comparatively large volumes of data can also be present in the local memory, e.g. intro sequences which are played back first before the possibly hitherto buffered data from the mass storage array 108 is prepared for playback.
[0040] In a further embodiment of the present invention, it can be determined which programs a user selects for his personal TV program, which he actually watches and how he otherwise uses “his” network-based PVR. On the basis of the consumer behavior determined in this way, Video on Demand offerings can then be made selectively to the user, which offerings can be delivered by a VoD server 150 ; it is also possible to match the pricing structure to the determined consumer behavior by, for example, offering films that are likely to be of particular interest to a user at a higher price and films in which he has previously not been interested at a lower price or free of charge.
[0041] The following information can be evaluated for example automatically in order to determine consumer behavior:
film genres, subject areas of reports and documentaries which are contained in a user's personal TV program or archive, the preferences input by the user from case to case, switchover, fast-forward and rewind actions by the user when viewing the recorded content, and/or Video on Demand offerings consumed hitherto.
[0046] Depending on currently applicable data protection regulations, it can be provided that the user first consents to the corresponding automated acquisition and use of personal data.
[0047] It is obvious, and has also already been presented in detail for individual combinations, how the described exemplary embodiments of the present invention can be combined.
[0048] It should be noted that the integration of the VoD server 150 in the arrangement 100 can be realized in different ways. For example, the PVR server 102 can, as shown in the figure, receive the video data from the VoD server 150 and forward it unchanged to the requesting user terminal 104 . Alternatively, the PVR server 102 can match the data rate to the data rate of the connection to the requesting user terminal 104 . It is also possible to link the VoD server to the user terminals 104 in such a way that the data does not have to pass through the PVR server (not shown).
[0049] If the VoD server 150 is operated by a different operator from the PVR server 102 , it can be provided for data protection reasons that the consumer behavior of users who have consented to a corresponding use of their data only in respect of the operator of the PVR server 102 , is made accessible to the operator of the PVR server 102 . In this case the VoD server 150 can supply a list of content that is available for download on demand along with content-describing metadata to the PVR server 102 , which then presents a user with the content that fits that user's profile based on his consumer behavior and in response to the user selection then requests the content for the user in question from the VoD server 150 .
[0050] If, on the other hand, the declaration of consent by the user also applies to the operator of the VoD server 150 (or if the operators of the PVR server 102 and the VoD server are identical), a user profile can also be sent to the VoD server 150 by the PVR server 102 or the database 130 , whereupon the VoD server 150 , bypassing the PVR server 102 , selects content for an offering and in response to a user request transmits requested content to the user. | The invention relates to a method and arrangement for storing and playing back TV programmes, in particular to an improved method and arrangement ( 100 ) for operating a network PVR ( 102 ). The inventive arrangement ( 100 ) for storing and playing back TV programmes comprises a PVR server ( 102 ) provided with means for receiving several digitally encoded TV channels, for feeding several terminals ( 104 ) and for recording storable TV programmes. The terminals ( 104 ) are provided with means for selecting storable TV programmes ( 106 ) and means for transmitting the choice to the PVR server. The inventive system also comprises means making it possible to playing back the TV programmes which are selected for storing by the terminal ( 104 ) in the form of a continuous TV programme on said terminal ( 104 ). | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a metallized high specular gloss polyethylene plexifilamentary film-fibril sheet with low emissivity, high moisture vapor permeability and good resistance to air and water penetration, and a process to prepare the high specular gloss and metallized sheets.
2. Description of the Prior Art
Materials with low emissivities have been used as thermal barriers to reduce the amount of heat transfer by radiation in many areas of construction. The lower the emissivity value, the better the barrier by virtue of reflecting infrared radiation. Specifically, a blackbody reference, of emissivity equal to 1, is capable of absorbing all radiant energy. A non-transmitting barrier with an emissivity of 0.1, for example, means that 10 percent of the radiant energy directed at it is absorbed and only that amount can be emitted to its surroundings. That is because, by definition, 90 percent of the radiant energy is reflected away.
In the past, bright aluminum foils or metallized films have been the most effective products due to their low emissivities and ease of installation. Low emissivity materials are typically referred to as "Radiant Barriers". Installation of radiant barriers in residential dwellings is usually in one of three locations in the attic space; (1) on the attic floor above the insulation installed over the floor joists, (2) under the roof rafters, or (3) draped under the roof deck. Other installation locations exist in vaulted ceiling arrangements and behind vertical knee walls.
In some installation locations, the radiant barrier may serve a dual energy saving function. That is, reducing the radiation heat transfer from the roof in the summer months and reducing convective heat losses in the winter months by restricting air exchange in and around installed insulation. However, in dwellings and other buildings, moisture migrates from the living space, creating a requirement for the radiant barrier to be able to transmit moisture. Aluminum foils and metallized films inherently are vapor barriers and are unsuitable for these locations. To overcome this moisture barrier problem in the radiant barriers of the prior art, perforations have been made in these products to increase their ability to transmit moisture. This is done at the expense of increasing the emissivity and reducing effectiveness as an air barrier.
Nonwoven sheets made from polyethylene film-fibrils have been known to provide a combination of high moisture vapor permeability and good resistance to air penetration. They have been used in this capacity as an air infiltration barrier housewrap product. Product Licensing Index, Research Disclosure, "Tyvek Air Infiltration Barrier In Housing Construction," p. 556 (Oct., 1979). This type of nonwoven sheet has a high emissivity, generally about 0.55, and is not suitable as a radiant barrier. Polyethylene plexifilamentary film-fibril sheets such as "Tyvek" (Registered Trademark of E.I. du Pont de Nemours & Co. Inc., Wilmington, Del.) Types 10, 1621C and 1622 which have been metallized are commercially available. Such metallized sheets have, for example, been used for screening commercial glass-houses as disclosed in U.S. Pat. No. 4,508,776. These metallized polyethylene sheets of the prior art have high emissivities, on the order of 0.2 to 0.32, and are generally unsuitable for use as radiant barriers.
SUMMARY OF THE INVENTION
There is provided by this invention a high gloss polyethylene plexifilamentary film-fibril sheet having a specular gloss on at least one side of at least 28 percent, a moisture vapor transport of at least 250 g/m 2 /24 hours, a Gurley Hill porosity of at least 30 seconds and a hydrostatic head of at least 55 inches.
Also provided by this invention is a process for preparing a high gloss polyethylene plexifilamentary film-fibril sheet comprising:
(a) hot calendering a polyethylene plexifilamentary film-fibril sheet to a specular gloss on at least one side of at least 28 percent by passing the sheet through a nip, with a pressure of at least 18 kilograms per centimeter, wherein a first roll in the nip is a metal roll with a surface smoothness of no greater than 5 rms micro-inch and is maintained at a temperature sufficient to heat a surface of the sheet to between 0° to 8° C. below the melting point of the polyethylene sheet and a second roll in the nip has a 70 Shore A durometer hardness or less.
Also provided by this invention is a metallized polyethylene plexifilamentary film-fibril sheet having an emissivity on at least one side of from 0.06 to 0.18, a moisture vapor transport of at least 250 g/m 2 /24 hours, a Gurley Hill porosity of at least 30 seconds and a hydrostatic head of at least 55 inches.
Also provided by this invention is a process for preparing a metallized polyethylene plexifilamentary film-fibril sheet having an emissivity on at least one side of from 0.06 to 0.18 comprising:
(a) hot calendering a polyethylene plexifilamentary film-fibril sheet to a specular gloss on at least one side of at least 28 percent by passing the sheet through a nip, with a pressure of at least 18 kilograms per centimeter, wherein a first roll in the nip is a metal roll with a surface smoothness of no greater than 5 rms micro-inch and is maintained at a temperature sufficient to heat a surface of the sheet to between 0° to 8° C. below the melting point of the polyethylene sheet and a second roll in the nip has a 70 Shore A durometer hardness or less;
(b) vapor depositing a metal on the calendered side of the sheet.
DETAILED DESCRIPTION OF THE INVENTION
The starting material for the substrate sheet of the present invention is a lightly consolidated flash-spun polyethylene plexifilamentary film-fibril sheet produced by the general procedure of Steuber, U.S. Pat. No. 3,169,899. According to a preferred method for making the starting sheets, a linear polyethylene having a density of 0.96 g/cm 3 , a melt index of 0.9 (determined by ASTM method D-1238-57T, condition E) and a 135° C. upper limit of its melting temperature range is flash spun from a 12 weight percent solution of the polyethylene in trichlorofluoromethane. The solution is continuously pumped to spinneret assemblies at a temperature of about 179° C. and a pressure above about 85 atmospheres. The solution is passed in each spinneret assembly through a first orifice to a pressure let-down zone and then through a second orifice into the surrounding atmosphere. The resulting film fibril strand is spread and oscillated by means of a shaped rotating baffle, is electrostatically charged and then is deposited on a moving belt. The spinnerets are spaced to provide overlapping, intersecting deposits on the belt to form a wide batt. The batt is then lightly consolidated by passage through a nip that applies a load of about 1.8 kilograms per cm of batt width. Generally, the thusly formed lightly consolidated sheet having a unit weight in the range of 25 to 50 grams per square meter is suitable for use in the process of the present invention.
The term "plexifilamentary" as used herein, refers to a strand which is characterized as a three-dimensional integral network of a multitude of thin, ribbon-like, film-fibril elements of random length and of less than about 4 microns average thickness, generally coextensively aligned with the longitudinal axis of the strand. The film-fibril elements intermittently unite and separate at irregular intervals in various places throughout the length, width and thickness of the strand to form the three-dimensional network. Such strands are described in further detail by Blades and White, U.S. Pat. No. 3,081,519 and by Anderson and Romano, U.S. Pat. No. 3,227,794.
The lightly consolidated sheet is preferably bonded on at least one side. The term "bond" as used herein, refers to bonding according to the general procedure of David, U.S. Pat. No. 3,442,740 before the hot calendering process of this invention. U.S. Pat. No. 3,442,740 is incorporated by reference.
In David U.S. Pat. No. 3,442,740, the lightly consolidated sheet, prepared as described above, is subjected in a heating zone to light compression between two surfaces to prevent shrinkage. The first surface is a hard, heat-conducting material and is maintained throughout the treatment at a temperature substantially equal to or greater than the upper limit of the melting range of the polyethylene. The second surface, a flexible poor heat conductor, is not heated. The polyethylene sheet is exposed long enough to allow the face exposed to the heated surface to reach a temperature within 7° C. of the upper limit of the melting range of the polyethylene but not substantially above the upper limit, and to allow the second face of the sheet to reach a temperature 0.8° to 10° C. lower than the first face of the sheet. The temperature to which the face of the sheet is heated is controlled by the process parameters of the heated roll, sheet speed and sheet thickness. The estimate of the temperature of the surface of the sheet is confirmed by acceptable abrasion resistance of the sheet surface. If the temperature is too high, the surface of the sheet partially melts and becomes film-like. If too low, the abrasion resistance is inadequate. Abrasion resistance can be measured quantitatively by a Crockmeter tester, as described in David, U.S. Pat. No. 3,532,589 col. 9, line 4, which patent is incorporated by reference. Finally, the sheet is directly passed, while under light restraining compression, through a cooling zone wherein the temperature of the sheet throughout its thickness is reduced to a temperature less than that at which the sheet distorts or shrinks when unrestrained.
The lightly consolidated sheet, or preferably a bonded sheet prepared as described above, is then hot calendered on at least one side. The hot calendering process of the present invention yields the high specular gloss sheet of this invention. The lightly consolidated sheet or the sheet bonded as described above, is hot calendered on a side by exposing the sheet to heat and pressure in a nip, using a pair of rolls of specific construction. One roll is metal having a surface finish of no greater than 5 rms micro-inch and preferably no greater than 2 rms micro-inch. The term "rms" as used herein, refers to the root mean square value above and below the mean surface and is obtained by taking the square root of the average square. The average square is simply the sum of squares of the individual values of the distance from the peaks and valleys to the mean surface divided by the total number of peaks and valleys on the roll surface. A value of 5 rms micro-inches or less generally requires the roll surface be lapped, polished or superfinished. The second opposing roll comprises a roll of 70 shore A durometer hardness or less, such as a resilient elastomer covered metal roll. The metal roll is maintained at a temperature sufficient to heat a surface of the sheet to between 0° to 8° C., preferably 0° to 2° C., of the polyethylene sheet melting temperature. Finally, the sheet is cooled before metallization.
In operation, the steam temperature in the heated metal roll is usually between about 150° and 185° C. Speeds of 30 to 100 meters per minute may conveniently be used. The pressure between the two rolls during operation is generally at least 18 kilograms per centimeter and usually from 18 to 40 kilograms per cm depending on temperature of the metal roll, the hardness of the second roll and line speed. Practice of this invention requires a reasonable combination of metal roll temperature, line speed, nip pressure and hardness of the second roll.
The polyethylene plexifilamentary sheet is calendered as described above so that at least one face has a Technidyne T-480 Glossmeter (75 degrees) specular gloss reading of at least 28 percent. Readings of at least 28 percent on the face of the substrate sheet to be metallized, are necessary to produce the low emissivity of the metallized polyethylene plexifilamentary film-fibril sheet of the invention.
The sheet, calendered as described above, can then be metallized on at least one side, a calendered side, for use as a radiant barrier. Vacuum metallizing is a well known process in which metals are vaporized by heat and vacuum, and are then deposited on the surface of a solid article. From a cost/performance standpoint, aluminum is the preferred metal. Generally, a typical metallization process takes place in an evacuated chamber at an absolute pressure of 0.005 to 0.010 millimeters Hg. The sheet passes over a number of crucibles containing molten aluminum Typical process speeds are 450 to 700 feet/min. Lower metallization speeds tend to correlate with lower emissivities but increased residence time in the chamber can damage the sheet. The thickness of the deposited aluminum depends on the pressure inside the chamber, temperature of the molten aluminum, and surface speed of the sheet. A cooled chill roll is used to back up the sheet and prevent damage from the high temperatures reached during metallization. The sheet is generally metallized to a metal thickness of between 75 to 300 Angstroms.
The metallized sheet of this invention is made from a substrate sheet having, as mentioned previously, high specular gloss on at least one side. In order to achieve the desired emissivity and air and vapor permeability, the characteristics of the substrate sheet must be carefully controlled.
The high specular gloss polyethylene plexifilamentary film-fibril sheet of this invention has a specular gloss on at least one side of at least 28 percent, a moisture vapor transport of at least 250 g/m 2 /24 hours, a Gurley Hill porosity of at least 30 seconds and a hydrostatic head of at least 55 inches.
The substrate sheet can be metallized, and the metallized polyethylene plexifilamentary film-fibril sheet of this invention has an emissivity on at least one side of from 0.06 to 0.18, a moisture vapor transport of at least 250 g/m 2 /24 hours, a Gurley Hill porosity of at least 30 seconds and a hydrostatic head of at least 55 inches. That is, the metallized sheet has an emissivity on the metallized side of from 0.06 to 0.18, and air and vapor permeability approximately the same as for the substrate high specular gloss sheet.
Test Methods
The various sheet characteristics referred to in the Examples below are measured by the following methods. In the test method descriptions "TAPPI" refers to the Technical Association of Pulp and Paper Industry. "ASTM" refers to the American Society of Testing Materials and "AATCC" refers to the American Association of Textile Chemists and Colorists.
Basis Weight is measured in accordance with either TAPPI T-410 OS-61 or by ASTM D3376-79 and is reported herein as g/m 2 .
Specular Gloss is measured using a Technidyne Model T-480 Glossmeter which conforms to the testing requirements of TAPPI T-480. The instrument measures the amount of reflected light off the surface of the sample at an angle of incidence of 75° and the value is expressed in percent. The instrument is available from Technidyne Corporation, 100 Quality Ave., New Albany, Ind. 471550.
Emissivity is measured using an Emissometer model AE according to manufacturer's procedure. The device is sold by Devices and Services Instruments, Dallas, Tex.
Moisture Vapor Transmission Rate is measured in accordance with ASTM E-96 condition B and is expressed in grams per square meter per 24 hours. This test measures the ability of a sheet product to pass moisture vapor over a fixed time period under fixed environmental conditions.
Gurley Hill Porosity is measured in accordance with TAPPI T-460 using a Lorentzen & Wettre Model 121D Densometer. This test measures the speed at which 100 cubic centimeters of air is pushed through a one inch diameter sample under a pressure of approximately 4.9 inches of water. The result is expressed in seconds and is usually referred to as Gurley Seconds. In essence, this test demonstrates the degree of air penetration resistance at a fixed pressure.
Hydrostatic Head is measured in accordance with AATCC 127-1980 using an Alfred Suter Company Tester Type 502. This test measures the amount of water that can be suspended above a sample without penetration through the sample in the form of water droplets. The results are expressed in inches of water.
EXAMPLES
In each of the examples described below, the starting material was a lightly consolidated sheet of flash-spun polyethylene plexifilamentary film-fibril strands prepared as described by the general method of Steuber, U.S. Pat. No. 3,169,899 and bonded by the general methods of David, U.S. Pat. No. 3,442,740. (Such sheets are sold commercially as "Tyvek" type 1050B). The polyethylene film-fibril sheet had a basis weight of 47.6 g/m 2 ,
EXAMPLE A
In this control, tests were conducted on a commercially available sheet of "Tyvek" type 1050B. Details of the tests and characteristics of the product on the basis of 5 to 12 samples are given in Table I.
TABLE I______________________________________ Standard Mean Deviation High Low______________________________________Specular Gloss % 11.4 0.6 12.3 10.5(Smoother Face)Moisture Vapor 678 28 720 635Transmission Rateg/m.sup.2 /24 hoursGurley Hill 14 4 26 10PorositysecondsHydrostatic Head 56 4 61 49inches______________________________________
EXAMPLE 1
In this example, "Tyvek" type 1050B was hot calendered on one side in accordance with the invention. In the hot calendering process, the sheet was passed through a nip with the smoother surface, i.e. the final bonded surface, of the sheet in contact with the heated metal roll. The nip was loaded to a pressure of 38 kg/cm and was operated at a line speed of 30 meters per minute. The metal roll was heated to 152° C. so that the sheet surface in contact with the roll was heated to within 5° C. of the polyethylene melting point. The heated metal roll had a surface finish of 5 rms micro-inch. The backup second roll was covered with an elastomer of 70 Shore A durometer hardness. Both rolls were 25.4 cm in diameter. The emerging calendered sheet was cooled by an air jet to minimize puckering and edge curling from the heat. Details of the tests and characteristics of the resultant unmetallized product based on 4 to 12 samples are given in Table II.
TABLE II______________________________________ Standard Mean Deviation High Low______________________________________Specular Gloss % 34.0 2.5 37.4 29.6(Smoother Face)Moisture Vapor 711 72 784 597Transmission Rateg/m.sup.2 /24 hoursGurley Hill 65 16 40 6PorositysecondsHydrostatic Head 64 4 70 58inches______________________________________
EXAMPLE B
In this control, the sheet of Example A was vacuum metallized on the smoother face of the sheet with aluminum at 500 feet per minute to a thickness in the range from 75 to 300 Angstroms by standard practice. Details of the tests and characteristics of the resultant product on the basis of 6 to 12 samples are given in Table III.
TABLE III______________________________________ Standard Mean Deviation High Low______________________________________Emissivity 0.28 0.02 0.32 0.24(Metallized Side)Moisture Vapor 910 81 1024 791Transmission Rateg/m.sup.2 /24 hoursGurley Hill 19 19 40 5PorositysecondsHydrostatic Head 51 5 50 42inches______________________________________
EXAMPLE 2
In this example, the sheet prepared as described in Example 1, was vacuum metallized, as in Example B, on the calendered side, the side with the higher specular gloss. Details of the tests and characteristics of the resultant product based on 5 to 12 samples are given in Table IV.
TABLE IV______________________________________ Standard Mean Deviation High Low______________________________________Emissivity 0.10 0.01 0.11 0.09(Metallized Side)Moisture Vapor 602 24 623 568Transmission Rateg/m.sup.2 /24 hourGurley Hill 80 15 100 40PorositysecondsHydrostatic Head 69 1 70 67inches______________________________________
EXAMPLE 3
In this example, "Tyvek" type 1050B was hot calendered on one side in accordance with the invention on full scale commercial equipment. In the hot calendering process, the sheet was passed through a nip with the smoother surface of the sheet in contact with the heated metal roll. The nip was loaded to a pressure of 36 kg/cm and was operated at a line speed of 51 meters per minute. The metal roll was heated to 176°-178° C. so that the sheet surface was heated to within 2° C. of the polyethylene melting point. The metal roll had a surface finish of 1 rms micro-inch. The backup roll was covered with an elastomer of 55 Shore A durometer hardness. Both rolls were 25.4 cm in diameter. The emerging calendered sheet was cooled by an air jet to minimize puckering and edge curling from the heat. Details of the tests and characteristics of the resultant unmetallized product based on 48 samples and are given in Table V.
TABLE V______________________________________ Standard Mean Deviation High Low______________________________________Specular Gloss % 35.2 1.5 38.9 32.2(Smoother Face)______________________________________
EXAMPLE 4
In this example, the sheet prepared as described in Example 3 was vacuum metallized on the side with the higher specular gloss as in Example B. Details of the tests and characteristics of the resultant product based on 5 to 12 samples are given in Table VI.
TABLE VI______________________________________ Standard Mean Deviation High Low______________________________________Emissivity 0.08 0.02 0.11 0.06(Metallized Side)Gurley Hill 170 39 209 127PorositysecondsHydrostatic Head 70 1 70 69inches______________________________________ | A metallized high specular gloss polyethylene plexifilamentary film-fibril sheet with very low emissivity is made by a process of calendering a polyethylene film-fibril sheet between a smooth metal roll and a soft, resilient roll to form a sheet of high specular gloss, followed by vacuum metallization of the smooth high specular gloss surface. Such metallized sheets are useful as radiant barriers or roof liners for energy savings purposes. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of co-pending International Application PCT/US96/20015, filed Dec. 13, 1996, which Designated the United States of America and claimed the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application 60/008,687, filed Dec. 15, 1995, and U.S. Provisional Application Serial No. 60/011,164, filed Feb. 5, 1996. It is related to: U.S. Provisional Serial No. 60/003,640, filed Sep. 14, 1995, U.S. Provisional Serial No. 60/050,268, filed Jun. 20, 1997; U.S. Provisional Serial No. 60/063,041, filed Oct. 24, 1997; and U.S. Provisional Serial No. 60/080,487, filed Apr. 2, 1998.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention has been created without the sponsorship or funding of any federally sponsored research or development program.
BACKGROUND OF THE INVENTION
The present invention is directed to a system for continuous physical integrity monitoring of large civil structures such as bridges and high-rise buildings . . . wherein the relevant sensor data stream is generated continuously and transmitted to the data gathering location without the need for an incoming triggering signal of any kind; i.e., it is a one way transmission system. Specifically, it is a concept for an interlinked multi-parameter Early Warning Sensor system with a full time data management capability for structures. The invention is also directed to both the system construction, with its communication capability, and also unique designs of specific sensors applicable to the system as a whole. As a practical example of application of the present invention to a structure, the description in this application is directed primarily towards system applications for bridge integrity early warning systems. However, it should be understood that the system and its benefits may be applied to a wide range of physical structures.
The system of the present invention, as applied to bridges, is unique in its ability to address the four principal failure mechanisms or precursors to failure most commonly associated with bridges. These are:
1. Catastrophic failure where some major structural defect progresses undetected to the point where some critical section of the bridge collapses. This will be designed Slow Movement Failure.
2. Vibration-associated Failure where sporadic traffic loading creates a vibration environment which can accelerate failure, such as fatigue, and also be a diagnostic tool useful in predicting failure. This is designated Rapid Movement Failure.
3. Corrosion-induced Failure where the steady winter applications of salt eventually permeate the concrete to the depth of the rebars which begin to corrode. This weakens the rebars and also causes the concrete to spall off the bars. It also weakens the concrete. This is designated Corrosion Failure.
4. Low temperature-induced failure where a freezing road bed can lead to frost formation and resultant pot-hole development. Pot-holes can exaggerate the stress on the entire bridge structure through vehicular impact. This is designated Temperature Related Failure, and it is addressed through Temperature Sensing and Pot-Hole Sensing.
The present invention encompasses to major aspect of novelty. The first aspect is a harness which is attached permanently to a structure. This harness permits an array of interconnected transducers to be deployed at specific sites on the structure for specific sensing applications. It also provides the sensors with a common electro-optic interface which may be linked with a remote communication system . . . by a one-way data transmission system which does not require an incoming signal stimulus to trigger the sensor data download.
The second aspect relates to various types of the sensors which may be attached to this harness. Both analog and digital sensor types are described, and specific embodiments for corrosion monitoring, pothole monitoring, vibration monitoring and temperature monitoring are included in the present disclosure, as well as traffic flow, scour, bridge deck deflection, cross-wind velocity, temperature, fire, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic general view of an optical monitoring system to which the present invention is applied;
FIG. 2 is a diagrammatic view of a portion of the optical monitoring system which includes a feature of the present invention for determining direction of movement;
FIG. 3 is a diagrammatic view of a conventional encoder pattern for an optical sensor which forms part of the optical monitoring system;
FIG. 4 is a chart showing relative displacement of the reticle and mask elements which form part of the optical sensor, plotted against reflected light intensity for the sensor encoder pattern of FIG. 3;
FIG. 5 is a chart showing the digitizing of the reflected light signals of the chart of FIG. 4;
FIG. 6 is diagrammatic view of a first embodiment of a encoder grid geometry for the reticle and mask of the optical sensor of the present invention;
FIG. 7 is a chart showing relative displacement of the grid elements of the optical sensor plotted against reflected light for the encoder pattern of FIG. 6;
FIG. 8 is a chart showing the digitizing of the reflected light signals of the chart of FIG. 7;
FIGS. 9 and 10 are diagrammatic views of an encoder pattern for the reticle and mask elements of the optical sensor of the present invention, showing a modification for detecting direction of relative movement of the reticle and mask by means of quadrature. FIG. 9 is the mask and FIG. 10 is the reticle with two tracks having the quadrature 90° offset;
FIGS. 11 and 13 are diagrammatic views of a further modified encoder pattern for reticle and mask of the optical sensor of the present invention;
FIGS. 12 and 14 are charts showing the optical power pattern resulting from the relative displacement of the reticle and mask of the optical sensor plotted against reflected light intensity for the encoder pattern of FIGS. 11 and 13, respectively; and
FIG. 15-17 are diagrammatic views of a further refinement of the modified encoder patterns of FIGS. 11 and 13 which permits deliberate alteration of the optical power patterns of FIGS. 12 and 14.
FIG. 18 is chart showing the relative displacement of the reticle and mask of the refinement of the modified encoder patterns of FIGS. 15-17;
FIG. 19 is a front elevational view of a tensioner/sensor assembly for monitoring a structure;
FIG. 19A is a diagrammatic view of the sensor portion of the tensioner/sensor assembly of FIG. 19;
FIG. 20 is diagrammatic view of a sensor as applied to a bridge for monitoring deflection;
FIG. 20A is an enlarged view;
FIG. 21 is a diagrammatic view illustrating a combination deck deflection and pier tilt monitoring system with the use of sensors;
FIG. 22 is a diagrammatic view illustrating a sensor system for detecting scour at the base of a bridge pier;
FIGS. 22A and 22B are diagrammatic illustrations of a tilt meter employing the principles of the present invention;
FIG. 23 is a diagrammatic view of a modified monitoring system for detecting scour at the pier portion of a bridge;
FIG. 24 is a diagrammatic view of an application of the monitoring system of the present invention for monitoring bridge temperature;
FIG. 25 is a diagrammatic view of a monitoring system of the present invention for monitoring wind velocity;
FIG. 26 is a diagrammatic view of a monitoring system of the present invention for detecting potholes in the deck portion of a bridge;
FIG. 27 is a graph illustrating the application of the pothole detection system of FIG. 26 for determining a repair threshold value;
FIG. 27A is a diagrammatic view of a modified application of the pothole detection system of FIG. 26;
FIG. 27B is a flow chart of the pothole sensing algorithm for the pothole monitoring systems of FIGS. 26 and 27A;
FIG. 28 is a diagrammatic illustration of the corrosion sequence of a rebar for monitoring corrosion in concrete which expands over time;
FIG. 29 is a graph showing the corrosion over time sequence of the rebar of FIG. 28;
FIG. 30 is a diagrammatic view of a corrosion sequence for a rebar for monitoring corrosion in concrete which shortens over time;
FIG. 31 is a graph illustrating the corrosion over time sequence of the rebar of FIG. 30;
FIGS. 32 and 33 is a diagrammatic view of the fit environment of a corrosion monitoring sensor for concrete employing rebars which shrink over time;
FIGS. 34 and 35 are diagrammatic views of a second modification of a corrosion sensor for concrete having rebars which shrink over time;
FIGS. 36-39 are diagrammatic views of a third modification of a corrosion monitoring sensor for concrete using rebars which shrink over time;
FIGS. 40 and 41 are diagrammatic view of apparatus for monitoring the surface hardness of concrete over time;
FIG. 42 is a top plan view of the reflective grid portion of a fatigue fuse embodying the principles of the present invention;
FIG. 43 is a top plan view of the transmissive mask portion of a fatigue fuse of the present invention;
FIG. 44 is a top plan view of the reflective grid and transmissive mask portions of FIGS. 42 and 43;
FIG. 45 is a side elevational view of a fatigue fuse of FIG. 44 shown applied to a structure to be monitored;
FIG. 46 is a chart showing testing results for the fuse of FIGS. 44 and 45;
FIG. 47 is a diagrammatic view of the monitoring system of the present invention as applied to monitoring temperature; and
FIG. 48 is diagrammatic view of a modification of the monitoring system of the present invention for monitoring temperature.
DETAILED DESCRIPTION OF THE INVENTION
Optical Monitoring System
The optical structural integrity monitoring system of the present invention includes a sensor interrogation harness which exploits a simple sensor differentiation technique known as Time Division Multiplexing, TDM. Since light travels through an optical fiber at a fixed velocity, each sensor is attached to the pulsed laser source by a different length of fiber. Further, by also causing the sensors' output to be reflected back down the same fiber to the photo-detector, the differential delay is precisely doubled.
Referring first to FIG. 1, the optical monitoring system of the present invention is generally indicated by the reference numeral 3 and includes a laser 2 which is capable of generating pulses of light 4 into one leg 7 of a Y-coupler 6. The other leg of the coupler is connected to a photo detector 14 which, in turn, is operatively connected to circuitry 18. A cabled bundle of optical fibers 8, is connected to the Y-coupler 6. A single optical fiber from the cable 8 is connected to each of a plurality of digital optical sensors 12 located at strategic locations on the structure which is being monitored, in those instances where the direction of motion of the sensor is unambiguous. Each sensor has an `on`, or reflecting condition and an `off`, or non-reflecting condition, to be described. Each light pulse from the laser 2 proceeds to the cables 20 and 22 via the coupler 6 to each of the sensors in the system. If a sensor is in its reflective condition, some tangible portion 10 of the light pulse will travel back down the same optical fiber and pass through the Y-coupler 6 and on to the photo detector 14 via the cable 9.
The circuitry 18, of the photo-detector is programmed to clock the arrival, or non-arrival depending on the sensor's condition, in certain time windows. These are known and programmed into the computer which will therefore know which sensor is responding in whatever mode, reflective (logical one), or non-reflective (logical zero). Because the laser 2 is pulsing at a frequency of up to half a million cycles per second, 0.5 MHZ, there is ample opportunity to capture the change from detectable signal to non-detectable without missing a step in the sequence.
Each optical sensor 12 is mounted on the structure to be monitored to detect the relative movement of a first element of the structure relative to a second element of the structure along a first axis. Each sensor comprises a probe 21 which is slidably mounted within a housing 23. The probe contains a transmissive grid, or reticle. The housing contains a reflective grid, or mask. The reticle moves longitudinally relative to the mask as the probe moves relative to the housing. An optical fiber from the fiber optic cable extends into the housing so that the end of the optical fiber is at the reticle for transmitting a pulse of light at a right angle to the reticle. Light passing through the transmissive areas of the reticle is reflected by the mask back to the end of the optical fiber. Such a sensor is known as a reflective optical sensor. The present invention is also applicable to a transmissive optical sensor which is similar to a reflective optical sensor except that the reflective areas of the mask are transmissive areas. Light from the optical fiber passes through the transmissive areas of the reticle and mask and strikes the end of a second optical fiber at the opposite side of the housing for transmission to the Y coupler. The probe is fixed to a first element of the structure to be monitored. The housing is fixed to the second element of the structure to be monitored.
The reticle and mask are located in separate spaced parallel planes. The mask is mounted in the encoder for movement relative to the reticle in accordance with the relative movement between the first and second elements of the structure to be monitored. The mask and the reticle function as an encoder for the light pulses received from the laser and reflected to the photo-detector 14. The reticle has a plurality of evenly spaced light impervious surfaces. The areas between the light impervious surfaces are pervious to light. The pervious areas are the active areas of the reticle and the light impervious areas are the passive areas of the reticle. The mask has a plurality of evenly spaced uniform reflective surfaces which are considered the active areas of the mask. The areas between the reflective surfaces are non-reflective and are considered the passive areas of the mask.
FIG. 2 shows a detail of the basic interrogation harness of FIG. 1 having to do with "quadrature", which allows the detection circuitry to be able to determine the direction of relative movement of the elements of the structure which are being monitored. The cable or bundle of optical fibers connected to the coupler 6 are divided into two groups of optical fibers, indicated by the reference numerals 20 and 22. A single optical fiber from each of the groups 20 and 22 is connected to each sensor 12 at various strategic locations along the structure to be monitored. A shown in FIG. 2, a single optical fiber 20a from the bundle of fibers 20 is connected to sensor 12a and a single fiber 22a from the bundle of optical fibers 22 is connected to sensor 12a. A single optical fiber 20b from the bundle of optical fibers 20 is connected to sensor 12b and a single optical fiber 22b from the optical fiber bundle 22 is connected to sensor 12b. The bundle of fibers, or cable 22 is configured to include an extra length, indicated by the reference numeral 25, immediately adjacent the Y-coupler 6. This enables any sensor in the system which requires a dual fiber quadrature feature may have a fiber selected, one from each of the two cables 20 and 22, at a specific physical location. The quadrature feature is described in greater detail hereinbelow in connection with FIGS. 9 and 10. The cables are sufficiently different in length so that their respective output pulses will be distinguishable via a TDM protocol.
The encoder geometry of the reticle and mask of conventional sensors employ equal active and passive areas for the reticle and mask patterns as shown in FIG. 3, wherein each pattern, generally indicated by the reference numeral 16, has a plurality of active areas 15 which alternate with a plurality of passive areas 17. The result of employing two equal patterns, each having an equal active area to passive area ratio, creates a saw-tooth pattern output as shown in FIG. 4. In many structural applications, it is important to be able to monitor small relative movements between two structural elements. Therefore, it is desirable to have this "off" intervals of the sensor equal the "on" intervals as closely as possible. The problem is that it is necessary to be able to locate the half-height intensity of the saw tooth 24, FIG. 4, if one is to divide the output into equal on and off intervals, see 26, FIG. 5. This is normally accomplished by the technique of measuring the full peak height 28, FIG. 4, and conducting the mathematics in the circuitry of the light detection logic circuit. In order to be able to power a multiplicity of different fiber-sensor systems from a single source and detecting their outputs at a single detector, the present invention provides a low cost and simple approach which accommodates widely varying power level from sensor to sensor.
The problems associated with conventional prior art sensors is overcome by the sensor 12 of the present invention. Each sensor 12 of the present invention includes a grid encoder design which differs substantially from those of conventional sensors. A first embodiment of applicant's encoder grid design is shown in FIG. 6, wherein the pattern or geometry of the reticle and the mask, generally indicated by the reference numeral 29, includes a plurality of equally spaced uniform active areas 33. The areas between the active areas 33, indicated by the reference numeral 31, are twice as wide as the passive areas 33 along the longitudinal axis of the grid or the first axis. The active areas 33 of the reticle are the light pervious areas and the active areas of the mask are the reflective areas. This mask geometry automatically causes the light output to blink on and off in equal proportions by the expedient of keying off the baseline triggering signal level 30, FIG. 7, rather than the sensor-specific mid-height peak intensity. As shown in FIG. 7, the absolute peak height range 32, has little affect on this new baseline triggering protocol, as seen by the output signal 36, FIG. 8.
Referring to FIGS. 9 and 10, there is shown a first modified grid design of the present invention, wherein the transmission grid, or reticle, generally indicated by the reference numeral 38, is identical to the grid design of FIG. 6, while the reflective grid, or mask, generally indicated by the reference numeral 40, has two identical portions, generally indicated by the reference numerals 40a and 40b, as shown in FIG. 10. The reticle 38 has active, or light pervious areas 35 and passive, or light impervious areas 37. Each portion 40a and 40b of the mask 40 has active, or reflective areas 39 and passive, or non-reflective areas 41. The non-reflective areas 41 are twice as wide as the reflective areas 39. The second portion 40b is offset from the first portion 40a by half the distance of the width of an active area along the longitudinal axis of the mask. In this embodiment, two optical fibers are employed as shown in FIG. 2. One optical fiber is aligned with the portion 40a and the other optical fiber is aligned with the portion 40b. Each optical fiber has an end surface which is parallel to the plane of the mask 40 for directing a pulse of light transversely of the active surfaces of the reticle and the mask. Directionality of the relative movement between the elements of the structure being monitored is resolved by quadrature as provided by the offsetting of the offset portions 40a and 40b. The variability in light directionality which is encountered in actual practice may require slight modification in the 2:1 ratio to produce the equal `on` and `off` condition.
Referring to FIGS. 11-13, there is shown another modification of the encoder geometry of the present invention, generally indicated by the reference numeral 48. In the sensor geometry 48, the reticle and the mask do not employ the same active area to passive area ratios.
The sensor geometry 48 includes a transmissive grid, or reticle 42 and a reflective grid, or mask 43. The reticle 42 has a plurality of uniformly spaced light impervious surfaces 45 which are the passive areas of the reticle. The areas between the surfaces 45, indicated by the reference numeral 47, are light pervious and are the active areas of the reticle. The widths of the active and passive areas of the reticle 42 along the first or central longitudinal axis of the sensor, is one-to-one. That is, the width of each light impervious surface 45 is equal in width to each light pervious area 47 along the first axis. The mask 43 has a plurality of uniform, equally spaced reflective surfaces 49. The areas between the reflective surfaces 49, indicated by the reference numeral 51, are non-reflective and represent the passive areas of the mask 43. Reflective surfaces 49 represent the active areas of the reflective mask 43. The width of each passive area 51 is substantially larger than the width of each active area 49 along the first axis, or longitudinal axis of the sensor.
It has been found that threshold triggering will yield an approximation of the 1:1 digital switching with either 4:1 or 5:1 reticle:mask active area ratios, see FIGS. 11 and 13. The corresponding signal threshold switching outputs are depicted in FIGS. 12 and 14, respectively. The lateral mask 43, motion relative to the fixed reticle 42, in FIG. 11 is shown as a descending sequence of zeros and ones against the sequential number on the right hand side of FIG. 11. The reflective ratio in FIG. 11 is 4:1 and a 5:1 ratio is shown in FIG. 13. The higher ratio will more closely approach the desired signal equality at threshold switching, but at the expense of reflective active area and concomitant reflected signal strength. It is apparent from FIGS. 12 and 14 that the `logical one` periods resulting from threshold triggering 44 are longer than the `logical zero` periods 46, FIGS. 12 and 14.
This analysis was conducted under the assumption that the reticle-impinging light is orthogonal to the structure 48, FIG. 16. However, in actuality this is not the case. The light will emerge from the optical fiber at a range of angles, typically up to 25 degrees or so to the vertical 50, as shown in FIG. 16. This results in a decrease in the effective area of the reflector patches, thus effectively reducing the on cycle, and evening up the intervals between "logical one" and "logical zero" for the desired threshold switching protocol. This is illustrated as light rays 52, FIGS. 16 and 17 and mathematically in FIG. 15. The precise relationship for the anticipated signal shift and the angle of light impingement is also given in FIG. 15.
FIG. 15 Illustrates a 1:1 switching with an asymetrical mask wherein a=Mean Angle of Incident Light and D=Distance from Reticle to mirror. When the reflective width W of the mirror is infintely small, the threshold switching is 50:50.
Therefore, when the shadowed width, `S` is equal to 0.5 W, then the effective reduction in W from both ends will have the effect of making `W` infinitely small.
This occurs when S=D.tan(a) and W=2S, so that: W=2D.tan(a) for 1:1 switching.
Thus, the true value of this approach is that a set threshold signal strength for switching can be established for a particular mask/reticle ratio, based on the system-imposed variables of an optical fibers Numerical Aperture and the specifics of the detector system. Once set, however, further variations in the specific fiber signal strength will not have any effect on the switching ratios.
The change in the threshold signal level switching is shown in FIG. 18, where the original orthogonal light-derived signal 54 is narrowed to the dashed signal profile 56 so that the threshold `one` interval 58 is equal to the threshold `zero` interval 60.
Referring to FIGS. 19 and 19A, there is shown a tensioner/sensor assembly, generally indicated by the reference numeral 62 for a drone cable 61. The assembly 62 includes an optical sensor 12 and a fixed pulley 63 which is fixed rotatably mounted on an axle 72 which is fixed to a mounting bracket 64 attached to a bridge deck or other structure to be monitored. The housing portion 23 of the sensor is also mounted on the angle 72. The probe portion 21 of the sensor 12 is rotatably mounted on an angle 73. One end of the axle 73 is fixed to a floating pulley 65. The other end of the axle 73 extends into a vertical slot in the mounting bracket 64 for guiding the axle 73 as the floating pulley 65 moves toward and away from the housing portion 23 of the sensor 12. The probe portion 21 of the optical sensor 12 is fixed outwardly by an internal spring in the housing portion 23 of the sensor. The outwardly biasing sensor 12 is used in the examples of the present application. However, in some applications of the invention, an inwardly biased sensor may be used or a sensor which does not have a bias. The drone cable 61 is wrapped at least once around the pulleys 63 and 65. An optical fiber 66 or fibers 66 extend from the optical fiber cable 67 which is deployed next to the drone cable 61.
The floating pulley 65 is compelled by the internally-sprung encoder to move away from the fixed pulley 63 to accommodate any slack in the drone cable 61.
Any such movement is registered by the digital mask in the encoder via the interrogating optical fibers.
In the event that larger cable length changes are anticipated than can be accommodated by the travel of the encoder, multiple pulley sheaves can be employed to demagnify the cable's travel. Any such adjustment would be readily compensated for in the computer software.
The optical sensor is preferably enclosed in a protective box or the equivalent in order to safeguard the sensor from environmental hazards.
The Encoder body is internally spring loaded to the maximum extension possible. Referring to FIG. 19A, certain movement-induced compressive forces will overcome the spring loading and cause the reticle Quadrature strip 68 to translate past the mask strip 69 and the interrogating optical fiber connector at point 71 whose entrained fiber will be emitting a constant high bit-rate steam of pulses. This output will be reflected back into the same fiber for the return trip to the detector so along as the openings of the reticle strip 68 coincide with the reflective strips of the mask strips 69.
Drone Cable Support System
One of the prime features of the distributed fiber cable sensor system has been its dual function as both the conduit for the sensor conductors and the actuator for sensor movement via strategic sensor placement. In some instances where extreme distances exist between the two interrogation anchors, in span deflection measurement for example, there may be problems of accumulated cable weight. Here, we are referring to the catenary effect of a cable stretched between two mutually distant points. Any change in separation between those points should translate directly into an equivalent change in the interposed encoder sensor. When the fiber cable is deployed over long distances, there is the risk that the cables own tendency to catenary under its own weight will nullify its ability to react to the extrinsic actuating agent, in this example the downward deflection of a bridge deck under load. The obvious palliative is to create an overwhelming tensile stress on the cable through imposition of a massive expansion spring in the cable. However, a vicious circle is created where the cable must be bulked up to survive these tensile forces which only makes the cable heavier and more prone to sagging under its own weight, raising the prospect of further strengthening and concomitant weight increase. In order to avoid this circular problem, a scheme has been derived which side-steps this problem.
The Drone Cable Solution
Many embodiments of the distributed cable system of the present invention employ the fiber cable and drone cable for the monitored structural segment. The goal of this improvement is to show that the basic principal of the system may be preserved while adding a series of application-specific distance-registering around fiber drone cables whose only function is to accurately and swiftly follow the relevant distance changes.
As shown in FIGS. 19 and 19A, tensioned drone cable is wrapped at least once around the two pulley assemblage which comprises the tensioner portion of the optical sensor. The floating pulley is compelled by the internal spring of the sensor to move away from the fixed pulley to accommodate any slack in the drone cables caused by movement of the monitored bridge section. Any such movement is registered by the digital mask in the sensor via the interrogating optical fibers. This way, otherwise separately supported and deployed optical fiber cable enjoys the ability to vicariously monitor the drone cable's movement without the onus of having to sustain the inter-anchor span stresses. FIG. 21 shows the system monitoring for bridge deck deflection. Here, the fiber cable monitors the drone cable's movement due to the deflection of deck-attached deflectors, which exaggerate the bridge deck motion and thus the drone cable motion, encoder translation, and optical signal transmission.
Deck Deflection and Pier Tilt Monitoring
Referring to FIGS. 20 and 20A, the bridge deck deflection and pier tilt monitoring system of the present invention is generally indicated by the reference numeral 70. The system 70 includes an optical sensor 12 applied to the bridge deck 74 which is supported between a pair of piers 76. The bridge deck motion to be detected is indicated by the arrows 75. A drone cable 78 is located below the bridge deck 74 and extends between the piers 76. Drone cable deflectors 80 are fixed to the underside of the bridge deck 74 for maintaining the drone cable 78 spaced from the underside of the bridge deck. The optical sensor 12 is operatively connected by the drone cable 78 and is supported from the underside of the bridge deck 74 by one of the deflectors 80, see FIG. 20 in particular. An optical fiber cable 82 is loosely supported on the bridge deck 74 and is attached to the deflector 80. An optical fiber 84 is broken out from the fiber cable 82 and is operatively connected to the optical sensor. The drone cable 78 is preferably made of an aramid fiber such as Kevlar®. The advantage of using aramid fiber cable as a censoring component is that it is very flexible but inextensible and has virtually zero thermal expansion. Further, it is extremely strong and hazard-resistant, particularly when sheathed by an environmentally-protective outer jacket, and is also light in weight. Thus, it lends itself perfectly to deployment as a remote sensing component on bridges and large structures alike. This modification in no way detracts from the original premise of the distributed structural monitoring system. Indeed, it extends the application of it through the use of application-specific drone cables whose sole task is to create the conditions for an otherwise environment-isolated fiber cable to address in its conventional and intended fashion.
It will permit the monitoring of many fiber cable-hazardous environments by deploying the appropriate drone cables between the hazardous locations and the fiber cable-benign sensing area. Obvious examples include high and low temperature, chemicals, nuclear radiation, under water, and many more. Applications that use the drone cables include deck deflection and pier tilt sensing, pier scour detection, pile movement monitoring, wind velocity determination, pothole detection and traffic monitoring, and building movement and fire detection.
As shown in FIGS. 20 and 20A, the drone cable 78 is artificially held away from the underside of the bridge deck 74 under consideration by one or more of the deflectors. These are interposed between the deck's lower surface and the drone cable 78 to obviate friction and its attendant abrasion, and also to artificially create a space for sensor deployment. It is possible, although not mandatory, for the deflectors to offer enough lateral flexibility to accommodate the sideways vector motion of the drone cable, the natural outcome of the deck's up-and-down motion, without the need for slidable means between the deflectors and the drone cable which would be otherwise necessary.
The lateral movement of a deflector whose base is fixed to the drone cable offers an alternative or even additional site for the location of a fiber cable and encoder sensor. In this instance, the drone cable could merely perform the inevitable task of accommodating the stretching and shortening effects on the drone cable of the deck's downward and upward movements.
As the deflector 80 flexes laterally under the impetus of the deck's vertical motion, the optical fiber cable 78 anchored to the deflector will respond and actuate the associated sensor.
FIG. 21 shows a combination deck deflection-pier tilt monitor. For simplicity, the fiber cable (which would run along the length of the bridge deck) and optical fibers leading to the encoders are not shown. Bridge deck deflection is indicated by arrow 86 and pier tilt is indicated by arrow 88.
Any movement within the sensor 12 of the bridge deck 74 or piers 76 would cause a change in Drone cable length, encoder movement within the sensor 12, and thus optical fiber signal transmission. And with movement sensing up to 60 cm, abnormal deck deflection and pier tilt could be detected and possible structural damage and catastrophic failure averted.
Pier tilting can also be monitored by deploying a tiltmeter on the pier. A tiltmeter is a device for detecting and measuring any change in angular attitude of a member to which the tiltmeter is attached, Referring to FIGS. 22A and 22B, an encoder-based tiltmeter of the present invention is generally indicated by the reference numeral 54. Tilt meter 54 includes an encoder wheel 55 rotatably mounted on a shaft 81 which is fixed to a housing 79. The wheel 55 has a mask with a radial encoder pattern and is disposed to a set position by means of a weight wheel 55 attached to its extremity in such a way so as not to interfere with the encoder wheel rotation within the housing 79. A reticle which corresponds to the encoder wheel's mask is attached to the tiltmeter housing 79. The tiltmeter 54 includes means for interrogating the relative translation of the mask and the reticle. Such means may be a conventional LED-photo diode pair, as employed in conventional electro optic encoders, or else optical fibers in either reflective or transmissive deployment geometries.
The mask and reticle layouts may be conventional or else according to that which has been described in connection with FIGS. 6-18. In the preferred embodiment on interrogating optical fiber 83 is located on a mounting bracket 85 which is fixed to the housing 79.
Function
The tiltmeter housing 79 is firmly attached to a relevant portion of the structure whose incipient change in angular disposition would be of importance. The interrogating electro optic or optical system will register the initial status through recording the relative locations of the reticle and mask. Upon a change in structure angularity, the housing will tilt, taking with it the reticle assembly. The encoder wheel with its mask will not change angularity, however, due to the weight attached to its lower extremity and acted upon solely by gravity. The resulting relative displacements of the reticle and mask will therefore quantifyably indicate the angular change in structural status.
Bridge Pier Scour Detection
It has long been known that one of the principal reasons for bridge collapse is scour, the erosion of the substrata beneath river-spanning bridge support piers. Monitoring this has prove to be so difficult that current protocol calls for suspect bridges to be visually examined every five years using frogmen to inspect the submerged portion of such piers. It is our proposition that the distributed fiber and drone cable system of the present invention can be configured such that even small movements arising from the leaning of a compromised pier can be detected and isolated early enough in the process that compensatory actions may be taken before the structure reaches the point of catastrophic failure.
1. Inferential Measurements
The encoder sensor can be calibrated to monitor movements as small as five microns, or one-third of the width of human hair. By intelligently deploying a series of the distributed the sensors, the system is able conceptually to detect minute relative movement shifts of the various bridge components.
The principal here is simple: the first structural effect of scouring, which is the washing away of supporting strata beneath bridge piers, is the movement of those piers in response. When this movement occurs, it causes the vertically deployed drone cables to change length. These changes are readily accommodated through sensor motion to detect such movement and to report it.
It should be pointed out also that the optical sensors which are located to span every critical member junction will monitor any localized movements, and will also almost certainly detect sympathetic movements. All of these inputs will be available to the computer data base in real time and accessible for correspondingly real time analysis and manipulation.
This illustrates that a major strength of the present system, i.e., is its ability to gather many often disparate data allowing them to be cross-correlated instantaneously.
2. Direct Measurements
While the foregoing describes the detection of an underwater problem through above wage monitoring, there is a strong argument for a more direct approach whereby the fiber cable system itself is deployed in the locality of suspected scour. Here, however, the logistics and necessary characteristics of the fiber cable system are rather different from the standard deployment addressed to date. In the first place, there is the questions of cable tie-off placement especially in the context of the tangible drag and disturbance of water flow and possible ice formation. Both of these agents could easily disrupt the system and cause it to broadcast phantom alerts. The location and nature of the suspected problem areas must first be determined. The problem areas will most likely involve the erosion of pier foundations, often where remedial actions are either contemplated, under installation, or else already in place. Any one of these three scenarios will permit an interactive design opportunity because the most critical erosion candidate areas will have already been identified. it will be necessary to have been appraised by the experts of critical parameters such as the location, the allowed erosion depth, the allowed sub-pier incursion distance, etc. This information will offer crucial knowledge of where and what to sense.
Small movement monitoring in an unpredictable and hostile environment, submerged in a potentially fast-flowing and foreign body-laden stream of water is the challenge. The sensing system must be isolated as far as possible from the spurious effects of the environment.
Referring to FIG. 22, the placement of the sensor will devolve from the experts' analyses, and will preferably have the form of under-water aramid fiber drone cable extensions. The sensors are sheathed within a rugged protective conduit to protect the sensors from floating detritus or even legitimate maritime traffic which could equally disrupt the detection system's integrity. The upper end of a drone cable 90 is attached to an optical sensor 12 at some point above the water on the bridge pier 96. After descending underwater, the cables will follow the length of the bridge pier to the floor 94 of the waterway. Here, the cable 90 is tied off to a weighted concrete block 96 that rests on the waterway floor. When the motion of the underlying substrata is large enough to move the concrete block, the corresponding drone cable and encoder movements will lead to signal changes in the interrogating optical fibers 97 from the optical fiber cable 98. Thus, both the occurrence and location of substrata erosion will be detected by the system. With the integrity of the bridge structure continuously monitored, sudden, drastic changes, in the stability of the substrata, such as during or after a major flood, can be evaluated, and if the pier scour damage is deemed severe, alarms can be posted and bridge authorities notified immediately.
The approach described above addresses the placement of the sensors above the water level but attached via drone cables to the submerged sites. Further, it creates a hybrid analog-digital sensing modality where real trouble is indicated by the gross movement associated with a concrete block whose large movement swill indicate the erosion of a section of river bed, but with the expectation that smaller detected precursor motions will most likely forecast the digital catastrophic sensor failure. It also addresses the hostile environment through keeping all fiber optical components above the water in the more controlled environment, but placing only rugged cable and concrete blocks, effectively, under the water.
Bridge pier scour, which is the erosion of the substrata beneath waterway-spanning support piers, is recognized as one of the principal reasons for bridge collapse. Thus, methods of averting pier scour disasters by strengthening the pier structure with deep foundation attachments have been the subject of much recent research. These deep foundation elements are known as piles (or micropiles when they are small diameter structures), and they have been used typically as a load transfer connection from the bottom of the bridge pier to competent subsurface strata. Piles have also been used in other water-spanning and landed structures alike, particularly micropiles, which have been used to strengthen historic buildings across the world. But like bridge pier scour detection, monitoring these structures has proven difficult since the piles may extend well below the floor of the waterway grand surface. It is our proposition that the fiber cable system of the present invention can be configured such that even small movements of the piles can be detected and isolated early enough in the process before the onset of erosion, loosening of the piles from the stable substrata, and possible catastrophic failure of the piles and/or the supported structure.
The first structural effect of scouring on bridge piers is the movement of those piers in response to the now unstable adjacent substrata. Similarly, as the soil moves or begins to erode around the pile, it too will move in response, and abnormally large translations will indicate the overall loosening of the pile from the stable substrata, and thus the imminent likelihood that pile failure would occur. Referring to FIG. 23, for each bridge pier 76, a vertically deployed, environmentally protected drone cables 100 are attached to optical sensors 12 at the top of the pier 76. While the sensors 12 and the interrogating optical fiber sensor cable 102 would remain well above the water, only the protected sheathed drone cables enter the potentially hazardous environment. As the drone cables 100 descend below the pile cap, they are looped around the top of the piles 104 in the river bed 106, each drone securely attached to a pile or a group of piles. Since they, like the other drones, are made of movement-sensitive arramed material, the slightest movements of the piles would be transmitted by the drones to the attached encoder sensors. the change in the incoming signal by the encoder would then be readily perceived by the outgoing fiber path, which would report such data immediately. All of these inputs will be available to the computer data base in real time and accessible for correspondingly real time analysis and manipulation.
This illustrated a major strength of the technique of the present invention, its ability to gather many often disparate data allowing them to be cross-correlated instantaneously. Thus, the entire pile system could be monitored full-time. And with a movement resolution as small as five microns, the state of the piles can be tracked and possible failure predicted, whether attached to bridge piers, oil rigs, historic buildings, or other structures with foundation support systems.
Bridge Temperature Sensor System
Referring to FIG. 24, an optical sensor 12 is tensioned between a zero-expansion fiber optical jumper cable 108 and a known thermal expansion calibrated rod 110 attached to a substantial portion of the bridge, such as a pier 107, away from direct sunlight.
The calibrated rod expands and contracts with the changes in temperature and cause the optical sensor 12 to accommodate any length changes resulting therefrom. The fiber cable jumper 108 (i.e. the interrogating optical fibers) carries the displacement information back to the trunk cable 112 and thence to the modem.
Wind Velocity Sensor System
Referring to FIG. 25, an arramed cable 114 is attached to a wind-sensitive sensor or material 116, and is strung from the bottom of the bridge deck 118 to the pier wall, where the cable is connected to an optical sensor 12. Wind speed and direction changes will cause the drone cable to move in response, and such changes are recorded instantaneously in the interrogating pulse signal which is carried back to the modem via the fiber cable jumper 120 and the trunk optical cable 122.
Pothole Detection and Traffic Flow Monitoring
Referring to FIG. 26, two drone cables 124 and 126 are stretched across the bridge deck surface 128 a set distance apart. They are each attached to a dedicated optical sensor 12 hooked into the fiber optic interrogation harness. Thus, any vehicle passing over the deck will trigger a response in the two sensors 12 which will transmit the information back to the modem. Alternatively, sensors placed at each end of a deck section to monitor deck motion and vibration will be actuated by the passage of proximal traffic. In FIG. 27A, the sensors 12 are positioned at seams 51 and 52 in the bridge deck. A pothole to be detected is indicated at TP in the span 127. A vehicle passing over the seams 51 and 52 will trigger a response in the two sensors 12.
When potholes appear in the roadbed, exaggerated pounding will accrue to the deck which will both eventually cause damage and, more immediately, cause the deck vibration sensors to see large amplitude excursions than would be expected with a pothole-free roadbed for the same vehicle conditions. The problem has always been to know the type and velocity of the vehicles involved with pothole interactions in order to quantify the vibrational effect.
With a full-time monitoring system there is a way to do this just as long as there is sometime during the twenty-four period when only a solitary vehicle is passing over the bridge. Better yet, the results would be far more indicative if the vehicle type and velocity were known.
Using the real-time monitoring capability of the present system and the appropriate computer algorithm, the computer will recognize a solitary vehicle, compute its velocity from both the time taken from point A to Point B and the time dwell of the tires on the drone cables, and recognize a tractor trailer, for example, from its distinctive wheel sequence signature. When the solitary tractor trailer conditions are recognized, the computer will record the deck vibration amplitude data and normalize them for the measured A-to-B velocity. These data will be stored and continuously trend-analyzed to see if some extrinsic factor, such as a pothole, or even ice build-up, is causing an anomalously large vibrational deck affect. The pothole sensing algorithm is illustrated in FIG. 27B.
Traffic Flow Monitoring
As illustrated in FIG. 27, a solitary vehicle's velocity can be determined from both the time taken from point A to point B and the time dwell of the tires on the drone cables. If traffic flow is light, then single vehicles traveling over a bridge or a certain segment will be more common, and their speeds thus computed with ease, so long as the distinctive wheel sequence signature is recognized. If, however, traffic is congested or even at a standstill on the bridge, the great amount of time that tires spend on the drone cables (since they will be moving at zero or near-zero velocity in heavy traffic) will be translated instantaneously through the optical sensor 12, with the new displacement information carried back to the modem via the fiber cable. Thus, as soon as traffic jams start to form on a monitored bridge or another installed section of roadway, TV and radio station traffic patrols can be notified immediately, and the general public alerted to these traffic problems sooner than with modern on-site helicopter monitoring practices.
Corrosion Monitoring
The system of the present invention integrates all factors leading to rebar corrosion by placing a sacrificial rod in contact with the concrete matrix under investigation and exploits two distinct aspects of this controlled corrosion.
Rod Increase Sequence
Referring to FIGS. 30 and 31, a rebar-like metal rod 137 in contact with a matrix 139 will corrode at its end which is in contact with the matrix to produce a corrosion product such as rust which sloughs off, a indicated by the reference numeral 141. This causes the metal rod 137 to decrease in size over time as shown in FIGS. 30 and 31.
Referring to FIGS. 28 and 28A a rebar-like metal rod 136 whose distal tip is corroding in contact with the concrete matrix 138 will follow an Error Function (erf) expansion length increase. This initially rapid and then progressively slowing length change is due to the increasing thickness of the corrosion layer, which forms with approximately fourteen times the volume of the metal consumed. This corrosion product 140 forms a barrier which progressively retards the reaction-critical ion counter-diffusion. This modality therefore promises a relatively rapid initial indication of rebar corrosion, but is of questionable future tracking value. It is designated the Corrosion Onset Sensor, COS.
Rod Shrinkage Sequence
The concrete deck corrosion monitoring system of the present invention is a retrofit-compatible concept with potential application to virtually every pre-existing or new concrete structure. The Federal Highway Administration had identified over 170,000 US bridges in need of some substantial repair, many of which were due to deck rebar corrosion. One of the nagging problems with such structures as bridges, high-rise parking lots and large building has been the absence of precise and quantifiable information regarding the corrosion state of the rebars and the corresponding need for counter-corrosion measures.
This approach offers an auto-integration of corrosion propensity if the rebar is corroding at a certain location and at a fixed depth, then, it is likely that its neighboring rebars are suffering similar fates. It there is a great deal of variability in corrosion potential within a set structure, then many of the intrinsically simple and incipiently low cost direct visualization sensors may be interspersed with a few number of the full-time and therefore more expensive sensors.
The Low Cost, Direct Visualization Bridge Deck Corrosion Sensor
Referring to FIGS. 32 and 33, the system relies on the sacrificial mini rebar rod concept for a remote sensor. The indicator is a bent resilient steel lath 148 held into its bent posture by one or two mini rebar rods 160. When the rods 150 begin to corrode,d the lath progressively opens up as shown in FIGS. 33 and 35. A glass observation port 152 is located above the borehole 154. The borehole 154 in the concrete matrix 156 is filled with a silicone filler 156 between the lath 148 and sides of the borehole.
Referring to FIGS. 34 and 35, a resilient cylindrical stainless steel tube 158 is inserted in a borehole 160 in the concrete matrix 162. The tube is squeezed into an elliptical shape by mini rebar rods 164. As the rods 164 corrode, the tube 158 returns to its normal cylindrical shape as shown in FIG. 35. Spring indicators 166 are located at the tip of the tube 158 to provide a visual indication of movement of the tube 164 as a result of corrosion of the rods 164. The tube 158 is surrounded by a silicone filler 168.
Alternate Concept
Referring to FIGS. 36 and 37, a right cylindrical resilient stainless steel tube 170 is employed in a borehole 174 in the concrete matrix 175 which has a single mini rebar rod 172 attached at a definite level above the base of the tube. This will become an interference fit in the borehole 174 such that the tube 170 is distorted into an elliptical shape at the rebar's location. This distortion provides the spring impetus maintaining the rebar 172 in contact with the borehole wall, as well as assuring that the rebar will progressively penetrate any corrosion product at the point of corrosion 173.
Any change in ellipticity resulting from corrosion-induced rod shortening will be reflected and magnified by a first degree lever 196 attached to the inside of the stainless steel tube at the rebar's anchor point. Acting through a simple fulcrum at a set distance proximal to the rebar, the lever's opposite extremity will terminate just below the plane of the bridge deck's surface.
The lever 176 is pivoted at 178 to a cross bar 180 which is fixed to the inner surface of the tube 170. The space between the tube 170 and the inner surface of the borehole which is occupied by the rebar 172 is filled with a silicone filler 182. A transparent cap 184 is located at the top of the borehole 174 for visual observation of the change of position of the top of the level 176 which is indicative of corrosion of the rebar. The cap 184 is provided with a scale 186.
Referring to FIGS. 38 and 39, a right cylindrical stainless steel tube 185 is employed which has a single rebar mini rod 187 attached at a definite level above the base of the tube. This will become an interference fit in the attached at a definite level above the base of the tube. This will become an interference fit in the borehole such that the tube is distorted into an elliptical shape at the rebar's location. This distortion provides the spring impetus maintaining the rebar in contact with the borehole wall, as well as assuring that the rebar will progressively penetrate any corrosion product. The tube distortion may be used to actuate an encoder or other remote monitoring device.
Any change in ellipticity resulting from corrosion-induced rod shortening will be reflected and magnified by a first degree lever 183 attached to the inside of the stainless steel tube 185 at the rebar's anchor point. Acting through a simple fulcrum at a set distance proximal to the rebar, the lever's opposite extremity will terminate just below the plane of the deck's surface.
Referring to FIGS. 40 and 41, there is illustrated two embodiments of a surface mounted probe assembly for monitoring the corrosion of concrete. Corroded concrete is referred to in the industry as "punky concrete".
The first embodiment of FIG. 40 is generally indicated by the reference numeral 191 and includes a cylindrical housing 192 which has a cylindrical bore 197 and a bottom outer flange 193. The flange 193 enables the assembly 191 to be mounted to the upper surface 194 of a concrete structure 195 by means of fasteners 196. A sealant 189 is located between the flange 193 and the surface 194 of the concrete. The upper end of a probe 198 is fixed to a cylindrical weighted piston head 199 which is slidably mounted in the bore 197. The lower end of the probe is biased into engagement with the surface 194 by the piston head 199. The downward biasing of the probe 198 could also be provided by a spring. An elastomeric sealant 200 is located between the probe 198 and the inside surface of the bore 197. The housing portion of an optical sensor 12 is fixed to the housing 192 of the probe assembly by a housing anchor 201. The probe portion of the sensor 12 is biased downwardly against the upper end of the piston head 199. The sensor 12 is operatively connected to the fiber optic cable by optical fibers 202. Corrosion or softening at the surface 194 of the concrete will cause the probe 198 to be moved downwardly by the weight of the piston head 199. This movement of the probe 198 causes the probe portion of the sensor 12 to move downwardly relative to the housing portion of the sensor, thereby producing an optical signal which is indicative of the softening condition of the concrete.
The second concrete monitoring assembly illustrated in FIG. 41 is generally indicated by the reference 203. Assembly 203 is identical to assembly 191 except that it does not include a sensor 12. The elements of assembly 203 which are identical to assembly 191 are identified by the same reference numerals. The probe assembly 203 includes a removable top cover 204 which is mounted on the cylindrical housing 192 above the piston head 199. A micrometer 205 is mounted in the cover 204. The micrometer includes a stilus 206 which extends below the cover for engaging the upper surface of the piston head 199 and a gauge 207 located above the cover. Any downward movement of the probe 198 resulting from corrosion or softening of the concrete can be read directly from the gauge 207.
Fatigue Fuse
A fatigue fuse is a pre-weakened metal member which is attached to a structure which may experience fatigue failure problems. The fuse member experiences the strain history of the structure and fractures at its pre-weakening notch site after a known accrual of fatigue. Fuses are generally made in sets of four with a sequenced fracture profile.
Referring to FIGS. 42-45, the fatigue fuse monitoring system of the present invention includes a reflective grid generally indicated by the reference numeral 230 in FIG. 42 and a transmissive mask, generally indicated by the reference numeral 232, in FIG. 43. The reflective grid 230 includes a plurality of parallel spaced tines 234 extending from a base 236. Each tine 234 has a small notch 238 which functions as a fatigue initiator. The transmissive mask of FIG. 43 has a plurality of spaced fiber optic connector locations 240 which correspond to the spacing of the tines 234 as depicted in FIG. 44 which shows the grid 230 overlaying the mask 232.
The assembled fatigue fuse assembly is generally indicated by the reference numeral 242 in FIG. 45. The reflective grid portion 230 of the fatigue fuse is attached to a substrate 244 being monitored by an adhesive 246. The base 236 of the transmissive mask portion of the fatigue fuse is fixed to the reflective grid portion of the fuse at 248.
The reflective grid 234 has a periodicity of 30 microns, which matches the fuse movement once the fatigue-initiated crack has propagated fully across the affected fuse leg or tine 234. When illuminated through the equivalently set up Transmission Mask, as shown in FIG. 43, the reflected light signal will change in magnitude by comparison with the other unaffected fuses.
Stereographic Representation of Mask Over Fuse
Fatigue monitoring, a development of Materiall Technology, Inc., "MaTech", is a remarkable achievement because it comprises the imperative two-step process which first evaluates the fatigue already present in the metal member and then goes on to continuously monitor that same member on a quantitative basis from the freshly established baseline.
The first phase, which is to diagnose the accumulated fatigue, is a one time hands-on procedure which, appropriately, yields an EKG-like waveform output which is interpreted. The result is an assessment of the level of the fatigue present in the member at that instant, to an accuracy of about 15 percent.
The second part of this fatigue equation is the Fatigue Fuse. The four-tined comb as shown in FIG. 42 is made from the same composition alloy as the member under investigation. The Fuse assemblage is cemented to the member at its extremities and therefore compelled to faithfully experience the very same surface stresses as the member itself from that time forward.
Each tine is preconditioned to fail at a different, say, 10 percentage increment of additionally accumulated fatigue. Thus, if the member had been diagnosed as evidencing a 40 percent fatigue level when the Fatigue Fuse was attached, each fuse failure will signal the additional 10 percent increments in a progressive fail-soft and remediable manner. The cable interrogation system has been configured to detect the minute 40 micron fuse failure cracks as they occur.
Fuse Optical Interrogation and Strain Gauge Attributes
The optically-interrogated Fatigue Fuses can provide exactly the type of data currently gathered in conventional strain gauge monitoring system, such as Lockheed Martin's IHUMS inferential fatigue monitoring approach, at least up to the point where they actually fatigue to fracture failure. At failure, of course, they are indicating in the most assertive manner that a critical accumulated strain datum of fatigue has been reached, regardless of what any inference-based software is indicating. This offers the best of both worlds.
With the optically-interrogated Fuse, one has an accelerometer whose constantly-monitored vibration signature lends itself directly to FFT analysis and the fundamental frequency information available gleaned therefrom. In addition, it provides a digital and therefore absolute value of any vibration amplitude excursions.
Optimally then, the Fuse System offers all of the standard strain gauge information plus the reassurance of the actual fuse fracture event and an adjacent and greater longevity fuse ready to assume the task of generating ongoing accelerometer data after the first fuse has failed.
The attraction of this scenario is that the same fatigue fuse which will eventually fracture will provide sub-critical strain accumulation data up to the point when it actually does fracture. These data will be amenable to fatigue-predictive manipulation. As such, this non-invasive and auto-generated data source should greatly assist in joint fatigue modeling and aid considerably in design refinement leading to a more basic understanding of the various uniform and jointed structure fatigue phenomena. An example of fuse testing results is shown in FIG. 46.
Fatigue Fuses: Reproductibility of Test Data
More than 50 precision Fatigue Fuses with 200 notched Tines have been Fatigue Tested
Most tests employed long variable stress sequences to simulate realistic conditions
Variables included: Fuse Material, Adhesive, Size of bond area, Shape of Fatigue notch, Thickness of fuse
Multiple replicates were employed
Scatter in results is relatively small
Fatigue Tines fail in the programmed sequence, indicating the progressive fatigue experienced by the substrate
Building Monitoring
The present system incorporates many conductors, most of them optical fiber. In the inter-high-rise building movement monitoring and fire detection scenarios, it is very desirable from a code and ease of implementation standpoint that there only be optical fibers or aramid fiber components since both are non-conductive and therefore present no electrical hazard. The Building Movement and Fire Detection System was developed using a combination of a digital encoder sensor-fiber optic interrogation harness in combination with a series of aramid drone cables. Using an aramid cable as the linkage medium between critical structural building members and the encoders, and the fiber cable harness as the sensor interrogation means, it is possible to create a whole-building network of sensors which will respond to building motions in any of the x, y, z coordinate directions.
The advantage of the aramid cable is that it is very flexible but inextensible and with virtually zero thermal expansion. Further, it is extremely strong and light in weight. Thus, it perfectly lends itself to deployment as a web network throughout large structures, typically placed above dropped ceiling and well out of the way.
Any motion in the building which causes the encoder-tensioned aramid cables to elongate or to shorten, such as during an earthquake, will immediately translate into encoder motion, in turn instantaneously transmitted back to the base computer monitoring system for analysis and response. In the event of a fire, the aramid drone cables' deployment in sprinkler-grade wax captured convolutions, see FIG. 47, will trigger site-specific sensor changes which may be computer recognized as distinct from earthquake events by their specificity. This will simply come about from the aramid cables' convolution release as the ambient temperature rises to soften the wax adhesive.
The drone aramid cables 244 may also be deployed using a simple pulley system generally indicated by arrow 246, as shown in FIG. 47, which increases the area coverage for fire detection. The pulleys 248 attached to the east-west walls only in this representation so that any changes in the drone cable will be due either to wax melting in one or more the wax-enclosed S-shaped cable sections 250 else specific relative displacement of the east-west walls. Further, the displacement will be directly proportional to the wall movement, albeit reduced by a pulley reduction factor. Given the high resolution capability of the Digital Sensor, this "pulley-induced demagnification effect" is not a problem. The drone cable 244 is connected to a sensor 12. An optical fiber 252 from a fiber optic cable 254 is connected to the sensor 12.
Buildings and Bridges
Bailey Bridge integrity, and other perhaps more permanent critical military structures would be excellent candidates for the system of the present invention, where the ease of uncoiling and deploying this two-way-reflective and therefore essentially one-ended "rope with ornaments attached" is readily adapted to a wide array of geometries. This system has the ability to instantly report on the "health" of high-rise buildings, post-earthquake. The military theater has much in common with earthquake-prone terrain from the standpoint of jarring vibrational damage and so may see useful parallels.
Naval Vessels and Aircraft
Another military fit for the Fatigue Fuse of the present invention is obviously airframes and oil tanker structural monitoring, naval vessels are obvious candidates. The nonelectric aspect of the fiber optic system should play here, in what would be a literally explosive environment, as well as it does in the equally dangerous milieu of oil freighters. In addition, the bolt clamp load monitoring system of the present invention will also fit in well here, particularly on some of the newest model airframes.
Temperature Monitoring
On at least one shaded portion of the bridge structure which is known to be extremely rigid, a section of thermally expandable cable will be utilized to deliberately react to changes in temperature. This is because several sections of the bridge structure will include metallic members which will expand and contract with temperature fluctuations. In order to be able to separate these effects from, for example, legitimate structural shifts as recorded by the relevant motion sensors, the corrective factor must be known. Referring to FIG. 48, one end of a temperature expanding cable 256 is fixed to an anchor 258 on the bridge structure 259. The other end of the expanding cable 256 is fixed to the probe portion 21 of a sensor 12. An aramid fiber cable 260 which does not expand. As a result of increases in temperature is fixed to the housing portion 23 of the sensor 12 to an anchor 262 which is fixed to the bridge structure 259.
Function
Referring to FIG. 66, the temperature-related changes of the Expanding Cable will be detected through the accommodating motion within the optical encoder. These changes will occur according to the laws of thermal expansion and contraction.
These state that the change in length, L1-L2=dL will be:
dL=L1×Tc×(T1-T2),
where:
Tc is the thermal expansion coefficient of the Expanding Cable
T1 is the starting temperature in degrees Celsius, and
T2 is the ending temperature in degrees Celsius
Note that the Drone cable is made of Kevlar which has a zero temperature coefficient of expansion. | The present invention is directed to a system for continuous physical integrity monitoring of large civil structures such as bridges and high-rise buildings . . . wherein the relevant sensor data stream is generated continuously and transmitted to the data gathering location without the need for an incoming triggering signal of any kind; i.e., it is a one way transmission system. Specifically, it is a concept for an interlinked multi-parameter Early Warning Sensor system with a full time data management capability for structures. The invention is also directed to both the system construction, with its communication capability, and also designs of specific sensors applicable to the system as a whole. As a practical example of application of the present invention to a structure, the description in this application is directed primarily towards system applications for bridge integrity early warning systems. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. Ser. No. 12/818,630 filed Jun. 18, 2010 now U.S. Pat. No. 7,975,821, which is a continuation application of U.S. patent application Ser. No. 11/814,934, filed Jul. 27, 2007 now U.S. Pat. No. 7,766,774, which is a U.S. National Stage Entry of International Application No. PCT/CA2006/000129 filed Feb. 3, 2006, which claims the benefits of U.S. Provisional Application Ser. No. 60/649,520, filed Feb. 3, 2005. The entire disclosure of each of the above applications are incorporated by reference as if fully set forth in detail herein.
FIELD
The present disclosure relates to a torque limited decoupler.
BACKGROUND
An automotive vehicle engine transfers a portion of the engine output to a plurality of belt driven accessories utilizing an endless serpentine belt. Typically, each component includes an input drive shaft and a pulley coupled to a distal end of the drive shaft for driving engagement with the belt. An example of such a belt driven accessory is an alternator.
A decoupler is operatively coupled between the pulley and the alternator to allow the alternator drive shaft to “overrun” or rotate at a faster speed than the pulley and to allow the speed of the pulley to oscillate with respect to the alternator drive shaft due to oscillations in the engine speed. Examples of decouplers are disclosed in U.S. Pat. No. 6,083,130, issued to Mevissen et al. on Jul. 4, 2000, U.S. Pat. No. 5,139,463, issued to Bytzek et al. on Aug. 18, 1992 and International Patent Application No. WO 2004/011818.
In PCT application no. WO 2004/011818, the decoupler reduces torsional fluctuations in the endless drive system. However, in certain applications in which the engine has an aggressive start profile or during conditions of rapid acceleration during a wide open throttle shift, the torques transmitted will over-stress the torsion spring reducing long term durability of the decoupler.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
According to one aspect of the present disclosure, a decoupler assembly is provided for transferring torque between a shaft and a drive belt. The decoupler assembly includes a hub configured to be fixedly secured to the shaft. A carrier is rotatably mounted on the hub. A torsion spring extends between the hub and the carrier for transferring torque therebetween. A pulley is rotatably coupled to the hub. The pulley has an inner surface formed therein. A clutch spring is secured to the carrier and has a plurality of helical coils frictionally engaging with the inner surface of the pulley to selectively couple the hub and pulley. The torsion spring and the clutch spring are mounted co-axially and wound in opposite senses enabling the clutch spring to expand into gripping engagement with the inner surface during acceleration of the pulley relative to the hub and to contract out of gripping engagement with the inner surface during deceleration of the pulley relative to the hub, while enabling the torsion spring to absorb minor torsional vibrations without decoupling the pulley from the hub. A torque limiter, in the form of a sleeve, is fitted about the torsion spring and is sized to limit expansion of the torsion spring enabling the torsion spring to fully couple the hub with the pulley at or above a predetermined torque.
According to another aspect of the present disclosure, the torque limiter is in the form of a wire coil, which is fitted about the torsion spring and is sized to limit expansion of the torsion spring enabling the torsion spring to fully couple the hub with the pulley at or above a predetermined torque.
According to a further aspect of the present disclosure, a decoupler assembly is provided with a hub, a drive member, a torsional damping system and a torque limiter. The hub that is configured to be coupled to a shaft for rotation therewith. The drive member is disposed concentrically about the hub and is configured to drivingly engage an endless power transmitting member to permit rotary power to be transferred between the drive member and the endless power transmitting member. The torsional damping system is disposed between the drive member and the hub and has a torsion spring that facilitates transfer of rotary power into the hub. The torque limiter is wrapped about the torsion spring and radially expands with the torsion spring as a magnitude of the rotary power transmitted through the torsion spring increases. Contact between the torque limiter and another structure in the decoupler assembly halts radial expansion of the torsion spring.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustrative purpose only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is a front view of an engine of an automotive vehicle incorporating a decoupler assembly according to one aspect of the invention;
FIG. 2 is an enlarged fragmentary sectional view of the decoupler assembly;
FIG. 3 is an exploded perspective view of a clutch spring in the decoupler assembly of FIG. 2 ;
FIG. 4 is an exploded perspective view of the clutch spring and carrier assembly in relation to the torque limiter and torsion spring of the decoupler assembly of FIG. 2 ;
FIG. 5 a perspective view of the clutch spring of the decoupler assembly of FIG. 2 ;
FIG. 6 is a perspective view of the carrier of the decoupler assembly of FIG. 2 ;
FIG. 7 is a perspective view of the clutch spring and carrier assembly of FIG. 2 ;
FIG. 8 is a perspective view of a second embodiment of the torque limiter of the decoupler assembly of FIG. 2 ;
FIG. 9 a is a perspective view of a third embodiment of the torque limiter of the decoupler assembly of FIG. 2 ;
FIG. 9 b is a perspective view of an alternate third embodiment of the torque limiter of the decoupler assembly of FIG. 2 ;
FIG. 10 is an exploded perspective view of the decoupler assembly of a fourth embodiment of the decoupler assembly of the present invention;
FIG. 11 is an exploded perspective view of the clutch spring and carrier assembly in relation to a torque limiter and torsion spring of the decoupler assembly of FIG. 10 ;
FIG. 12 a perspective view of the clutch spring of the decoupler assembly of FIG. 10 ;
FIG. 13 is a perspective view of the carrier of the decoupler assembly of FIG. 10 ; and
FIG. 14 is a perspective view of the clutch spring and carrier assembly of FIG. 10 .
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
An engine for an automotive vehicle is generally indicated at 10 in FIG. 1 . The engine 10 includes a crankshaft 12 driving an endless serpentine belt 14 , as commonly known by those having ordinary skill in the art. The engine 10 also includes a belt driven accessory 16 driven by the belt 14 . Described in greater detail below, a decoupler assembly 20 is operatively assembled between the belt 14 and the belt driven accessory 16 for automatically decoupling the belt driven accessory 16 from the belt 14 when the belt 14 decelerates relative to the belt driven accessory 16 and allowing the speed of the belt 14 to oscillate relative to the belt driven accessory 16 . Additionally, a detailed description of the structure and function of a decoupler assembly can be found in applicant's U.S. Pat. No. 6,083,130, which issued on Jul. 4, 2000 and PCT Application No. WO 2004/011818, the contents of which are incorporated herein by reference.
Referring to FIGS. 2 and 3 , the decoupler assembly 20 generally includes a hub 22 , a pulley 50 , a clutch assembly 70 , a torsion spring 90 and a torque limiter 110 . In the first embodiment, the torque limiter 110 is preferably a sleeve.
Hub 22 has a generally cylindrical body 28 having an axially extending bore 24 and a flange 26 at one end thereof. Flange 26 has a generally helical first slot 46 on an inner face thereof. Since the slot 46 is helical, the slot 46 will have a step. The bore 24 is configured for fixedly securing the hub 22 to a drive shaft extending from the belt driven accessory 16 .
A pulley 50 is rotatably journaled to the hub 22 . A ball bearing assembly 57 is coupled between the pulley 50 and the hub 22 at a distal end while a bushing journal 102 mounts the pulley 50 on the circumferential face of flange 26 . The bearing assembly 57 is conventional comprising an inner race, an outer race and a plurality of ball bearings rollingly engaged therebetween. The pulley 50 typically includes a plurality of V-shaped grooves 66 formed on the outer periphery for engaging and guiding the belt 14 . Other belt or chain profiles may be utilized to facilitate other drive configurations, well known in the art.
A one-way clutch assembly 70 is operatively coupled between the hub 22 and the pulley 50 . The clutch assembly 70 includes a clutch spring 71 and a carrier 75 . The clutch spring 71 includes a plurality of helical coils 72 . Preferably, the clutch spring 71 is formed from an uncoated, spring steel material and has a non-circular cross-section to improve frictional contact. Most preferably, the cross-section of clutch spring 71 is rectangular or square. The clutch spring 71 is press fitted into frictional engagement with the inner surface 56 of the pulley 50 . Preferably, a lubricant similar or compatible with grease used in the ball bearing assembly 57 is applied to minimize wear between the clutch spring 71 and the inner surface 56 of the pulley 50 .
The carrier 75 is rotatably mounted on the hub 22 . The carrier 75 is generally ring shaped and has an inner face 78 , a bore 80 and an outer circumferential surface 82 . A slot 84 is formed on the inner face 78 and is configured to retain an end of the clutch spring 71 . A generally helical second slot 86 is also formed on the inner face 78 and inside of slot 84 , defining a second locating surface 88 and a step.
An annular thrust washer 39 is seated against the end of the carrier 75 and abuts against the inner bearing race of bearing assembly 57 . The outer periphery of the thrust washer 39 is circular with a step 41 to complementarily fit with a tab. Thrust washer 39 has one or more radial or circumferential serrations 43 to engage hub 22 and mechanically lock the thrust washer 39 to the hub 22 to prevent relative motion therebetween.
A helical torsion spring 90 is axially compressed between the hub 22 and the carrier 75 . The torsion spring 90 and the clutch spring 71 are co-axial and typically coiled in opposite directions. In certain applications, the torsion spring 90 and clutch spring 71 can be wound in the same sense to produce a desired decoupling action. One end of the torsion spring 90 is retained in the first slot 46 of the hub 22 and the other end is retained in the slot 86 of the carrier 75 . Axial forces due to the compression of the torsion spring 90 retain the carrier 75 in abutting engagement with the thrust washer 39 .
Typically, the shaft of the hub 22 has an area of reduced diameter 23 to provide clearance between the torsion spring 90 and the shaft 28 of hub 22 to prevent uncontrolled contact and friction wear at the interface between shaft 28 and torsion spring 90 . Thus, the torsion spring 90 allows relative movement between the carrier 75 and the hub 22 to accommodate minor variations in the speed of the pulley 50 due to oscillations in the operating speed of the engine. The oscillations are not sufficient to activate the clutch assembly 70 .
A torque limiter 110 is wrapped about the torsion spring 90 in a surrounding relation. Preferably, torque limiter 110 has a split or opening 112 and a circumferentially extending shoulder step 114 . Shoulder step 114 configures the torque limiter 110 to complementarily fit with bushing 102 mounted on the flange 26 of hub 22 . In a first preferred embodiment, torque limiter 110 is an organic resinous material, preferably a Nylon™ material, with or without reinforcement material such as glass fibres, etc. Torque limiter 110 has a thickness selected to take up the play between the torsion spring 90 , the clutch spring 71 and the inside diameter of the pulley 50 . As torque increases, the torsional spring 90 expands outwardly until physically constrained by the torque limiter 110 against the clutch spring 71 and the inside diameter of bore 56 . When the radial clearance between the torsion spring 90 , torque limiter 110 , the clutch spring 71 and the inside bore 56 of the pulley 50 is closed, the spring 90 is prevented from further expanding, locking the decoupler 10 , coupling the hub 22 with the pulley 50 . In other words, the torque limiter 110 limits the amount of outward expansion of the torsion spring 90 , preventing overloading of the torsion spring 90 . The amount of radial expansion of the torsion spring 90 can be calculated and the torque limiter 110 can be designed to ensure that the torque transferred through the torsion spring 90 is maintained below a predetermined torque value.
A second embodiment of the sleeve is illustrated in FIG. 8 . Torque limiter 110 ′ is a closed metal ring. The metal ring would only expand to a relatively small degree, directly limiting outward expansion of the torsion spring 90 .
A third embodiment of the sleeve is illustrated in FIG. 9 a . Torque limiter 110 ″ has a plurality of axially elongate openings 116 spaced circumferentially spaced about the torque limiter 110 ″. The openings 116 enable the grease lubricant to travel outwardly to the clutch spring 71 .
An alternative third embodiment of the sleeve is illustrated in FIG. 9 b . The torque limiter 110 * has a series of circumferentially spaced openings 116 * and 117 . Preferably, openings 116 * are elongate and openings 117 are circular and spaced in a regular pattern, resembling dimples on a golf ball. Additionally, torque limiter 110 * has an integrally extending radial flange 119 that acts a thrust bearing.
A cap 100 is attached to the end of pulley 50 for preventing contaminants from entering the decoupler assembly 20 and for retaining the lubricant within the decoupler assembly 20 .
In operation, the engine 10 is started and the pulley 50 is accelerated and rotated in a driven direction by the belt 14 driven by the engine 10 . Acceleration and rotation of the pulley 50 in the driven direction relative to the hub 22 creates friction between the inner surface 56 of the pulley 50 and preferably all of the coils 72 of the clutch spring 71 . It should be appreciated that the clutch spring 71 will function even where at the onset at least one of the coils 72 of the clutch spring 71 is frictionally engaged with the inner surface 56 of the pulley 50 . The clutch spring 71 is helically coiled such that the friction between the inner surface 56 of the pulley 50 and at least one of the coils 72 would cause the clutch spring 71 to expand radially outwardly toward and grip the inner surface 56 of the pulley 50 . Continued rotation of the pulley 50 in the driven direction relative to the hub 22 would cause a generally exponential increase in the outwardly radial force applied by the coils 72 against the inner surface 56 until all of the coils 72 of the clutch spring 71 become fully brakingly engaged with the pulley 50 . When the clutch spring 71 is fully engaged with the inner surface 56 , the rotation of the pulley 50 is fully directed toward rotation of the drive shaft 15 ( FIG. 1 ) of the belt driven accessory 16 . Additionally, centrifugal forces help to retain the clutch spring 71 in braking engagement with the inner surface 56 of the pulley 50 .
The rotational movement of the carrier 75 in the driven direction is transferred to the hub 22 by the torsional spring 90 such that the carrier 75 , thrust washer 39 , hub 22 , and the drive shaft 15 ( FIG. 1 ) from the belt driven accessory 16 rotate together with the pulley 50 . Additionally, the torsional spring 90 resiliently allows relative movement between the carrier 75 and the hub 22 to accommodate oscillations in the speed of the pulley 50 due to corresponding oscillations in the operating speed of the engine 10 .
When the pulley 50 decelerates, the hub 22 driven by the inertia associated with the rotating drive shaft 15 ( FIG. 1 ) and the rotating mass within the belt driven accessory 16 will initially “overrun” or continue to rotate in the driven direction at a higher speed than the pulley 50 . More specifically, the higher rotational speed of the hub 22 relative to the pulley 50 causes the clutch spring 71 to contract radially relative to the inner surface 56 of the pulley 50 . The braking engagement between the clutch spring 71 and the pulley 50 is relieved, thereby allowing overrunning of the hub 22 and drive shaft 15 ( FIG. 1 ) from the belt driven accessory 16 relative to the pulley 50 . The coils 72 may remain frictionally engaged with the inner surface 56 while the pulley 50 decelerates relative to the clutch assembly 70 and the hub 22 . The coils 72 of the clutch spring 71 begin to brakingly reengage the inner surface 56 as the pulley 50 accelerates beyond the speed of the hub 22 .
In conditions of high loading, such as a fast engine start profile and/or rapid acceleration during a wide open throttle shift, the coils of the torsion spring 90 will be urged to expand outwardly, due to relative rotation between the hub 22 and the pulley 50 . The torsion spring 90 will expand, frictionally engaging the torque limiter 110 which will then engage the clutch spring 71 . Full frictionally engagement is selected to occur at a predetermined torque value by selecting the thickness of the torque limiter 110 . Once fully engaged, the hub 22 will be locked with the pulley 50 and torques above a predetermined torque value will be transmitted directly therebetween. Thus, the higher torques do not overstress the torsion spring 90 and ultimately improving durability of the decoupler assembly 10 .
Referring to FIGS. 10 to 14 , a fourth embodiment of the torque limiter 110 is illustrated. Elements common with the embodiment of FIGS. 2 and 3 retain the same reference number.
In this embodiment, the torque limiter 110 ′″ is in the form of a wire coil spring. Torque limiter 110 ′″ is positioned about the torsion spring 90 . Preferably, torque limiter 110 ″ is formed of a small gauge wire, compared to torque spring 90 , with a square or rectangular cross-section. The gauge and dimensions of torque limiter 110 ′″ are selected such that any play which would otherwise be present between torsion spring 90 , clutch spring 71 and the inside surface 56 of pulley 50 is substantially removed, while still allowing relative motion between torsion spring 90 and clutch spring 71 . Further, the coils of torque limiter 110 ′″ allow grease, or any other lubricant, to travel outwardly to the clutch spring 71 .
It is presently preferred that the coils of torque limiter 110 ′″ be wound in the same sense of the coils of clutch spring 71 , although this is not essential to proper operation of decoupler 20 .
As torque to pulley 50 increases, torsional spring 90 expands outwardly until physically constrained by torque limiter 110 ′″. When the radial clearance between torsion spring 90 , torque limiter 110 ′″, clutch spring 71 and the inside surface 56 of pulley 50 is closed, spring 90 is prevented from further expanding, locking decoupler 20 , coupling the hub 22 with the pulley 50 . In other words, torque limiter 110 ″ limits the amount of outward expansion of the torsion spring 90 , preventing overloading of torsion spring 90 .
The amount of radial expansion of torsion spring 90 can be pre-determined and torque limiter 110 ′″ can be designed to ensure that the torque transferred through torsion spring 90 is maintained below a preselected torque value.
Referring to FIGS. 12 to 14 , a second variant of the clutch assembly 70 is illustrated. The clutch assembly 70 includes clutch spring 71 ′, comprising a helical coil, and a carrier 75 ′. Preferably, clutch spring 71 ′ is formed from an uncoated, spring-steel material and the material forming the helical windings 72 has a non-circular cross-section to improve frictional contact. Most preferably, the cross-section of the helical winding material is rectangular or square. Clutch spring 71 ′ is press-fitted into frictional engagement with the inner surface 56 of the pulley 50 . Preferably a lubricant, similar or compatible with the grease used in the ball bearing assembly 57 , is applied to minimize wear between the clutch spring 71 ′ and inner surface 56 of the pulley 50 .
Carrier 75 ′ is rotatably mounted on the hub 22 and carrier 75 ′ is generally ring shaped, with an inner face 78 , a bore 80 and an outer circumferential surface 82 . A slot 84 ′ is formed on inner face 78 and is configured to retain an end of the clutch spring 71 ′. A generally helical second slot 86 is also formed on the inner face 78 and inside of slot 84 , defining a second locating surface 88 and a step.
In this variant, the end of clutch spring 71 ′ is bent at 73 and 77 . Slot 84 ′ is complementarily configured to receive the end of the clutch spring 71 ′ and frictionally engage with the bends 73 and 77 .
The bore 80 of carrier 75 ′ has a keyway 81 and a series of axially extending dimples.
The decoupler illustrated in FIGS. 10 to 14 operates in the same fashion as described with respect to the decoupler illustrated in FIGS. 1 to 9 .
In conditions of high loading, such as a fast engine start profile and/or rapid acceleration during a wide open throttle shift, the coils of the torsion spring 90 will be urged to expand outwardly, due to relative rotation between hub 22 and pulley 50 . The torsion spring 90 will expand, expanding torque limiter 110 ′″ in turn, which will then frictionally engage the clutch spring 71 . Full frictional engagement is selected to occur at a predetermined toque value by selecting the thickness of the windings of torque limiter 110 .
Preferably, decoupler 20 further includes an adapter 104 which is press fit into the inner race of bearing 57 and which allows decoupler 20 to be fit to belt driven accessories with drive shafts of different sizes and/or to position decoupler 20 on the driven shaft to ensure correct alignment of grooves 66 with the serpentine belt. However, adapter 104 is not necessary and decoupler 20 can be installed directly onto the drive shaft of a belt driven accessory if the diameter of that drive shaft will properly engage the inner race surface of bearing 57 and/or if grooves 66 will be properly aligned with the serpentine belt.
The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modification and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described. | A decoupler assembly with a torsional damping system and a torque limiter. The torsional damping system has a torsion spring that facilitates transfer of rotary power into a hub. The torque limiter is wrapped about the torsion spring and radially expands with the torsion spring as a magnitude of the rotary power transmitted through the torsion spring increases. Contact between the torque limiter and another structure in the decoupler assembly halts radial expansion of the torsion spring. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to sailboats, specifically to an apparaus for mounting a jibsail and mainsail on a sloop, so that the entire rig may rotate to follow the shifting wind or to compensate for the helmsman's maneuvers.
2. Description of the Prior Art
The prior patent art does not teach the detailed structure of automatically rotatable sailing rigs. In his U.S. Pat. No. 3,968,765, the inventor described the aerodynamics and claimed the automatically rotatable sail rig. A principal advantage is that its thrust is reliably adjustable over a wide range in a steady wind; said thrust, being voluntarily set, is substantially unaffected by possible errors at the helm and by the directionally-shifting wind. Another advantage is its inherently high lift/drag ratio at angles of attack below stall, which is the condition to the windward. Another advantage is its ability to sail on any possible point, stalled or not, without adjusting sheets when changing course.
Many fore and aft sails have heretofore been twisted too much in moderate to strong winds, and their proximity to other sails also has deleteriously affected performance; forward drive has been reduced and lateral wind force has been unnecessarily high. Being fixed with respect to the hull, conventional sails commonly luff and stall by turns in the deviating wind, resulting in decreased thrust and increased drag.
SUMMARY OF THE INVENTION
This improved structure for sloop rigs permits shaping sails and adjusting their juxtaposition, thus accurately controlling their aerodynamic parameters. When operating below stall, the sails trim themselves to the shifting wind, rather than being adjusted repeatedly by the sailor.
The automatically rotatable sloop rig of U.S. Pat. No. 3,968,765 utilizes a novel boom (carrier boom) which rotates freely about a centrally located step, even when the sloop is heeled. Said carrier boom herein mounts two airfoils, one before and the other aft of the step. These airfoils are adjustable about their vertical axis of rotation, and therefore are quickly fixed at chosen angles with respect to the carrier boom, and not with respect to the hull proper. Under the force of the wind, the entire assembly of carrier boom, airfoils and associated rigging rotates about the step to assume a desired boom attitude with respect to the apparent wind. Each airfoil operates at its desired angle of attack in the wind regardless of the attitude of the hull proper.
On a beat to windward, a close reach, and a beam reach, the average angle of attack on the airfoils is a function only of the foil-boom angles set voluntarily. If the sailor wishes to increase the angle of attack, to increase the thrust, he draws in all the sail sheets. These sheets pass down from the rig to the hull in the immediate vicinity of the step, whereby rotation of the entire rig does not affect the foil-boom angles set by hand. No matter how the sailor performs at the helm (within a range of relative wind angle), the effective angle of attack and the concommitant thrust remain fixed, because the force of the wind keeps the rig at a fixed wind-attitude while the boat turns underneath. The automatically rotatable sail rig operates by always balancing the moments of the horizontal sail forces about the vertical axis of the freely rotating step. One object of the present work is to specify spars and rigging to shape the sails and permit the rig to respond to the wind by rotating bi-directionally according to the foregoing considerations.
The desired and efficient local form of any sail depends on water course, water speed relative to wind speed and the height of the sail above the water. Accordingly the well tuned sail is twisted through a small controlled angle determined by the shifting true wind, and its variable orientation with respect to other sails is determined by the same course, speed, and height. Controlling said shapes and mutual orientations by exerting appropriate forces readily adjustable imposes absent loads on the spars. Means are specified for coping with these augmented forces, yet limiting the inertia of the rig. These specific means are a further development of the inventor's prior U.S. Pat. No. 3,968,765.
The mainsail of the conventional sloop rig has been commonly twisted to an undesirable degree because it has been impossible to pull sufficient tension on the leech. The crews of large yachts sometimes set powerful vangs and the sheet to pull the mainsail boom downward, but this vertical force is limited by the allowable strain on the mast, and applying this force is inconvenient and often impractical when course changes are frequent. These same comments apply with less emphasis to the jib of a sloop. The overall effect has been loss of potential speed or wasted sail area. Often the foot of the sail has been stalled (too high attack) while the head has been flagging (no attack).
The present structure is a compromise between the aerodynamic ideal and acceptable weight or roll moment of inertia. For excess weight above the hull's metacenter defeats the purpose of shaping the sails.
The twist of a sail must be quickly and easily adjustable. This may be accomplished in part by varying tension on the mainsail leech, since the wind force varies over a wide range and the required lateral deflection of the leech also depends on the water course with respect to the true wind. The lowest twist and therefore a sometimes high leech tension is required when the sloop sails close on the wind, when the heeling force is a maximum. The prime objective is to maximize the ratio of water speed to relative wind speed at an acceptable heel angle in weather that permits coordinated sailing.
The fundamental reason why a minor sail twist is permissable and necessary is that the wind velocity in the turbulent air boundary layer above water varies approximately as the fourth root of height up to a few thousand feet or less. Since the sloop's water speed while sailing on the wind may be about half the true wind speed measured at the height of the main truck, the angle of relative wind off water course varies from nearly zero at the water surface to thirty degrees at the head of the sail, and said required twist between sail foot and head is about five degrees if one operates with the angle of attack invariant with the height. However, because of the proximity of the foot to the water surface the angle of attack should be allowed to decrease with height by a degree or two, so that the total twist is 6° or 7°. This means that the horizontal deflection of the leech is to be 1 to 2 percent of the leech length when sailing close on the wind. Two or three times more deflection is appropriate when sailing on the beam reach.
A leech tension of about 2.6 times the mainsail air force is needed to achieve the correct mainsail shape. This "vertical" force is applied to the after end of the mainsail boom by means of a conventional vang between said boom and a bearing near the foot of the step in order to allow the sail to rotate about the step and yet maintain its shape. Because the mainsail boom is conventionally located close above deck, the leech force is multiplied on the vang by reason of mechanical disadvantage. In turn, the horizontal component of the vang tension places a similarly high axial compressive load on the mainsail boom. A step structure is installed to resist these sometimes high forces and to accomodate suitably light bearings rotating about the mast. The structure of the step assembly is built fairly stiff to permit reliable performance of the bearings, imposing only a minor penalty in the way of increased roll moment of inertia. The step assembly permits the rig to rotate freely. The mast is inserted within a step housing, which is supported by three hull-bedded struts. At the top of the step housing is the main bearing assembly which comprises upper and lower thrust bearings to resist vertical forces and a radial bearing between said thrust bearings to resist horizontal forces, said main bearing assembly being external to the step housing. The mainsail boom is connected to the main bearing by means of a load spreader. A rotatable compression strut transmits a vertical force from the vang to the upper thrust bearing. The carrier boom also rotates about the main bearing just above the lower thrust bearing. The carrier boom rotates with respect to the outer race of the main bearing only when the mainsail foilboom angle is adjusted by hand. The step assembly also has a second bearing assembly, similar to the main radial bearing in construction, at the base of the step housing near the hull structure. It is to this lower bearing that the vang is attached and to which the rotatable compression strut is attached.
The forespar is a beam loaded with a distributed sail force varying from zero at the head to a maximum near its second jib sheet. This spar is lightened by means of tension stays, and it rotates in loose bearings at the head and foot. The function of said spar is to spread the jibsail, and to permit sail shape to be controlled by multiple jib sheets. Also, when going about, the jib is unrestrained so that it may change tack without manual adjustments to the sheets. (The conventional headstay, which mounts the genoa jib, is often badly deflected, since it is a cable. This deflection causes compounded difficulty in shaping the jibsail.)
At the mast head, the aft horizontal component of the mainsail leech tension is opposed by the tension on the forestay, and thus the mainsail leech and forestay together put a compressive load on the mast amounting to 5.4 times the mainsail air force. These forces are in addition to the usual compressive load and bending moment on the mast by both sails and weather shrouds. In sum, the axial compressive load on the mast is increased by about seventy percent through controlling the twist of the mainsail on the most severe sailing point.
The jib twist is controlled by multiple sheets and their tensile forces are small compared to those imposed by the mainsail.
Sheets are arranged to be all operated from a single tackle or winch. Or, the multiple jib sheets can be ganged as a unit separate from the main sheet, at the preference of the sailor. All sheets, or only the jib sheets, may be freed quickly in the event of emergency, to reduce sail thrust promptly.
On a run before the wind, or a broad reach, with stalled airfoils, the shape of battened sails has only minor influence. The mainsail leech may then be slacked off. Any subsidiary cloth that may be flown is at least marginally effective in dragging the boat, and sailors presume the bigger the better, which is not far from true provided the large cloth is manageable. If one does not fly a spinnaker (or ballon or reacher) in normal weather, he should delay turning into the run, while tacking downwind at non-stall, until the mark bears about 45° off the lee bow. The figure 45° could be locally refined, especially for the case of a long run when there may occur appreciable wind shift. It averages:
Lay Angle = ArcCosine ((Water Speed, Run)/(Water Speed, Broadest Reach permitting Non-Stall)) (1)
As Forumla 1 implies, in heavy weather the Cosine above is unity or nearly so, sail shape is a relatively minor issue, and the speediest downwind course is straight for the mark, regardless of what sail may be carried safely and in spite of short periods sailed by the lee.
The rotatable rig of U.S. Pat. No. 3,968,765 follows the fickle wind with its transient pressures and veerings more efficiently than can a sailor. Hence, for rudder automatic control, a stick bored with numerous holes can be used to link the carrier boom with the extended helm. Though possibly slowing response of the sensing and steering system, a rig thus equipped concomitantly attenuates and filters out low-amplitude, transient deviations, for as a sensing device the rig has comparatively huge chords and area. For the air in the downwash from any sail is straighter, or less oscillatory, than the relative wind as measured by a vane-actuated rudder controller whose wind vane is comparatively small.
Yet the usual gradual wind veerings over amplitudes of five to ten degrees are followed accurately by a boat using practically any gain on the helm when the helm is linked to the carrier boom.
With its helm clamped over appropriately, a boat equipped with the automatically rotatable rig, and provided its keel is of sufficient draft, circles repeatedly, going about and jibing automatically. Also, either with rudder automatic control, or with a clamped helm, the boat may be reliably hove to, regardless of the efficiency of its keel system.
In crowded water, the automatically rotatable rig could be operated as a conventional sloop by constraining the carrier boom straight fore and aft with two preventers. With the rig thereby constrained, a sailor is much less apt to cause a collision, for the sails no longer draw well on all possible points and so may be luffed up over a wider range of azimuthal angle.
The sail sheets are important to the desired operations described in the foregoing disclosure. They are used to set the two foil-boom angles and thus determine the sails' angles of attack, and for this purpose sails are sheeted to the freely rotatable carrier boom, and not to the hull as on the conventional sloop. As the automatically rotatable rig rotates to follow the wind, the geometric angle of attack, when below stall, remains fixed. The helmsman does not have to act according to tradition to maintain the angle of attack, though he nevertheless steers to take advantage or cope with the shifting wind, unless the steering function is taken over by the rudder automatic controller.
In summary, this is an automatically rotatable sail apparatus for a sloop comprising: a single vertical tubular mast assembly supporting a battened cloth mainsail along its luff; a substantially horizontal carrier boom freely rotatable about the vertical axis of the mast; a rotatable inclined tubular forespar assembly mounted at its lower extremity on the fore end of the carrier boom and at its upper extremity on the mast head, said forespar supporting a battened cloth jibsail along its luff; a tubular mainsail boom to accommodate the foot of the mainsail; a freely rotatable, stiff step structure including pairs of radial and thrust bearings bedded to the hull near the foot of the mast, said step structure mounting the rotatable spar frame including mast, carrier boom, forespar, and mainsail boom; a vang, to pull a weather-varying tension on the leech of the mainsail, being made fast at its extremities to the mainsail boom and to the lower bearing of the step structure; a main sheet between the mainsail boom and the carrier boom to control the azimuthal angle of the mainsail with respect to the rotatable carrier boom (not with respect to the hull); a coordinated system of multiple jib sheets made fast to jib battens to shape the jib sail generally and to control the azimuthal angle of the jib sail entirely over its surface with respect to the carrier boom as the corresponding mainsail is similarly controlled by the main sheet; a forestay set from the mast head to the nose of the hull to resist the horizontal component of tension imposed on the mainsail leech; and athwartships shrouds to support the mast. The forestay and shrouds are flexibly anchored to permit the free rotation of the entire apparatus of spars, sails, vang, sheets and halyards.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side perspective view of a sloop rigged in accordance with the principles of U.S. Pat. No. 3,968,765.
FIG. 2 is a cross-sectional view of the mast taken along the line 2 -- 2 of FIG. 1.
FIG. 3 is a cross-sectional view of the forespar taken along the line 3 -- 3 of FIG. 1.
FIG. 4 is a cross-sectional view of the carrier boom taken along the line 4 -- 4 of FIG. 1.
FIG. 5 is a view of the structure of the step.
FIG 6 is a vertical section taken along the line 6 -- 6 of FIG. 1 showing details of the main bearing assembly.
FIG. 7 is a fragmentary view of the jib showing the arrangement of one of the multiple jib sheets.
FIG. 8 is a diagram showing an alternative main sheet arrangement, suitable for sloop rigged catamarans particularly.
FIGS. 9 A, B, C, D, E, F, and G are diagrams showing the positions of the carrier boom and sails automatically assumed as the rig circles repeatedly.
FIG. 10 is a wind trace, showing direction as deviations from the mean and its time-integral recorded mechanically.
FIG. 11 is a schematic drawing of the electrical circuit used to indicate the ratio of water speed to relative wind speed.
FIGS. 12 A, B, C, D, E, and F show the constructions of smaller automatically rotatable rigs.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a side perspective view of a yacht using the automatically rotatable sloop rig. Yacht 10 includes a hull 12 having a keel 14, a rudder 16, a helm 18 and the automatically rotatable sail rig, designated generally by the reference numeral 20. Rig 20 includes a centrally located, stiff step structure 22, described in detail hereinafter. A tubular vertical mast assembly 24 is mounted within said step structure 22. A horizontal carrier boom 26 is mounted to and rotates freely about said step structure 22 and consequently said carrier boom 26 is freely rotatable about the vertical axis of said mast assembly 24, even when sloop 10 is heeled. Said carrier boom 26 mounts, fore and aft of step structure 22 two airfoils: a mainsail 28 aft of the step structure 22, and a jibsail 30 forward of the step structure 22. Mast assembly 24 supports mainsail 28 along its luff 32. A tubular mainsail boom 34 accommodates the foot of mainsail 28. Rig 20 further includes a freely rotatable, inclined tubular forespar assembly 36 mounted at its lower extremity on the fore end of carrier boom 26 and at its upper extremity on the head of mast assembly 24. Said forespar assembly 36 supports jibsail 30 along its luff 38. Both mainsail 28 and jibsail 30 are battened cloth sails, the mainsail battens being indicated by the reference numeral 40 and the jibsail battens by numeral 42.
Rig 20 further includes a vang 44 used to pull a weather-varying tension on the leech 46 of mainsail 28, vang 44 being made fast at its extremities on mainsail boom 34 and to the lower bearing of step structure 22. A main sheet 48 connects the mainsail boom 34 to the carrier boom 26 to control the azimuthal angle of the mainsail boom 34 with respect to the carrier boom 26. A coordinated system of multiple jib sheets 59 are made fast to the jib battens 42 along the leech 52 to shape the jibsail 30 generally and to control the azimuth angle of jibsail 30 over its surface simultaneously with respect to the carrier boom 26 as the corresponding mainsail 28 angle is controlled by main sheet 48. Rig 20 further includes a forestay 54 from the head of mast 24 to the nose of hull 12 to resist the horizontal component of tension on leech 46 of mainsail 28, and athwartships shrouds 56 to support the mast 24. Shrouds 56 are held in position by spreaders 58. The forespar assembly 36 also includes bands 60 separated by spreaders 62. As shown in FIG. 1, forestay 54 and shrouds 56 are flexibly anchored to permit free rotation of the entire apparatus of spars, sails, vang, sheets and halyards.
FIG. 2 is a cross-sectional view of mast assembly 24. Assembly 24 includes a tubular spear 64, whose wall thickness decreases with its height, enclosed by a fairing case 66 which rotates about said spar 64. Loose fitting rings 68 are utilized to permit free rotation of fairing case 66. Fairing case 66 encloses from the elements the mainsail track 70, the main halyard, jibsheets 50 in opening 72, and other auxiliary lines. Fairing case 66 is strengthened by ribs 74 and braces 76.
FIG. 3 is a cross-sectional view of the forespar assembly 36, taken just above a strut 62 which is shown in a fragmentary view. Forespar assembly 36 includes a tubular spar 78 enclosed by a fairing case 80. Forespar assembly 36 rotates in its entirety about the vertical axis of spar 78. Fairing case 80 encloses from the elements the jibsail track 82, the jib halyard, and auxiliary lines. Forespar assembly 36 is strengthened with spaced longitudinal forespar bands 60 spread apart on short horizontal struts 62, as shown in FIG. 1. Fairing case 80 is reinforced by ribs 84 and braces 86.
FIG. 4 is a cross-sectional view of carrier boom 26. Carrier boom 26 has two longitudinally oriented tubular spars 88 encased in a fairing 89, said tubular spars being held in shape by web struts 90. Carrier boom 26 has a central opening (not shown) to permit it to rotate about the main bearing of step structure 22, as shown in FIGS. 5 and 6. It also has an arcuate opening in the fairing, (not shown) just aft of the main bearing assembly to permit compression strut 104 to pass through freely, as shown in FIGS. 5 and 6.
FIG. 5 is a side view illustrating the general assembly of step structure 22, which is a stiff structure bedded to the hull 12 at the foot of mast 24. It comprises a step housing 92 which fits snugly about the foot of mast 24 surrounded at its base by a lower bearing 94 and just above by a main bearing 96. Both bearings 94 and 96 rotate about step housing 92 as will be described hereinafter. Mainsail boom 34 is attached by a load spreader 98 to the upper portion of main bearing 96. Carrier boom 26 bears on a fitting near the base of main bearing 96 and is separated therefrom only by a wear ring 100 (FIG. 6). Immediately below main bearing 96 is a fitting 101 which anchors three struts 102 (two shown). Struts 102 from fitting 101 to hull 12 support the step housing 92. A fourth compression strut 104 is set from a fitting 122 on lower bearing 94 vertically upward through carrier boom 26 to mainsail boom 34. Vang 44 is also attached to the base of compression strut 104.
FIG. 6 is a sectional view of the basic structure of main bearing 96. The internal structure of lower radial bearing 94 is essentially the same except for differences in length. FIG. 6 illustrates the base of mast 24 within step housing 92. Upper and lower thrust bearings 106 and 108 are provided to take the axial loads of rig 20. Thrust bearings consist, in a specific case, of a plurality of ball bearings 110 running in a groove 112. The upper race is 114 planar and makes "point" contact with the balls 110. Between thrust bearings 106 and 108 is the radial bearing 116, which has a plurality of rollers 117 vertically oriented and positioned between an inner race 118 and an outer race 120. The load spreader 98 of the mainsail boom 34 is fixed to the outer race 120 of radial bearing 116. The carrier boom 26 is separated from outer race 120 of radial bearings 116 by a wear ring 100. The step housing 92 is held in position by fitting 101, to which struts 102 are welded. Compression strut 104 is also shown as passing between tubes 88 of carrier boom 26 to mainsail boom 34.
The construction of lower bearing 94 is identical with that of upper radial bearing 116 except for differences in size and in fitting 122 to which compression strut 104 is attached.
The automatically rotatable sloop rig described is responsive to shifts in the wind direction and permits tuning of the sails. This tuning imposes additional forces on the spars of any rig, automatically rotatable or not. The structure described, and in particular the step structure, is designed to resist these high forces yet permitting the carrier boom and associated rigging to freely rotate about the vertical axis of the mast. While particular claimed spars have been described, standard spars now sold may be utilized. But, the carrier boom and the step structure must be fabricated in the novel manner herein described.
As shown in FIG. 1, a boom-to-helm link 124 is a rudder automatic controller, which is simply a stick with a plurality of holes drilled therein, and adjustably secured to the fore end of extended helm 18 and to some point on carrier boom 26. Boom-to-helm link 124, and the extended helm 18, could slow down the responsiveness of sloop 10, but then also obviate possible excessive speed loss due to high frequency rudder oscillation in unusually gusty winds. Hence, with link 124 in commission, transient wind deviations are more or less attenuated and filtered out by rig 20, and the generally desired course is held with respect to the wind.
Sail sheets 48 and 50 on the automatically rotatable rig 20 are used to set the foil-boom angles. Thus said sheets 48 and 50 (or the tackle to which they are all cleated) determine the angle of attack -- the total sail force -- over a wide range of existing wind speeds. This is an important change to the wind driven vessel, as for thousands of years sails were sheeted or braced to the hull, and the helmsman then used the rudder (or paddle) to adjust the attack. For instance, when the Master ordered: "Keep her full and by the wind," he was instructing the helmsman alone to maintain a high attack, but below stall, after the sails had been set close hauled to the hull by others in the crew. When the wind shifted and the sails shook at the luffs, the helmsman hardened up, steered the vessel farther off the wind, so as to increase the attack and fill the sails again.
Instead, as the auto rig 20 rotates to follow the shifting wind, or as the helmsman steers the boat, the geometric angle of attack remains fixed. (Except of course when a carrier boom 26 limit line (not shown) constrains the sails to stall, as when running, for instance. FIG. 9)
FIG. 7 shows the arrangement of the typical jib sheet 50, which in this particular case is the No. 3, four-strand sheet. The indicated symbols are defined as follows:
A is the horizontal distance between the axis of forespar 36 and the sheet anchor 51 on mast 24.
B is the horizontal distance between the axis of forespar 36 and the sheet fastening 53 at the leech 52 of jib 30.
H is the vertical distance between the sheet anchor 51 on mast 24 and the sheet fastening 53 on the leech 52 of jib 30, when the foil boom angle is zero.
S is the effective length of the jib sheet 50, that is, the length between the sail fastening 53 and the anchor 51 on mast 24.
f is the foil-boom angle measured in a plane normal to mast 24.
φ is the angle between the inclined forespar 36 and mast 24.
The arrangement shown on FIG. 7 is efficacious because the main sheet 48 and four jib sheets 50 may be controlled with a single tackle or winch to alter equally the mainsail 28 and jib 30 azimuthal angles with respect to the carrier boom, called the foil-boom angles f.
As an example, the distances A, B and H are specified for a sloop rig of 600 square feet, on which certain jib battens 42 and therefore the jib sheet fastenings 53 are located at 0/9, 1/9, 3/9, 5/9, of the vertical span of the jib 30. FIG. 1 shows the general arrangement.
Table I______________________________________Sail Sheets SpecificationSheet φ Strands A B H______________________________________Main 0 3 102.4 in. 162.4 in. 4.0 in.#1 Jib 15.9° 4 125.1 80.2 4.0#2 Jib " 3 128.0 124.0 60.0#3 Jib " 4 96.0 93.0 45.0#4 Jib " 6 64.0 62.0 30.0Main* 0 3 92.6 131.1 4.0______________________________________ Then, df/dS is the same for all five sheets 48 and 50at a given foil boom angle (not for Main*, as explainedhereinafter).______________________________________f 29.0° 43.9° 59.0°df/dS 0.606 0.562 0.577 Degree/Inch______________________________________
That is, the sheet length is increased about 1 inch to increase the foil-boom angles by 0.6 degrees. Or, at the helm, all sheets 48 and 50 are payed out five inches to increase the foil-boom angles by one degree, since the differential multiplication of travel by the blocks of all the sheets 48 and 50 is uniformly three.
The relationship between boom-jib angle and the commanded jib angle of attack is:
Boom-Jib Angle = 41.7° - 0.58 (Jib Attack°) + (20.4°)°/(Jib Attack°) (2)
Equation 2, above, is an approximation of Equation 5, U.S. Pat. No. 3,968,765.
This particular operating characteristic was designed and later measured for a specific rig. It is most difficult to measure the angle of attack, because of the upwash, and said angle is obtained in a roundabout fashion. A similar characteristic may be altered a priori, but only little ex post facto (by providing several seats for the forespar 36 in the carrier boom 26, fore end.)
It is efficacious aerodynamically, and moreover easily practical, to maintain a higher geometric angle of attack on the mainsail 28, compared with the attack on the jib 30. This is called positive decalage, and it reduces interference between the jib 30 (upper wing) and mainsail 28 (lower wing). The upwash on the jib (upper wing) is stronger, and sailors have found that this sail therefore draws more in proportion to its area. That is, due to its juxtaposition, the jib 30 has its average dynamic wind pressure boosted higher than that of the mainsail 28. (Also, there is a modicum of confusion about the so-called slot effect between mainsail and jib. Early airplane wings were built with slots near the leading edge, but this whole idea was abandoned for valid aerodynamic reasons.) The jib 30 stalls first with increasing angle of attack both in the wind tunnel and fullscale, unless the jib attack, geometric of course, is lower than the mainsail's about as follows:
Mainsail Attack = 1.10 (Jib Attack) (3)
The optimum factor in Equation 3 might in fact be higher than 1.10, especially if the aspect ratio of the sails is lower than drawn on FIG. 1. However, the best practical way for a sailor to tune his rig is pragmatically -- by measuring how fast the boat goes, with a systematic tuning procedure (marked sheets).
Along with Equations 2 and 3, the following equations state the applicable geometry:
Wind-Attitude of Boom = Foil-Boom Angle + Attack (4)
Effective * Relative Wind Angle = Wind-Attitude of Boom - Boom-Boat Angle + Leeway (5)
Equations 2, 3, 4 and the required sheet lengths are conveniently expressed in tabular form. Here, the main sheet 48 is located as defined by "Main*" in Table I, and it is this manner of location that maintains the positive decalage at all angles of attack.
TABLE II__________________________________________________________________________Sail Tuning--Auto RigGeom.Geom. Boom- Boom- Wind #2Jib' Main' Jib' Main Attitude Jib Sheet Main SheetAttackAttack Angle Angle Of Boom Length Length__________________________________________________________________________ 3.0' 3.3° 46.8° 46.5° 49.8° 120.8" 95.2" 4.0 4.4 44.5 44.1 48.5 6.0 6.6 41.6 41.0 47.6 9.0 9.9 38.8 37.9 47.812.0 13.2 36.4 35.2 48.415.0 16.5 34.4 32.9 49.418.0 19.8 32.4 30.6 50.4 95.5" 69.9"+15.0'+16.5° -14.4° -15.9° 49.0±1.4° -25.3" -25.3"__________________________________________________________________________ "Boom" above means carrier boom 26. Sheet lengths are for a rig of 600 ft..sup.2
As listed in Table II, the geometric angle of attack is determined on each of the mainsail 28 and jib 30 by properly designing the location of all the sheet anchors 51. The locations of the sheeted jib battens 42 shown on FIG. 1 are at 0/9, 1/9, 3/9, and 5/9 of the vertical span of the jib 30. And the locations of all anchors 51 are defined in Table I. Then, a change in foil-boom angle divided by a corresponding change in sheet length is as desired to maintain the decalage at all angles of attack, even though individual sheets 50 may be displaced a few inches to correct for structural deflections.
By contrast with wind-tunnel tests, it is practically impossible to measure the geometric angle of attack on the full scale foil, what with the fickle wind. See FIG. 10. One can but measure the time-averaged lift and drag on the stationary rig with an untwisted wind. Instead, for accuracy in tuning the sails 28 and 30 on water, the main sheet 48 and No. 2 jib sheet 50 are better set at the dock with the help of a tape rule, as a sailboom angle of 45° or so, and these two sheets are not re-adjusted during subsequent routine tuning under way. The other three sheets 50 and the vang 44 suffice to control the shapes of the sails 28 and 30. This can be done by eye, of course, or by reference to the more unbiased criterion; ratio of water speed to wind speed.
Alternatively, if a sailor wishes to man the main sheet 48 separately from the multiple jib sheets 50 (a large yacht with accurate instruments and careful supervision could profit from this method of control), the mainsheet anchors 51 can easily be re-located on the mainsail boom 34 and carrier boom 26 so as to set the boom-main angle exactly as the boom-jib angle is set. See Table I.
Note that the sheets 48 and 50 have 3 to 6 strands, or different numbers of blocks to multiply their travel below deck to make it possible for all sheets to be operated as a unit, not primarily to multiply force. For only the main sheet of any sizable rig exerts tension requiring mechanical advantage. But when the jib is struck, about 120 feet of 1/8 inch line reeves through the blocks of the six-strand, No. 4 jib sheet 50 in order to let that sail down. The No. 3 and No. 4 jib sheets 50 are then started from the control tackle; the other, more crucial, remain as tuned.
Three of the four jib sheets 50 exert tension on the leech 52 of jibsail 30, though not much. However, the vertical span between the sheeted battens 42 is relatively short, and any localized deflection of the leech 52 is of only minor importance in respect of the general shape of the jib 30.
Note in Table II that the wind-attitude of the carrier boom 26 is 49.0 ± 1.4° over the operating range of attack. The carrier boom 26 is the most reliable wind instrument aboard the boat, for its dead zone is normally shaken out by any wave action at all. There is no need to watch the luffs (unless of course the rig is so badly out of tune that one or the other shakes steadily). Instead, the helmsman watches the boom-boat angle and perhaps the water surface to windward in gentle breezes. Said angle is easily measured with a marked stick and the Cosine Law.
From Equation 5, one may deduce that the effective relative wind angle may be closely approximated if both the carrier boom-boat angle and leeway are known. Measuring the leeway presents some difficulty with a fixed keel boat; where said angle may be as high as 5° or 6° to windward. But after the sailor has calibrated his boat to windward, he may just as well use the angle of carrier boom 26 and the water speed or ratio of water speed to wind speed, as prime information requiring no further processing. The sheets 48 and 50 may require tuning, and the carrier boom supplies the basic information needed to avoid falling off the wind too much on a long board. Table II shows why.
In connection with trimming any sail for sailing to windward, there is a qualitatively different limitation on the boat's windward career, and this is a form of hydrodynamic instability caused by the keel's behavior against a wind too close. For purpose of explanation, one can assume the keel area is elliptical in planform and large enough to assure non-stall operation on any point of sailing however close on the wind. Also one can assume that the keel is rotatable or has a large flap so that the hull may operate with substantially zero leeway. (These simplifying assumptions obviate mathematical complications but are not really needed to arrive at the general conclusion.) Then the minimum operating angle of the relative wind, here equal to the true wind angle since the water speed approaches zero, may be called the Wind Pinch Angle, as follows:
Wind Pinch Angle = ArcTan(.sup.C D/C.sub.L) (Aero) + ArcTan([2(LWL) (f(Re)/Pi).sup.0.5 ]/Keel Vertical Span) (Hydro) (6)
where C D is the total wind drag coefficient of the entire vessel, both parasitic and induced, C L is the lift coefficient of the sails, LWL is the load waterline length, and f(RE) is the dimensionless function of water Reynolds number used to correlate hulls' parasitic water drag, said drag being equal to: f(Re) (LWL 2 ) (Water Speed 2 ) (Water Density)/2g, at zero leeway but not necessaily at zero heel. Keel Vertical Span is the measureable draft from hull to lower tip.
Rating rules limit the keel span, for instance, to about 0.15(LWL). f(Re) averages about 0.0014 for hulls operated at low water speed. Hence, the second term on the right of Equation 6 is ArcTan ((2/0.15) (0.0014/Pi) 0 .5) = ArcTan(0.281) = 15.7°. This is the hydro effect.
The first term on the right of Equation 6 measures the aerodynamic inefficiency of the entire craft, and with care in design, construction and sail tuning, it could be reduced to eight to ten degrees. This is the aero effect. Hence, the sum, the Wind Pinch Angle, is 23° to 26°.
To correct for the varying upwash in the pinch is hopeless without the help of a wind tunnel over a water tank. Suffice it to say that the usual boat decelerates into irons, or cannot accelerate, when the true wind is 25 to 30°, with the result that even skillful helmsmen beating to windward with a relative wind angle varying around 30° are often pinched in because of the shifting wind. See FIG. 10. Water speed plummets with but a few degrees shift in way of a header. So the usual reaction is to bear off too far in order to maintain water speed, at a loss in speed made good. This was also an inherent fault of the speedy clipper ships, still unmatched on the beam reach but evidently not too smart on the long board.
With the automatically rotatable rig 20 working to windward, the first term of Equation 6 is substantially constant at any relative wind angle greater than said first term, which is reliably adjustable over a wide range of drag/lift ratio. (This condition is impossible to achieve with the conventional sloop rig whose lift coefficient depends on the varying angle of the relative wind.) Hence, the automatically rotatable rig 20 may be reliably hove to with any keel, either by carefully clamping the helm 18 off neutral or by setting the rudder automatic controller 124 to hold a course very close on the wind. Again, the boom-boat angle is the operating parameter to set, once the foil-boom angles f are tuned for the prevailing weather. ("Hove to" means here pinched in reliably, not by backing the jib sail.)
In general, these improvements comprise many details in construction and operation directed to maximizing the performance of the automatically rotatable said rig 20.
For instance, while beating to windward in a strong wind, the heel angle and its consequent water resistance may be reduced appreciably by either paying out the jib sheets 50 only a degree or two, or drawing in the main sheet 48 only a degree or two. This increase in positive decalage above that normally tuned in is accompanied by some decrease in total sail force, especially since the air induced drag and resulting heeling force are reduced to a greater proportional extent. However, on the beam reach, instead, excessive decalage does not affect the heel angle to a helpful degree; it simply slows the boat somewhat. For such fine tuning as this, well calibrated instrumentation is particularly useful.
It is indeed possible and practical to adjust automatically the decalage, not only with respect to attack, as in Table II, but also with varying relative wind angle, i.e., with varying course, by using an alternative main sheet arrangement as shown in FIG. 8. The object is to reduce the induced drag when sailing high on the wind. Then, the induced drag and the drag/lift ratio are appreciably reduced with some reduction in total lift and heel. On the other hand, when necessarily sailing lower, the sails 28 and 30 automatically tune themselves to increase the total lift, for then wind drag is considerably less detrimental to the yacht's overall career.
Said alternative sheeting is particularly applicable to catamarans, which by inherent geometry have a broad deck suitable for mounting the blocks 164 and 166 through which the main sheets 48 are rove. A subsidiary advantage is that the after length of the carrier boom 26 is physically eliminated, at the expense of providing doubled main sheets 48, each of which must be located and manned separately to achieve identical operations on both starboard and port tacks. And, as shown, the main sheets 48 are manned separately from the jib sheets 50.
As a typical installation in the size of 600 square feet of sail, assume that the catamaran has a mainsail boom 34 situated four feet above the blocks 164 and 166 mounted on the deck (E = 4 ft.), and that the carrier boom 26 is located 0.7 feet above the same level (G = 0.7 ft.), so that eliminating the after length of the carrier boom 26 is practically a necessity in order to leave space for the crew to operate. On this basis, the lengths and angles depicted on FIG. 8 are chosen:
______________________________________A = 8 feet b = 30°B = 8 feetC = 11 feet n = 90°D = 6.4 feet s = 60° (to locate the single jib block 166)E = 4 feet (height of mainsail boom above blocks 164, 166)G = 0.7 feet (height of carrier boom 26 above blocks 164, 166).M.sup.2 = 4.sup.2 + 8.sup.2 + 8.sup.2 - 2(8)(8)Cos(m) = 144 - 128Cos(m)Oblique length.sup.2 on FIG. 8.J.sup.2 = 0.7.sup.2 + 11.sup.2 + 6.4.sup.2 - 2(11)(6.4)Cos(j) = 162.45 -140.8Cos(j) = Oblique length.sup.2 on FIG. 8.N.sup.2 = 8.sup.2 + 6.4.sup.2 = 104.96 = 10.24.sup.2.Mainsail Arm = (AB/M) Sin(m) = MA.Jib Arm = (CD/J)Sin(j) = JA.______________________________________
The sail arms defined above are effective distances that should balance the turning moments of the two sails 28 and 30, so that the entire rig 20 may rotate to follow the shifting relative wind. (Angle w varies.) Hence these two arms must be close to equal, or the rig 20 must be purposefully unbalanced if they are not equal.
The calculation shown in Table III below is done by first choosing angle m, and from said angle is found the length M. Since M + J is a constant, which along with the jib sheets 50, determines the set angles of attack on the sails, J is next found by difference. And from length J, angle j is computed. A small change in the sum (j + m) is equal to the change in boom-mainsail angle (j + m + n - 180°) as boom-boat angle (j - s) is varied. Said change in (j + m) is the negative of the change in decalage d, provided the jib sheets 50 remain as set while the entire rig 20 rotates on its free bearings 94 and 96 to follow the shifting wind or the maneuvers of the helmsman or both. The magnitude of the change is decalage d is voluntarily adjustable by setting the location of the single jib block 166 shown on FIG. 8, that is by adjusting the length D. Also, as rig 20 is rotated by hand at the dock, this small change in (j + m) is reliably measurable. In mathematical terms, the function of (j + m) with boom-boat angle, or with relative wind angle w, or with course, is adjustable over a wide span and is measurable once set.
TABLE III__________________________________________________________________________m M J J + M j MA JA Decalage__________________________________________________________________________90° 12.00' 6.36' 18.36' 30.00° 5.33' 5.54' 0.3°75 10.53 7.83 " 44.08 5.87 6.26 1.260 8.94 9.42 " 58.43 6.20 6.37 1.945 7.31 11.05 " 73.35 6.19 6.10 1.930 5.76 12.60 " 88.50 5.56 5.59 1.8__________________________________________________________________________
The boom-boat angle is j - 60°, and this varies over the span from - 30° to + 28.5°. Decalage, d = 120.3° - j - m, and the constant = 120.3° is set by means of the jib sheets 50.
Each of the two main sheets 48 has a length of 2J + 2M + N = 47 feet. This long length of line should be relatively stout to limit stretch. For stretch has the effect of increasing the boom-mainsail angle, decreasing the decalage d, during wind puffs. So, increased wind pressure is accompanied by an increase in the effective angle of attack, and this deleterious phenomenon should be held within acceptable limits. On the other hand, stretch of the jib sheets 50 has the effect of increasing the decalage d, thereby lowering the effective angle of attack, and this is as it should be.
As calculated in Table III, the change in decalage d is 1.5° (or 1.6°) when the entire rig 20 rotates through an angle of 58.5°. If it is desired to augment the change in decalage d, the single jib block 166 is set farther from the mast 24; D is increased beyond 6.4 feet. For instance, if D is increased to 6.6 feet (a shift of 2.4 inches) the change in decalage d becomes 3.4° for the same span of rotation of the entire rig 20.
FIG. 9 is a diagram of the positions assumed by the spars of the automatically rotatable rig 20 as the boat circles repeatedly. In order for the boat the change tack on the wind and jibe automatically, as shown, the auto rig 20 must be fitted with a limit stop. This stop permits the rig to rotate freely over a limited span of azimuthal angle. Said stop is designed so that the maximum allowable boom-boat angle as defined earlier is equal to mainsail-boom angle voluntarily set on the rig 20.
The stop may be a limit line set in any convenient location. Usually the best fastening for said line is on the fore length of carrier boom 26, and its anchor is on the centerline of the hull 12 on deck. Since this line is conveniently cleated to the same control tackle as are sheets 48 and 50, it should have the same tuning differential as the sheets, which is shown by study of Table I. In other words, when the mainsail foil-boom angle is changed by plus 1°, the maximum boom-boat angle is also changed by plus 1°. Distances corresponding to A, B, and H of Table I are similarly specified for the limit line. And said line must run freely in its blocks, in order to obviate possible upsets in the angle of attack.
Instead of a limit line, cushioned mechanical stops may be used to limit the free rotation of fig 20. In either case, said stops permit the rig 20 to change course from any tack to any other tack by manning only the helm leaving all the sheets 48 and 50 cleated and the vang 44 set for the average point.
Rig 20 may be tuned by eye as it circles repeatedly with a clamped helm 18 and the stops set.
The directional deviations of a typical sailing wind are shown on FIG. 10. Sometimes the wind deviates much more from its mean direction, at higher average frequency.
Study of many such traces reveals that the massive hull of a sailboat cannot change course rapidly enough to follow the higher frequency deviations. Fortunately these are usually of low amplitude. However, rotatable rig 20, being much less massive, follows the directional deviations more closely, and so the strategy at the helm 18 is appropriately altered to take advantage of heretofore unavailable wind energy that can be converted to forward thrust. This is the subject matter of Patent Number 3,830,183.
The trace shown on FIG. 10 was obtained with a wind vane having low polar inertia and negligible dead zone. This is made clear, as experienced siilors and boat builders are invariably appalled by FIG. 10 and similar traces. Nevertheless, these data, along with reported wind speeds, represent the basic input to the detailed design of the automatically rotatable rig 20.
The automatically rotatable sail rig operates by always balancing the horizontal sail forces, their moments actually, about the vertical axis of the freely rotating step. This balance of moments is written:
______________________________________ Sum of: /LAC.sub.L Sec(n) Cos(a+m+f-n)/.sub.j Ft.sup.3,for instance- Sum of: /EAC.sub.L Sec(n) Cos(a-n)/.sub.j= Sum of: /LAC.sub.L Sec(n) Cos (a+m+f-n)/.sub.z+ Sum of: EAC.sub.L Sec(n) Cos (a-n)/.sub.z+ Sum of: /CAC.sub.M /.sub.j+ Sum of: /CAC.sub.M /.sub.z ** (7) Equation 5 of Patent NO. 3,968,765 is an approximation of this.n = ArcTan (8) Equation 4 of the same patent. (C.sub.D /C.sub.L)______________________________________
The subscript j denotes airfoils whose axes of rotation are located forward of the step on the centerline of the carrier boom, and z aft of the step on the same centerline.
L = distance of the axis of rotation of an airfoil, along the centerline of the carrier boom, from the axis of the step -- always positive in the above equation. For the sloop rig, the single L z = 0, since the axis of rotation coincides with the axis of the step, for the mainsail.
A = planform area of an airfoil, (airplane nomenclature)
C L = lift, or thrust, coefficient of a clean airfoil, a function of camber, attack, aspect ratio, and proximity to other airfoils (airplane nomenclature).
C D = drag coefficient, the sum of parasitic and induced drags, a function of Reynolds number, camber, attack, aspect ratio (the "equivalent monoplane aspect ratio" according to Prandtl), and proximity to other airfoils. (airplane nomenclature)
E = distance of an airfoil's center of air effort from its own axis of rotation -- always positive. At zero attack, this center is at mid-chord. It moves abruptly upstream at low attack to about the quarter point of the chord, where it remains more or less fixed with increasing attack until stall is reached. At angles of attack beyond stall it moves downstream to the midchord again.
C M = pitching moment coefficient, a function of camber, especially, attack, and proximity to other airfoils. (airplane nomenclature)
C = average chord of an individual airfoil. (airplane nomenclature)
a = geometric angle of attack, unperturbated by the upwash, or "angle of attack", or "attack".
m = offset angle of an airfoil's center of effort, off the airfoil's effective plane by reason of camber, usually small.
f = foil-to-boom angle, the angle between the longitudinal centerline of the carrier boom and the effective plane of an airfoil. Since the sail is twisted, the "effective plane" is only a geometric approximation taken at the elevation of the foil's center of air effort.
n = drag angle of an airfoil, a measure of aerodynamic inefficiency. In the case of the auto rig, the drag angle of the entire rig (not of individual foils) is easily measurable.
Angles f, m, and n are always positive in the above equations. Angle a, and thus coefficient C L , could conceivably be negative, but not with conventional cloth sails, in which case a is zero or positive.
At small attack, C L approaches zero and n approaches one-half-Pi, or 90°. Then C L Sec(n) approaches the parasitic drag coefficient since the induced drag approaches zero also.
When the chamber is restrained to be always low, by means of the conventional battens, C M is small and the rig operates stably over a wide range of C L . A range of C L was measured to be 0.2 to 1.5 for a sloop rig of 100 square feet, with stable operation. At lower lift or thrust the sails shook sometimes, because of high-frequency wind deviations in angle.
The principal use of Equations 7 and 8 is in determining f as a function of a, or what foil-to-boom angle to set by hand for a desired said thrust and drag with a trial sail configuration. If said function is not satisfactory, the spars or sails or both must be changed. Such a function is presented earlier as Equation 2.
The objective of the present work is to design the sails 28 and 30 according to the requirements of Equations 7 and 8 and to specify structures that permit the rig 20 to respond to the wind. For five thousand years that we know of, sailors have been trying to do this by trial and error.
To maximize the speed of the rig described, a few simple instruments are useful. The most useful measurement a sailor needs to tune his sails is the ratio of water speed to relative wind speed. An instrumentation system that indicates the ratio is shown on FIG. 11.
A water turbine 126 drives a DC generator 128 in a circuit biased by a flashlight battery 129 and having a fixed resistor 130 and a variable resistor 132. An ammeter 134 reads the current in milliamperes and, in effect, the water speed in knots.
Likewise, an anemometer 136 drives a DC generator 138 in a similar circuit biased by a flashlight battery 139 and having a fixed resistor 140 and a variable resistor 142. An ammeter 144 reads the current in milliamperes and, in effect, the wind speed in knots. The two circuits each utilize a variable calibration resistor 146, 148.
A voltmeter 150 is used to equalize manually the voltage drops across the grounded resistors, thus to give an angular indication of the ratio of the set resistances on a reostat 152. This angle indicates the inverse ratio of the electric currents and the direct ratio of speeds, which is a pragmatic criterion of performance in light to moderate winds.
Instead of manually adjusting the reostat 152 to null the voltage as read by voltmeter 150, a simple servo system (not shown) may be used to turn the reostat 152.
Then, voltmeter 150 is replaced by a high-gain, integrated circuit, operational amplifier (not shown). Output from said amplifier is fed to the bases of a pair of common-emitter power transistors. The boosted current then drives a toy DC motor in either direction. Said motor has its shaft coupled through a gear reducer to the reostat, and the voltage is nulled continuously. Again, the ratio is read off a dial. Such a simple, high-gain servo tends to oscillate a bit about the null point, or the ratio point, but the reading is nevertheless quite accurate if properly calibrated and it is certainly precise.
Automatically rotatable rigs of small size, in the range from 40 to 200 square feet, could indeed operate, through less efficiently, with fewer components than have been described. FIGS. 12 A, B, C, D, E, and F show the constructions of small rigs that have performed well.
FIG. 12 A shows a construction that functions without standing rigging. It used no forestay, backstay, or shrouds. The rotatable mast was stepped in a bearing assembly consisting of a lower spherical thrust bearing and a water-lubricated journal higher up near the carrier boom. The step housing was supported by struts similar to struts 102 shown on FIG. 5. This rig could be assembled in minutes from a rolled-up parcel tied to automobile door handles. Sailing surfboards could use this rig. The hull was a catamaran-surfboard.
FIGS. 12 B and E show a general type of construction useful on sailsleds and sailcars. The sail or sails are relatively limber airplane-type wings, or relatively stiff sails, that operate with low wind twist because of the high speeds attained. Small sailcars carrying 1.5 square feet of said, ballasted on the windward wheel, traveled faster than any sailboat ever sailed or will ever sail, despite the low speed of the low-level wind. Fullscale sailsleds have traveled faster (143 mph?).
FIG. 12 D shows a rig using a mainsail boom welded to a sleeve outside the mast and projecting upward inside the mainsail luff, so that no vang is needed. This particular rig suffered excessive wear on the mast, due to friction by the sleeve, but presumably Teflon bearings could be used to eliminate the wear.
FIG. 12 C shows a structure that ultimately will prove most efficient aerodynamically. Wind tunnel test show that, from the aerodynamic standpoint, the required sail area is best split up into a number of high-aspect-ratio airfoils. What the optimum number is from all viewpoints remains to be determined. The America, for example, carried five airfoils.
FIG. 12 F shows an efficient rig for planing hulls, which can carry stout standing rigging but only a minimum of weight and no instrumentation. Planing hulls are always small and light. A standard aluminum mast section used on this rig is best strengthened by pouring its lower third full of sailboat resin, along with fiber glass mat. For safety, only the ganged jib sheets need to be started in an emergency.
In conclusion is should be said that an automatically rotatable rig must be accompanied by a deep keel, as Equation 6 states. Otherwise the inherent aerodynamic efficiency is lost to hydrodynamic instability close on the wind. This assumes rig 20 is used on water.
Rig 20 may also be used on land and ice, on sailcars and sailsleds.
A sailcar is a vehicle comprising:
a. A said rig,
b. Three wheels or wheeled trucks, any of which are rotatable about vertical axes by means of a tiller or tillers,
c. A cockpit,
d. A frame to hold a), b), and c) together, and
e. Movable ballast placed near any of the wheels or trucks.
A sailsled is a sailcar with the wheels or trucks replaced by runners. | An apparatus for mounting a jibsail and a mainsail on a sloop, the structure including a step assembly bedded to the hull and supporting conventional roller and ball bearings; a mast spreading the mainsail; a generally horizontal boom located close above deck and rotating freely about the step; a forespar rotatable about its own axis and extending from high up on the mast to said boom, spreading the jibsail; and rigging connecting the jib and mainsail with said boom. The spars, sails, and cord rigging are freely rotatable on the bearings as a unit about the step as the wind deviates in direction. The rotatable spar-frame allows the sails to respond directly and accurately to shifting winds without requiring repeated manual adjustments, so that the orientations of the sails with respect to the direction of the apparent wind may be voluntarily set, and once set remain constant while the sails operate below stall, in order, first, to provide maximum thrust with minimum drag for sailing to windward and, second, to provide for automatic going about and jibing and sailing on any possible point by manning only the helm. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a coating composition for metal conductors such as, for example, wires, with improved partial discharge resistance and good mechanical properties.
Three-phase a.c. motors, for example, frequency converter-controlled motors or high voltage asynchronous machines require the use of wire wrappings which satisfy the stringent requirements in respect of thermal endurance and the mechanical properties, mainly the flexural strength of the insulation layer, in order to be able to withstand high voltage loads and pulse-shaped voltage loads without damage.
A further requirement in respect of wire wrappings of electrical equipment is the partial discharge resistance of the wire coatings. Adjacent wire wrappings in particular may be exposed to high voltage loads and pulse-shaped voltage loads. For these purposes, the coatings must exhibit a high partial discharge resistance.
According to WO 96/41 909, within the context of a multi-layer coating for wires, a coating composition is used which comprises a binder and a particulate material, wherein the particulate material may be present in the binder in an amount from 1 wt. % to 65 wt. % and may be metal oxides, for example, titanium dioxide, zirconium oxide, zinc oxide, iron oxide or aluminas. The particulate material has no chemical reactivity whatsoever. During the manufacture of such coated wires, preliminary extension may occur which leads to destruction of the coating layers and hence to a drastic decrease in the partial discharge resistance.
Similar compositions with comparable properties are described in DE-A 198 32 186.
According to DE-A 196 50 288, at least one of the electrically insulating coating layers contains an organically modified silica (hetero)polycondensate prepared by hydrolytic condensation of compounds of silicon and optionally of boron, aluminum, phosphorus, tin, lead, the transition metals, lanthanides and actinides, the monomer units being composed essentially of inorganic and organic components which are substantially crosslinked. The coatings obtained have good thermal shock resistance and surface quality. Good flexibilities are not obtained.
In the as yet unpublished German patent application 198 11 333.1 of the same Applicant, a partial discharge-resistant coating is proposed which, in addition to binders, also contains element-organic compounds, particularly of silicon, germanium titanium and zirconium. The organic radicals used are C1 to C20 alkyl radicals or chelating radicals, alkylamine, alkanolamine, acetate, citrate, lactate and/or acetonate radicals. The organometallic compounds used are monomeric compounds.
In the as yet unpublished German application 198 41 977.5, inorganic-organic hybrid polymers are used. The transition from monomeric element-organic compounds to element-organic hybrid polymers leads to a further improvement in the partial discharge resistance of the coating layer in question.
For stringent requirements, particularly for three-phase a.c. motors in continuous operation and frequency converter-controlled motors, the partial discharge resistance obtained is still in need of improvement.
The object of the present invention is, therefore, to provide a coating composition for metal conductors, particularly wires, the partial discharge resistance of which is increased compared with the solutions of the prior art, particularly when the coated wire is extended. Moreover, the applicability of the coating composition as a single-layer application or as a coating in a multi-layer application, and the surface quality and flexibility of the coating should be improved.
SUMMARY OF THE INVENTION
It has become apparent that is object may be achieved by a coating composition which contains
A) 1 wt. % to 60 wt. % of one or more reactive nanomers based on an element-oxygen network with elements of the series comprising aluminium, tin, boron, germanium, gallium, lead, the transition metals and the lanthanides and actinides, particularly of the series comprising silicon, titanium, zinc, yttrium, cerium, vanadium, hafnium, zirconium, nickel and/or tantalum, B) 0 wt. % to 90 wt. % of one or more conventional binders, and C) 0 wt. % to 95 wt. % of one or more conventional additives, solvents, pigments and/or filters.
wherein the reactive nanomer of component A is based on the element-oxygen network, on the surface of which reactive functions R 1 and optionally non-reactive and/or partially reactive functions R 2 and R 3 are bound by way of the oxygen of the network,
R 1 being contained in an amount up to 98 wt. %, preferably up to 40 wt. %, particularly preferably up to 30 wt. %, R 2 and R 3 in an amount from 0 wt. % to 97 wt. %, preferably 0 wt. % to 40 wt. %, particularly preferably 0 wt. % to 10 wt. % in the nanomer according to the invention, in which
R 1 represents radicals of the metal acid esters such as, e.g., OTi(OR 4 ) 3 , OZr(OR 4 ) 3 , OSi(OR 4 ) 3 , OSi(R 4 ) 3 ; OHf(OR 4 ) 3 ; NCO; urethane, epoxide, epoxy, carboxylic acid anhydride; C═C double bond systems such as, e.g., methacrylate, acrylate; OH; alcohols bound by way of oxygen, e.g., bis(1-hydroxymethylpropane)-1-methylolate, 2,2-bis-(hydroxymethyl)-1-propanol-3-propanolate, 2-hydroxypropan-1-ol-3-olate, esters, ethers, e.g., 2-hydroxyethanolate, C 2 H 4 OH, diethylene glycolate, C 2 H 4 OC 2 H 4 OH, triethylene glycolate, C 2 H 4 OC 2 H 4 OC 2 H 4 OH; chelating agents, e.g., aminotriethanolate, aminodiethanolate, acetyl acetonate, ethyl acetoacetate, lactate; COOH; NH 2 ; NHR 4 ; and/or esters, reactive resin components such as, e.g., OH—, SH—, COOH—, NCO—, capped NCO—, NH 2 —, epoxy, carboxylic acid anhydride, C═C, metal acid esters, silane-containing polyurethanes, polyesters, poly(THEIC) esters, poly(THEIC)ester imides, polyamide imides, polyamides, polysiloxanes, polysulfides, polyvinyl formals, polymers, e.g., polyacrylates. R 2 represents radicals of aromatic compounds, e.g., phenyl, cresyl, nonylphenyl, aliphatic compounds, e.g., branched, linear, saturated, unsaturated alkyl radicals C1 to C30, fatty acid derivatives; linear or branched esters and/or ethers, R 3 represents resin radicals, e.g., polyurethane, polyester, polyester imide, THEIC-polyester imide, polytitanic ester resins and derivatives thereof; polysiloxane resins with organic derivatives; polysulfide, polyamide, polyamide imide, polyvinyl formal resins, and/or polymers such as, e.g., polyacrylates, polyhydrantoins, polybenzimidazoles, and R 4 represents radicals of acrylate, phenol, melamine, polyurethane, polyester, polyester imide, polysulfide, epoxide, polyamide, polyvinyl formal resins; aromatic compounds, e.g., phenyl, cresyl, nonylphenyl; aliphatic compounds, e.g., branched, linear, saturated, unsaturated alkyl radicals with C1 to C30; esters; ethers, e.g., methyl glycolate, methyl diglycolate, ethyl glycolate, butyl diglycolate, diethylene glycolate, triethylene glycolate; alcoholates, e.g., 1-hydroxymethyl-propane-1,1-dimethylolate, 2,2-bis-(hydroxymethyl)-1,3-propane diolate, 2-hydroxypropane-1,3-diolate, ethylene glycolate, neopentyl glycolate, hexane diolate, butane diolate; fats, e.g., castor oil and/or chelating agents, e.g., aminotriethanolate, aminodiethanolate, acetyl acetonate, ethyl acetonacetate, lactate.
DETAILED DESCRIPTION OF THE INVENTION
The nanomer of component A) according to the invention is composed of an element-oxygen network on the surface of which the reactive functions R 1 and optionally non-reactive or partially reactive functions R 2 and R 3 are bound by way of the oxygen of the network. The nanomers with the described functions R 1 to R 4 are particles whose average radius is in the range from 1 nm to 300 nm, preferably in a range from 2 mm to 80 nm, particularly preferably in a range from 4 nm to 50 nm.
The nanomer according to the invention is contained in an amount from 1 wt. % to 60 wt. %, preferably 5 wt. % to 30 wt. %, in the coating composition.
The element-oxygen network of the nanomer according to the invention contains the above-mentioned elements which are bound by way of oxygen. The network may contain one or more identical or different elements in a regular and/or irregular sequence bound to the oxygen in each case.
The inorganic network preferably contains the elements of the series comprising titanium, silicon, aluminium and/or zirconium.
For example, compounds based on the products Nyacol DP 5480 from Nyacol Products Inc. may be used as component A).
Optionally, organic units such as, e.g., radical of aromatic compounds, aliphatic compounds, esters, ethers, alcoholates, fats and chelating agents, imides, amides, acrylates may also be implemented in the network of the nanomer according to the invention.
The use of OTi(OR 4 ) 3 , OZr(OR 4 ) 3 , acetyl acetonate, 2-hydroxyethanolate, diethylene glycolate, OH as function R 1 is preferred.
The use of radicals of polyester imides and/or THEIC polyester imide resins as function R 3 is preferred.
The use of acrylate resin, aminotriethanolate, acetyl acetonate, polyurethane resin and butyl diglycolate as function R 4 is preferred.
The radicals R 1 to R 4 in each case may be the same or different.
Examples of the nanomers of component A) which may be used according to the invention are shown in FIGS. 1 to 4.
FIG. 1 shows a nanomer which has OH groups as reactive function R 1 . It is able, by way of these OH functions, to react with the corresponding functions of, for example, esters, carboxylic acids, isocyanates, epoxides, anhydrides and the like.
The reactivity of the nanomer according to FIG. 2 is determined by means of the OH functions as R 1 and the various resin sequences polyester imide and THEIC polyester imide as examples of R 3 .
The nanomers according to FIGS. 3 and 4 are provided with ortho-titanic acid ester functions as reactive component R 1 . The nanomer according to FIG. 4 also has a THEIC polyester imide as polymer fragment R 3 .
The organic radicals Z stand for isopropyl, butyl, butyldiglycol, triethanolamine, acetyl acetone, polyamide imide, polyurethane and polyester imide groups and aminotriethanolate and epoxide groups, particularly selected from the group comprising R 4 .
In addition to the nanomers of component A) used according to the invention, monomeric and/or polymeric element-organic compounds may be contained in the coating composition. Examples of polymeric element-organic compounds include inorganic-organic hybrid polymers as mentioned, for example, in the as yet unpublished German patent application 198 41 977.5. Examples of monomeric element-organic compounds include ortho-titanic acid esters and/or ortho-zirconic acid esters such as, for example, nonyl, cetyl, stearyl, triethanolamine, diethanolamine, acetyl acetone, acetonacetic acid esters, tetra-isopropyl, cresyl, tetrabutyl titanate or zirconate, and titanium tetralactate, hafnium and silicon compounds, e.g., hafnium tetrabutoxide and tetraethyl silicate and/or various silicone resins.
Additional polymeric and/or monomeric element-organic compounds of this kind may be contained in the composition according to the invention in an amount from 0 wt. % to 70 wt. %.
The preparation of component A) may take place by conventional hydrolysis and condensation reactions of appropriate element-organic or element-halogen compounds in the presence of organic reactants corresponding to functions R 1 to R 3 .
Similarly, organic resin and/or nanomer components may be reacted with corresponding element-oxide compounds to the corresponding nanomers.
Such methods of preparation are known to the skilled person, see, e.g., Ralph K. Iler, John Wiley and Sons, “The Chemistry of Silica”, New York, p. 312 ff, 1979.
The composition according to the invention may contain one or more binders as component B) of the kind known and customary in the wire coating sector. Examples include polyesters, polyester imides, polyamides, polyamide imides, THEIC polyester imides, polytitanic acid ester-THEIC ester imides, phenolic resins, melamine resins, polymethacrylamides, polyimides, polybismaleinimides, polyether imides, polybenzoxazine diones, polyhydantoins, polyfinyl formals, polyvinyl acetals and/or capped isocyanates. Further binders also include, e.g., epoxides and acrylate resins.
The use of polyesters and/or polyester imides, particularly THEIC-polyester imides is preferred.
Polyesters used may include, for example, those that are well known for wire coating. These may also be polyesters with heterocyclic, nitrogen-containing rings, for example, polyesters with imide and hydantoin and benzimidazole structures condensed into the molecule.
The polyesters include, in particular, condensation products of polyvalent, aliphatic, aromatic and/or cycloaliphatic carboxylic acids and anhydrides thereof, polyhydric alcohols, in the case of imide-containing polyester amino group-containing compounds optionally with a proportion of monofunctional compounds, for example, monohydric alcohols.
The saturated polyester imides are based preferably on terephthalic acid polyesters which, in addition to diols, may also contain polyols and, as an additional dicarboxylic acid component, a reaction product of diaminodiphenylmethane and trimellitic anhydride.
Moreover, unsaturated polyester resins and/or polyester imides may also be used. The use of unsaturated polyesters and/or polyester imides is preferred.
Moreover, polyamides may be used as component B), for example, thermoplastic polyamides and polyamide imides of the kind prepared from, e.g., trimellitic anhydride and isocyanotodiphenyl methane. Examples of phenolic resins and/or polyvinyl formals which may be used as component B) include novolaks obtainable by polycondensation of phenols and aldehydes, or polyvinyl formals obtainable from polyvinyl alcohols and aldehydes and/or ketones. Capped isocyanates may also be used as component B), such as, e.g., adducts of polyols, amines, CH-acid compounds (e.g., acetoacetic acid esters, malonic ester i.a.) and diisocyanates, cresols and phenols usually being used as capping agents.
The composition may contain pigments and/or fillers as component C), for example, colour-imparting inorganic and/or organic pigments such as titanium dioxide or carbon black, and special-effect pigments such as metal flake pigments and/or pearlescent pigments. Examples of additives contained include conventional pain additives, for example, extenders, plasticising components, accelerators (e.g., metal salts, substituted amines), initiators (e.g., photoinitiators, initiators which respond to heat), stabilisers (e.g., hydroquinones, quinones, alkyl phenols, alkyl phenol ethers), defoamers, levelling agents.
In order to increase solubility, the compositions may contain organic solvents such as, for example, aromatic hydrocarbons, N-methylpyrrolidone, cresols, phenols, xylenols, styrenes, vinyl toluene, methyl acrylates. The compositions according to the invention may contain, for example, 30 wt. % to 95 wt. % of organic solvents.
Optionally, the composition according to the invention may also be mixed with conventional wire coatings and then applied by conventional methods.
The application of the composition according to the invention may take place by conventional methods irrespective of the type and diameter of the wire used. The wire may be coated directly with the composition according to the invention and then stored in an oven. Coating and stoving may optionally take place several times in succession. The ovens may be arranged horizontally or vertically, the coating conditions such as duration and number of coatings, stoving temperature, coating speed depending on the nature of the wire to be coated. For example, the coating temperatures may be in the range from room temperature to 400° C. Moreover, ambient temperatures above 400° C., for example, up to 800° C. and above may also be possible during coating without any discernable deterioration in the quality of the coating according to the invention.
During the stoving process, the components of the composition according to the invention, particularly component A) and component B) may undergo a chemical reaction with one another. Depending on the chemical nature of components A) and B), various chemical reactions are possible, for example, transesterification reactions, polymerisation reactions, addition reactions, condensation reactions. According to the preferred use of components A) and B), condensation reactions may take place preferentially.
The use of the composition according to the invention may take place irrespective of the nature and diameter of the wire; for example, wires with a diameter from 5 μm to 6 mm may be coated. Suitable wires include conventional metal conductors, for example, of copper, aluminium, zinc, iron, gold, silver or alloys thereof.
The coating composition according to the invention may be contained as a constituent of a multi-layer according of the wire. This multi-layer coating may contain at least one coating composition according to the invention.
According to the invention, the wires may be coated with or without coatings already present. Existing coatings may include, for example, insulation coatings and flame retardant coatings. In such cases, the layer thickness of the coating according to the invention may differ considerably.
It is also possible to undertake further coatings by way of the coating according to the invention, for example, further insulation coatings. Such coatings may also be used, e.g., as a top coat for improved mechanical protection and for the creation of desired surface properties and for smoothing. For example, compositions based on polyamides, polyamide imides and polyimides are particularly suitable as top coats.
More particularly, the composition according to the invention is also suitable as a one-coat application.
According to the invention, the composition may be applied in conventional layer thicknesses. It is also possible to apply thin layers without affecting the partial discharge resistance obtained according to the invention, and the adhesion, strength and extensibility of the coatings. The dry layer thickness may vary in accordance with the standardised values for thin and thick wires.
The coatings obtained with the composition according to the invention permit an increased partial discharge resistance of the coating compared with the compositions known hitherto, as a result of which continuous loading under the effect of high voltages, particularly pulse-shaped voltages, becomes possible. They are characterised by a high continuous loading capability and a long service life compared with the coatings based on monomeric and/or polymeric element-organic compounds alone. The partial discharge resistance of the coated wires may be increase so that these are particularly suitable for use with high voltage loads and loads of pulse-shaped high voltages.
The invention is illustrated on the basis of the examples below:
Preparation of a Wire Coating According to the Prior Art
Example 1a (comparison)
261.2 g of tris-(2-hydroxyethyl)-isocyanurate (THEIC), 93.2 g of ethylene glycol, 194.2 g of dimethyl terephthalate (DMT) and 0.5 g of zinc acetate were heated to 210° C. within a period of 4 hours in a 2 liter three-necked flask with stirrer, thermometer and distillation unit. 60 g of methanol were distilled. After cooling to 150° C., 192.1 g of trimellitic anhydride (TMA) and 99.0 g of methylene dianiline (DADM) were added. The mixture was heated with stirring to 220° C. within a period of 3 hours and kept at this temperature for a further 3 hours. 33 g of water were distilled. The mixture was then cooled to 180° C. and 500 g of cresol were added.
With further stirring, a ready to use formulation of the resin solution present was prepared with 882.0 g of cresol, 273.0 g of Solvesso 100, 100.0 g of xylene, 9.0 g of a commercial phenolic resin A, 45.0 g of a commercial phenolic resin B and 18.0 g of ortho-titanic acid-tetrabutylester.
The resulting wire coating had a solids contents of 31.3% and a viscosity of 410 mPas.
Example 1b (comparison)
140 g of a particulate SiO 2 material according to WO 96/41 909 and 320 g of cresol were added to 1800 g of the wire coating according to Example 1a and stirred for 60 minutes. A coating dispersion with a solids content of 30.3% and a viscosity of 530 mPas was obtained.
Preparation of Wire Coatings According to the Invention
Example 2
200 g of “Nyacol DP5480” (Si—O nanomer with OH functions, 30% in ethylene glycol, nanomer radius: 25 nm, from Nycol Products Inc.) were added with vigorous stirring to 1800 g of the wire coating according to Example 1a and stirred for 60 minutes. A coating dispersion with a solids content of 30.9% and a viscosity of 390 mPas was obtained.
Example 3
400 g of “Nyacol DP 5480” were added with vigorous stirring to 1600 g of the wire coating according to Example 1 a and stirred for 60 minutes. A coating dispersion with a solids content of 30.6% and a viscosity of 370 mPas was obtained.
Example 4
In a 2 liter three-necked flask with stirrer, thermometer and distillation unit, 130.5 g of tris-(2-hydroxyethyl)-isocyanurate (THEIC), 62.0 g of ethylene glycol, 194.2 g of dimethyl terephthalate (DMT) were mixed thoroughly with 180.0 g of an OH-functional Si—O nanomer (average radius: 25 nm) prepared in the manner described by Ralph K. Iller, loc. cit., at 70° C. to 80° C. with vigorous stirring and then heated with 0.5 g of zinc acetate to 210° C. within a period of 4 hours. 60 g of methanol were distilled. After cooling to 150° C., 192.1 g of trimellitic anhydride (TMA) and 99.0 g of methylene dianiline (DADM) were added. The mixture was heated to 220° C. within a period of 3 hours, with stirring, and kept at this temperature for a further 3 hours. 33 g of water were distilled. The mixture was then cooled to 180° C. and 500.0 g of cresol were added.
With further stirring, a ready to use formulation of the resin solution present was prepared with 900.0 g of cresol, 284.5 g of Solvesso 100, 100.0 g of xylene, 9.2 g of a commercial phenolic resin A, 46.2 g of a commercial phenolic resin B and 18.4 g of ortho-titanic acid-tetrabutylester.
The resulting wire coating had a solids content of 30.8% and a viscosity of 380 mPas.
Example 5
In a 2 liter three-necked flask with stirrer, thermometer and distillation unit, 261.2 g of tris-(2-hydroxyethyl)-isocyanurate (THEIC), 93.2 g of ethylene glycol, 194.2 g of dimethyl terephthalate (DMT) and 0.5 g of zinc acetate were heated to 210° C. within a period of 4 hours. 60 g of methanol were distilled. After cooling to 150° C., 192.1 g of trimellitic anhydride (TMA) and 99.0 g of methylene dianiline (DADM) were added. The mixture was heating to 220° C. within a period of 3 hours, with stirring, and kept at this temperature for a further 3 hours. 33 g of water were distilled. The mixture was then cooled to 180° C. and 500 g of cresol were added. 45.0 g of ortho-titanic acid-tetra-isopropyl ester were added at 60° C. to 80° C. and, with vigorous stirring, 190.0 g of an OH-functional Al—O—Si—O nanomer (average radius: 20 nm) prepared in the manner described by Ralph K. Iler, loc. cit., and heated to 205° C. within a period of 5 hours, and 38.2 of isopropanol were distilled. After cooling and with further stirring, a ready to use formulation of the resin solution present was prepared with 1100.0 g of cresol, 355.0 g of Solvesso 100, 129.0 g of xylene, 11.0 g of a commercial phenolic resin A, 50.0 g of a commercial phenolic resin B.
The resulting wire coating had a solids content of 30.5% and a viscosity of 370 mPas.
Tests:
Solids content 1 g, 1 h, 180° C. [%]. DIN EN ISO 3251
Viscosity at 25° C. [mPas] or [Pas] DIN 53015
Application
Copper wires with a bare wire thickness of 0.3 mm were coated on a conventional wire coating plant with the wire coatings described according to Examples 2 to 5 and Comparison Examples 1a and 1b (single-layer coating). The resulting layer thickness was 18 μm.
TABLE 1
Technical data of the coated copper wires (according to DIN 46453 and DIN EN 60851)
Comparison
Comparison
Example 1a
Example 1b
Ex. 2
Ex. 3
Ex. 4
Ex. 5
Softening Point
394° C.
396
402° C.
404° C.
357° C.
402° C.
Thermal
220° C.
220° C.
220° C.
220° C.
220° C.
220° C.
shock l × d
Adhesion and
25%
10%
20%
15%
20%
15%
extensibility during
wrapping l × d
Pencil hardness
3-4 H
4-5 H
6-7 H
6-7 H
6-7 H
6-7 H
Paintability
Satisfactory
Satisfactory
Satis.
Satis.
Satis.
Satis.
Service life on
0.8 h
>1000 h
>1000 h
>1000 h
>1000 h
>1000 h
converter*
Service life on
0.5 h
390
80 h
420 h
480 h
430 h
converter*
With 5% pre-
0.3 h
21 h
70 h
430 h
490 h
410 h
extension of
coated wire
With 10% pre-
02 h
13 h
60 h
430 h
500 h
430 h
extension of
coated wire
430 h *frequency converter from Siemens: Simovert P 6SE2103-3AA01
Output: 2.8 kVA, cycle frequency: 10 kHz | An electrically conductive wire coated with a curable coating composition that forms a cured coating having a high partial discharge resitance and good mechanical properties. A process for coating an electrically conductive wire with a curable coating composition and curing the coating composition to form a coating having high partial discharge resistance and good mechanical properties. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to toilet cleaning devices which may be concealed within the flush tank of a toilet, and more particularly to a foldable toilet plunger device which may be concealed and attached to the interior surface of a toilet.
BACKGROUND OF THE INVENTION
[0002] Toilet plungers and other cleaning devices have long been used to unblock and clean toilet drains. It is preferable to store such devices out of sight, since they are generally unsightly and unsanitary, but such devices are often difficult to store because of the limited amount of space in most bathrooms. Furthermore, the means of storage should securely support the cleaning devices and allow for drainage, yet allow them to be readily available when needed to clean or remove blockages in the drains.
[0003] Earlier efforts have attempted to respond to the storage and convenience-of-use problems, providing toilet plunger covers and/or combination toilet plunger covers and toilet plungers. For example, in U.S. Pat. No. 5,114,006 to Wilk, and U.S. Pat. Nos. 5,335,374 and 5,305,880 to Wilk et al., the toilet plunger housing is part of the toilet plunger. The Wilk ('006) combination toilet plunger and housing device has a housing with a slotted base which rests directly on the floor, wherein the plunger cup rests upon the slots when the plunger is in storage, and the same slots are used for grasping of the housing when the plunger is extended for use. Other embodiments of Wilk ('006) disclose the plunger cup resting on a removable base plate when the plunger is in a storage position. The '374 and '880 patents further expand upon this basic concept.
[0004] More recently, in U.S. Pat. No. 5,958,150 by Borger et al. disclosed a separate storage device which can be opened and closed without being manipulated directly by the user. The storage device also serves to partially conceal the plunger when closed and allows the plunger to drain while sitting in the device. Both the Borger and Wilk devices are stand-alone assemblies for housing the plunger apart from the toilet.
[0005] U.S. Pat. No. 2,701,702 by Deiderich, on the other hand, provides an accessory for use within a toilet flush tank which supplies deodorant or disinfectant and may also support a toilet brush. The accessory is preferably a metal wire apparatus which is supported by the overflow pipe. Thus use of toilet plungers is not disclosed in the '702 patent.
[0006] Thus, while there has been substantial effort in the design of bathroom accessory storage devices for toilet plungers and other cleaning devices, the art has not adequately responded to date with the introduction of a means for storing a toilet plunger or other cleaning device which securely stores the toilet plunger or other cleaning device in a concealed fashion that allows for drainage and ready access, while not occupying additional scarce bathroom space or presenting an unattractive visage. The present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
[0007] The concealed toilet cleaning system of the present invention provides a system for concealing and storing a toilet plunger within a toilet flush tank to allow for drainage and ready access to the plunger without occupying additional space within the bathroom or risking unsanitary and unsightly exposure to the toilet plunger when the toilet plunger is not in use. Furthermore, the present invention provides a toilet plunger device which can be more readily stored within a toilet flush tank. Additionally, the cleaning system of the present invention provides a method of storing and using a concealed toilet plunger or toilet brush.
[0008] Generally a holder is attached to the interior of the toilet flush tank in order to secure the toilet plunger out of sight within the toilet flush tank. The holder retains the plunger or other cleaning device securely so that it does not detach and drop into the toilet flush tank. Preferably, this holder is secured to the cover of the flush tank. Furthermore, in one embodiment, the toilet plunger is fashioned to include a pivot point behind the plunger cup to allow the toilet plunger to be folded so that it is more planar and can be more readily stored close to the surface of the interior of the toilet flush tank. The holder within the toilet flush tank can also be used to secure and conceal other toilet cleaning devices (ex. a toilet brush).
[0009] The present invention allows the toilet plunger to be concealed within the flush tank of a typical household toilet, thus allowing any household toilet to be readily converted into a storage device. Through use of a folding toilet plunger, the plunger can be much more readily stored within the toilet flush tank since it less bulky when folded. In particular, when folded it is much more planar and therefore adapted to be closely positioned to the toilet flush tank cover. In addition to preventing unsightly exposure to the toilet plunger, storage within the toilet flush tank is also more sanitary as it prevents contamination of the bathroom by waste material which may accumulate on the plunger cup. Storage within the toilet flush tank also facilitates the drying of the toilet plunger by allowing residual moisture to drain into the lower portion of the toilet flush tank.
[0010] 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 design of other structures 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above and other objects and aspects of the invention will be apparent from the description of embodiments illustrated by the following accompanying drawings:
[0012] FIG. 1 is a perspective view of a toilet flush tank where the cover has been lifted to reveal an attached toilet plunger; and
[0013] FIG. 2 is a perspective view of a toilet plunger with an elongated handle and pivoting plunger cup.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present invention relates to a concealed toilet cleaning system. Generally, the cleaning system of the present invention includes a toilet cleaning device and a holder 16 for releasably securing the toilet cleaning device to an interior surface of a toilet flush tank 12 . The toilet cleaning device of the present invention normally comprises a handle 24 and a cleaning attachment, such as a plunger cup 26 or a toilet brush (not shown).
[0015] A concealable toilet plunger storage system in accordance with an embodiment of the present invention will now be described with reference to FIGS. 1 and 2 . Referring to FIG. 1 , a conventional toilet 10 is shown, focusing on the upper toilet flush tank 12 . Both components are typically made of porcelain, though many other materials with similar properties can be used. The toilet flush tank contains the water reservoir and apparatus necessary to operate the toilet. Toilet flush tanks are typically provided with a toilet flush tank cover 14 which enables easy access to the toilet flush tank for maintenance or other purposes.
[0016] An embodiment of the toilet plunger 20 of the present invention is shown in FIG. 1 secured to the bottom surface of the toilet flush tank cover 14 . While it is preferable to secure the toilet plunger to this surface, as this surface provides the most ready access, the use of other surfaces within the toilet flush tank for mounting the toilet plunger 20 are also envisioned, as other surfaces will allow the toilet plunger 20 to be securely stored in an inconspicuous location while allowing drainage and satisfying various other criteria. The typical toilet flush tank 12 contains a flush mechanism and a float device (not shown), which present potential obstacles to the toilet plunger 20 . Thus, it is most preferable to position the toilet plunger 20 so that the plunger cup 26 is positioned over the float device, as there is typically more space available here than over the flush mechanism. Toilets that have anti-siphon ballcock devices rather than a float device will generally have a greater amount of space. When less room is available for the toilet plunger 20 , a light-duty 4″ plunger cup size can be used. As will be described below, the plunger is preferably capable of folding in order to take up less space within the toilet flush tank.
[0017] A holder 16 is used to secure the toilet plunger 20 to whatever portion of the toilet flush tank 12 surface is chosen. A wide variety of devices can serve as the holder 16 ; all that is necessary is to be able to attach the holder to the surface of the toilet and then use it to releasably grip the toilet plunger so that it can be positioned within the flush tank but withdrawn for use. The holder may be secured to the surface of the toilet flush tank 12 or the toilet flush tank cover 14 using a variety of adhesives, or other attachment means such as clamps, bolts, or screws Alternately, the holder 16 may be integrated into the surface of the flush tank 12 or flush tank cover 14 at the time of manufacture. In one embodiment, a Velcro® fastener with an adhesive backing may be used, as this allows the holder to be repositioned as needed. Preferably, the holder grips the handle of the plunger using friction and tension. There are a variety of hardware clips, such as roller jaw clips, that can be used to hold the toilet plunger 20 . A preferred holder 16 is a broom clip composed of a semi-rigid plastic or metal.
[0018] Referring to FIG. 2 , the toilet plunger 20 can be of a conventional type and is comprised of an elastomeric or resilient plunger cup 26 and an elongated handle 24 having one end attached to or inserted into cup 26 . As previously suggested, the cup 26 is made of an elastomeric or resilient material. Suitable cup materials include, but are not limited to, rubber, neoprene or any elastic polymer. A conventional plunger typically has a 6″ plunger cup and 20″ handle. However, any size cup or handle that can fit within the toilet tank can be utilized in the present invention. The handle 24 is preferably an elongated cylinder or rod, but many other shapes that transmit force and distance the user from the working cup 26 (i.e., function as a handle) can be used. The handle is preferably composed of a rigid material such as acrylic plastic which resists damage from moisture within the flush tank. Other suitable handle materials are metal, fiberglass, or water-resistant wood. Preferably, the handle 24 attaches to the cup 26 by means of a hinge 28 which allows the cup 26 to pivot so that the plane defined by cup 26 is parallel rather than perpendicular to the line formed by the handle 24 . In an alternate embodiment, the hinge 28 may include a locking mechanism to prevent the cup 26 from wobbling while being used. Once folded, the toilet plunger 20 will take up much less space within the toilet flush tank 12 . It is also preferable to sheath the cylindrical handle 24 in a elastomeric or rubber-like grip material 22 which makes it easier to securely hold the toilet plunger. In another embodiment, the handle of the toilet plunger 20 is designed so that it can be collapsed to reduce its length. For example, the plunger handle 24 could be made of several overlapping cylinders capable of telescoping into the outer cylinder for storage within the flush tank 12 .
[0019] To use the toilet plunger 20 , the toilet flush tank cover 14 is first lifted to reveal the toilet plunger 20 . The plunger 20 is then removed from its holder 16 , unfolded, and used to unblock the toilet. After use, the toilet plunger 20 is refolded and secured back to the holder 16 and the toilet flush tank cover 14 is replaced on the toilet flush tank 12 . A label, preferably one with a logo and made up of transparent plastic, can be used to designate the toilet as one with a concealed plunger, in order to alert a potential user to the plunger's presence.
[0020] Although the preferred embodiments of the invention have-been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | The present invention relates to a system for concealing a cleaning device such as a toilet plunger within a toilet flush tank. A modified toilet plunger has been designed to include a hinge so that the plunger cup can pivot on the end of the plunger handle, thereby taking up less space. The folded toilet plunger is secured to the inside of the toilet flush tank by a holder, preferably on the toilet flush tank cover, so that the toilet plunger is readily accessible yet out of sight and will drain into the toilet flush tank after use. | 4 |
TECHNICAL FIELD
The present invention relates to the field of manufacturing semiconductor devices and, more particularly, to an improved salicide process of forming metal silicide contacts.
BACKGROUND OF THE INVENTION
An important aim of ongoing research in the semiconductor industry is the reduction in the dimensions of the devices used in integrated circuits. Planar transistors, such as metal oxide semiconductor (MOS) transistors, are particularly suited for use in high-density integrated circuits. As the size of the MOS transistors and other active devices decreases, the dimensions of the source/drain regions and gate electrodes, and the channel region of each device, decrease correspondingly.
The design of ever-smaller planar transistors with short channel lengths makes it necessary to provide very shallow source/drain junctions. Shallow junctions are necessary to avoid lateral diffusion of implanted dopants into the channel, since such a diffusion disadvantageously contributes to leakage currents and poor breakdown performance. Shallow source/drain junctions, for example on the order of 1.000 Å or less thick are generally required for acceptable performance in short channel devices.
Metal silicide contacts are typically used to provide low resistance contacts to source/drain regions and gate electrodes. The metal silicide contacts are conventionally formed by depositing a conductive metal, such as titanium, cobalt, tungsten, or nickel, on the source/drain regions and gate electrodes by physical vapor deposition (PVD), e.g. sputtering or evaporation; or by a chemical vapor deposition (CVD) technique. Subsequently, heating is performed to react the metal with underlying silicon to form a metal silicide layer on the source/drain regions and gate electrodes. The metal silicide has a substantially lower sheet resistance than the silicon to which it is bonded. Selective etching is then conducted to remove unreacted metal from the non-silicided areas, such as the dielectric sidewall spacers. Thus, the silicide regions are aligned only on the electrically conductive areas. This self-aligned silicide process is generally referred to as the “salicide” process.
A portion of a typical semiconductor device 40 is schematically illustrated in FIG. 1 A and comprises a silicon-containing substrate 4 with source/drain 30 regions formed therein. Gate oxide 10 and gate electrode 12 are formed on the silicon-containing substrate 4 . Sidewall spacers 14 are formed on opposing side surfaces 13 of gate electrode 12 . Sidewall spacers 14 typically comprise silicon based insulators, such as silicon nitride, silicon oxide, or silicon carbide. The sidewall spacers 14 mask the side surfaces 13 of the gate 12 w hen metal layer 22 is deposited, thereby preventing silicide from forming on the gate electrode side surfaces 13 .
After metal layer 22 is deposited. heating is conducted at a temperature sufficient to react the metal with underlying silicon in the gate electrode 12 and substrate surface 5 to form conductive metal silicide contacts 24 (FIG. 1 B). After the metal silicide contacts 24 are formed, the unreacted metal 22 is removed by etching, as with a wet etchant, e.g., an aqueous H 2 O 2 /NH 4 OH solution. The sidewall spacer 14 , therefore, functions as an electrical insulator separating the silicide contact 24 on the gate electrode 12 from the metal silicide contacts 24 on the source/drain regions 30 , as shown in FIG. 1 B.
Various metals react with Si to form a silicide, however, titanium (Ti) and cobalt (Co) are currently the most common metals used to create silicides (TiSi 2 , CoSi 2 ) when manufacturing semiconductor devices utilizing salicide technology.
Use of a TiSi 2 layer imposes limitations on the manufacture of semiconductor devices. A significant limitation is that the sheet resistance for lines narrower than 0.35 micrometers is high, i.e., as TiSi 2 is formed in a narrower and narrower line, the resistance increases. Another significant limitation is that TiSi 2 initially forms a high resistivity phase (C 49 ), and transformation from C 49 to a low resistivity phase (C 54 ) is nucleation limited, i.e., a high temperature is required to effect the phase change.
Cobalt silicide, unlike TiSi 2 , exhibits less linewidth dependence of sheet resistance. However, CoSi 2 consumes significant amounts of Si during formation, which increases the difficulty of forming shallow junctions. Large Si consumption is also a concern where the amount of Si present is limited, for example, with silicon on insulator (SOI) substrates. Without enough Si to react with Co to form CoSi 2 , a thin layer of CoSi 2 results. The thickness of the silicide layer is an important parameter because a thin silicide layer is more resistive than a thicker silicide layer of the same material, thus a thicker silicide layer increases semiconductor device speed, while a thin silicide layer reduces device speed.
Recently, attention has turned towards using nickel to form NiSi utilizing salicide technology. Using NiSi is advantageous over using TiSi 2 and CoSi 2 because many limitations associated with TiSi 2 and CoSi 2 are avoided. When forming NiSi, a low resistivity phase is the first phase to form, and does so at a relatively low temperature. Additionally, nickel (Ni), like Co, diffuses through the film into Si, unlike Ti where the Si diffuses into the metal layer. Diffusion of Ni and Co through the film into Si prevents bridging between the silicide layer on the gate electrode and the silicide layer over the source/drain regions. The reaction that forms NiSi requires less Si than when TiSi 2 and CoSi 2 are formed. Nickel silicide exhibits almost no linewidth dependence of sheet resistance. Nickel silicide is normally annealed in a one step process, versus a process requiring an anneal, an etch, and a second anneal, as is normal for TiSi 2 and CoSi 2 . Nickel silicide also exhibits low film stress, i.e., causes less wafer distortion.
Although the use of NiSi in salicide technology has certain advantages over utilizing TiSi 2 and CoSi 2 , there are problems using NiSi in certain situations. Forming NiSi on doped, crystallized Si usually produces a smooth interface between the NiSi layer and the doped, crystallized Si layer. However, when crystallized Si is doped with arsenic (As), a rough interface between the NiSi and the doped, crystallized Si forms, which leads to certain problems.
FIG. 2 illustrates the degree of interface 36 roughness between a conventional nickel silicide (NiSi) contact 24 and arsenic doped source/drain region 30 . In this system, the mean peak to valley interface roughness height d is about 300 Å to about 400 Å. This large degree of interface roughness can cause a variety of electrical problems such as spiking and increased junction leakage. The interface roughness could penetrate all the way through the source/drain region in a shallow junction device, causing a local short circuit, thereby resulting in junction leakage. In order to prevent these problems, a thinner metal layer can be deposited, thereby resulting in a thinner silicide layer, or the depth of source/drain junction can be increased. However, neither of these approaches is satisfactory: the former approach would result in higher sheet resistance and a slower semiconductor device, and the latter approach runs counter to the trend toward smaller device dimensions, both vertically, and laterally, in order to increase switching speeds.
Interface roughness becomes more pronounced as the concentration of the dopant increases. In an As doped device with NiSi contacts, interface roughness is especially a problem where the peak concentration of the doped arsenic is in the vicinity of the upper surface of the source/drain regions. In a typical arsenic doped MOS device the arsenic ions will be implanted with an energy and dose of 10 to 20 keV and 1×10 15 to 6×10 15 ions/cm 2 , which results in a peak arsenic concentration at about 200 Å to about 400 Å below the upper surface of the source/drain region. When the peak arsenic concentration is located in this region an unacceptably high degree of interface roughness results when nickel silicide is formed.
Implanting the arsenic ions deeper into the silicon substrate reduces the interface roughness. However, this has been avoided in conventional practice. A Gaussian type distribution of dopant concentration versus implant into depth is obtained when dopants are implanted into bulk silicon substrates. Driving the peak concentration of the dopant deeper into the bulk silicon substrate to overcome the interface roughness effects shifts more of the dopant even deeper into the substrate. In a bulk silicon substrate, deep implantation of dopant to overcome the silicide interface roughness problem results in slower, larger-dimension devices.
The term semiconductor devices, as used herein, is not to be limited to the specifically disclosed embodiments. Semiconductor devices, as used herein, include a wide variety of electronic devices including flip chips, flip chip/package assemblies, transistors, capacitors, microprocessors, random access memories, etc. In general, semiconductor devices refer to any electrical device comprising semiconductors.
SUMMARY OF THE INVENTION
There exists a need in the semiconductor device art to provide silicide contacts for planar transistors which overcome the problem of silicide contact-source/drain region interface roughness. There exists a need in this art to deeply implant dopant in the source/drain regions to prevent silicide interface roughness while maintaining the desirable dimensional and electrical characteristics of shallow implantation. There exists a need in this art to provide arsenic doped source/drain regions with nickel silicide contacts without an unacceptably high degree of silicide-source/drain interface roughness.
These and other needs are met by embodiments of the present invention, which provide a method of manufacturing a semiconductor device comprising providing a silicon-containing substrate having an upper surface. The substrate is doped by ion implantation to form source/drain regions such that the concentration of the dopant and the depth below the upper surface of the implant substantially reduce interface roughness between subsequently formed nickel silicide contacts and the source/drain regions. A nickel layer is deposited over the upper surface of the substrate and the nickel layer is heated so that the nickel layer reacts with the silicon layer to form nickel silicide contacts.
The earlier stated needs are also meet by other embodiments of the instant invention that provide a semiconductor device comprising a silicon-containing substrate having an upper surface. The silicon-containing substrate contains doped source/drain regions and nickel silicide contacts, wherein the doping concentration and depth below the upper surface of the substrate are such that interface roughness between nickel silicide contacts and the source/drain regions is substantially reduced with respect to conventional semiconductor devices comprising nickel silicide contacts.
The earlier stated needs are further met by other embodiments of the instant invention that provide a method of manufacturing a semiconductor device comprising providing a silicon on insulator substrate comprising an insulating layer on a substrate base and a silicon layer is on the insulating layer. A gate oxide layer and conductive gate material are, in turn, formed over the silicon layer. The gate material layer and gate oxide layer are then patterned to form a gate electrode having an upper surface and opposing side surfaces. An insulating material is deposited over the gate electrode and silicon layer. The insulating material is patterned to form sidewall spacers on the opposing sides of the gate electrode. Source/drain implants are formed by ion implanting a dopant into the silicon layer, such that the dopant concentration and depth significantly reduces the interface roughness between subsequently formed nickel silicide contacts and source/drain regions. The source/drain implants are subsequently heated to activate the source/drain regions and then a nickel layer is deposited over the gate electrode and source/drain regions. The nickel layer is heated so that the nickel reacts to form nickel silicide contacts with the underlying silicon on the gate electrode and source/drain regions. The unreacted portions of the nickel layer are removed from the device.
This invention addresses the needs for an improved method of forming high conductivity silicide contacts to source/drain regions and gate electrodes with reduced silicide interface roughness and improved electrical characteristics. The present invention reduces the possibility of spiking and junction leakage.
The foregoing and other features, aspects, and advantages of the present invention will become apparent in the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B schematically illustrate a prior art semiconductor device before and after forming silicide contacts.
FIG. 2 is a detailed view of a silicide-source/drain region interface of the prior art.
FIGS. 3A-3G schematically illustrate the formation of metal silicide contacts for semiconductor devices according to an embodiment of the present invention.
FIG. 4 is a detailed view of a silicide-source/drain region interface formed according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention enables the production of semiconductor devices with improved performance and reduced failure rates by reducing source/drain junction interface roughness. The present invention provides semiconductor devices with reduced spiking and junction leakage. The present invention provides an improved semiconductor device with nickel silicide contacts. These are achieved by forming source/drain implants by ion implantation into the substrate at a predetermined concentration and depth.
The invention will be described in conjunction with the formation of the semiconductor device in the accompanying drawings. However, this is exemplary only as the claimed invention is not limited to the formation of and the specific device illustrated in the drawings.
A silicon on insulator (SOI) substrate 2 is illustrated in FIG. 3 A. The SOI substrate 2 comprises a semiconductor substrate base layer 3 with an insulating layer 6 on the base layer 3 and a silicon layer 8 on the insulating layer 6 . The substrate base layer 3 comprises a conventional semiconductor substrate, such as a silicon wafer. The insulating layer 6 comprises a conventional insulating material such as silicon dioxide or silicon nitride. The thickness of silicon layer 8 is about 500 Å to about 2,000 Å. A gate oxide layer 10 and a conductive gate material layer 12 . such as polysilicon, are formed on the silicon layer upper surface 9 . The gate oxide 10 and gate electrode 12 layers are patterned by conventional photolithographic techniques to form gate electrode 12 and the underlying gate oxide layer 10 , as shown in FIG. 3 B. An insulating layer, such as silicon dioxide, silicon nitride, or silicon carbide, is deposited over the substrate 2 and patterned using an anisotropic etch to form sidewall spacers 14 on the opposing sides 13 of the gate electrode 12 , as shown in FIG. 3 C.
Using the gate electrode 12 and sidewall spacers 14 as masks, dopant 16 is introduced into the silicon layer 8 , as shown in FIG. 3D, forming source/drain regions 18 . Conventional dopants. such as antimony, arsenic, phosphorous, or boron can be introduced into the source/drain regions 18 . The dopant can be introduced by ion implantation. The dopant ions are implanted to a predetermined depth belong the upper surface 9 of the silicon layer 8 .
To minimize silicide-source/drain region interface roughness, the ions are implanted to a predetermined depth so that the concentration of dopant ions is greatest at a depth of about 450 Å to about 700 Å below the substrate upper surface 9 . In order to implant the ions at this depth, the tons are implanted with an energy of about 15 keV to about 40 keV, at a dose of about 1×10 15 to about 6×10 15 ions/cm 2 . When arsenic is implanted into the source/drain regions, a suitable peak arsenic concentration is about 1×10 20 ions/cm 3 to about 4×10 20 ions/cm 3 . After ion implantation, the source/drain regions are activated by a first rapid thermal anneal at a temperature greater than 1000° C. for about 5 to about 30 seconds.
By comparison, in the prior art method of FIG. 1A, the source/drain regions 30 are formed in a bulk silicon substrate 4 . The ions implanted in the source/drain regions 30 are near the upper surface 5 of the bulk silicon substrate 4 .
Referring to FIG. 3E, after the first rapid thermal anneal, a metal layer 22 is deposited over the source/drain region 18 and the gate electrode 12 . Metal layers are deposited by a PVD method such as sputtering or evaporation, or a CVD method. The metal is deposited to a layer thickness of about 100 Å to about 500 Å. The metal layer 22 can comprise Co, Ni, Ti, Mo, Ta, W, Cr, Pt, or Pd. Because it forms silicide by a low temperature, single step anneal, among the other reasons herein described, nickel is a preferred metal.
The deposited nickel layer 22 is subsequently annealed in a second rapid thermal anneal step to form the metal silicide contacts 24 , as depicted in FIG. 3 F. The nickel layer 22 is annealed for about 15 to about 120 seconds at about 350° C. to about 700° C. to form NiSi. If the annealing temperature is below about 350° C. or greater than 700° C. relatively low conductivity Ni 2 Si or NiSi 2 are respectively formed.
Silicide contacts 24 are formed on the gate electrode 12 and source and drain regions 18 as shown in FIG. 3 F. As shown in FIG. 3 G and FIG. 4, interface 26 is formed between silicide contact 24 and source/drain region 18 . The silicide-source/drain region interface 36 formed according to the prior art process, FIG. 3, has a larger peak to valley distance d than the peak to valley distance d of the silicide interface 26 formed according to the present invention. The prior art mean peak to valley distance d is about 300 Å to about 400 Å. In embodiments of the present invention the mean peak to valley distance d of the silicide-source/drain interface is reduced to less than 100 Å.
The methods of the present invention provide reduced silicide/silicon interface roughness by deeply doping while maintaining the favorable electrical characteristics of shallow doping. Deeply implanting dopant into a bulk silicon substrate would result in forming source/drain junctions deeper than 1000 Å below the upper surface of the silicon-containing substrate. In certain embodiments of the present invention the source/drain junctions are confined to the silicon layer 8 . Oxide layer 6 prevents the source/drain junctions from extending deeper into the substrate.
For example, in one embodiment silicon layer 8 is about 1000 Å thick. Oxide layer 6 prevents the source/drain regions from extending deeper into the substrate. as they would if they were implanted Into a bulk silicon substrate. By confining the source/drain regions to the silicon layer thickness, the present Invention provides greater conductivity in the source/drain junctions and prevents spiking and junction leakage because of interface roughness. The present invention produces silicide contact-source/drain region interfaces with reduced interface roughness and increased conductivity in a novel, elegant manner.
The embodiments illustrated in the instant disclosure are for illustrative purposes only. It should not be construed to limit the scope of the claims. As is clear to one of ordinary skill in the art, the instant disclosure encompasses a wide variety of embodiments not specifically illustrated herein. | Metal silicides form low resistance contacts on semiconductor devices such as transistors. Rough interfaces are formed between metal silicide contacts, such as NiSi and the source/drain regions of a transistor, such as doped source/drain regions. Interfaces with a high degree of roughness result in increased spiking and junction leakage. Interface roughness is minimized by deeply doping the source/drain regions of a silicon on insulator substrate. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/438,646, filed May 22, 2006 and now U.S. Pat. No. 7,422,201, which claims priority under 35 U.S.C. §119 (e) to U.S. Provisional Application Ser. No. 60/683,456, filed May 20, 2005.
FIELD OF THE INVENTION
[0002] This invention relates generally to food preparation and more particularly to cutting boards used in the preparation of food.
BACKGROUND OF THE INVENTION
[0003] In commercial kitchens, maintaining sanitary conditions is of critical importance. This can be difficult where counter space as it a premium and significant preparation involving cutting needs to be undertaken. Limited space increases the risk of cross contamination where, for example, poultry and vegetables are both being cut on contiguous or substantially contiguous surfaces. Generally, thick plastic cutting boards are employed that raise the cutting surface off the counter on which the cutting boards are placed from about ¼ of an inch to about ¾ of an inch. This minimal height difference makes it more likely than not that material (germs, chemicals, particulate matter, etc.) will be transferred to or from the cutting board to or from the counter.
[0004] Often, when cutting is done, scrap is created. The scrap is typically piled up on the cutting board or periodically thrown into a nearby trash receptacle. Where the scrap is piled up on the cutting board, the space necessary to cut is diminished and the possibility of the scrap becoming intermingled with the material to be used is quite high. Where the scrap is thrown into a nearby trash receptacle, floor space may be compromised by having to station the receptacle nearby and additional handling of scrap material is required that could increase the risk of sanitation issues.
[0005] When the object being cut is juicy, the risks increase still further. Juices can run randomly off the cutting board onto the counter and the floor creating numerous hazardous conditions.
[0006] Finally, the placement of cutting boards on typical height countertops forces food preparation workers to have bend over to perform their tasks. This creates the possibility of back injuries, makes it more difficult to see what is being cut and contributes to a more hazardous and less ergonomic work environment.
[0007] As can be seen, current cutting boards suffer from certain drawbacks and limitations. Accordingly, a need exists for cutting boards that are designed to address the drawbacks and limitations in a cost-effective manner
SUMMARY OF THE INVENTION
[0008] In one preferred embodiment, the present invention comprises one or more cutting boards mounted on a stand. The cutting board(s) are thus, raised off the counter or other work surface. This accomplishes a number of things. First, it places the cutting board at a more comfortable height for cutting while bringing the work surface closer to the user's eyes for greater visual acuity. Second, it permits the placement of one or more pans in or beneath the cutting board(s) to catch scraps or juice or hold sauces or other accompaniments for service. Third, it permits full pans of scrap or juice to be removed without having to displace the cutting board. And fourth, it helps avoid contamination with other things that may also be on the counter.
[0009] Preferably, the cutting boards of the present invention have a hole therein through which waste materials can be dropped. When the cutting board is supported on a stand that lifts the cutting board off the work surface, waste materials can be pushed through the hole directly into a catch pan mounted in or below the cutting board. Alternatively, the cutting board, with or without a supporting device, can be extended over the end of the counter, placed on a trash receptacle or extended over a sink having a garbage disposal so as to make disposal of scrap juice and materials through the hole even simpler.
[0010] In one preferred embodiment, the cutting board has at least one set of grooves cut into at least one side that can catch juices and carry them to a pan mounted in or underneath the cutting board. The collected juices can then either be discarded or used for or as a sauce. Preferably at least one set of grooves are sized to match the dimensions of a pan such that the cutting board can be mounted. directly on top of a conventional pan without the need for a separate stand.
[0011] These and other objects and advantages of the present invention will become apparent from the detailed description, claims, and accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a top perspective view of one embodiment of a cutting board, stand and pan in accordance with the present invention;
[0013] FIG. 2 is a top perspective view of a second embodiment of a cutting board, stand and pan in accordance with the present invention;
[0014] FIG. 3 is an exploded top perspective view of the embodiment of FIG. 1 , without the pan;
[0015] FIG. 4 is a top perspective view of a third embodiment of the present invention with a pan underneath;
[0016] FIG. 5 is a top perspective view of the embodiment of FIG. 4 with a pan dropped into the hole in the cutting board and without the pan underneath.
[0017] FIG. 6 is an exploded top perspective view of a fourth embodiment of the present invention;
[0018] FIG. 7 is a bottom exploded perspective view of the embodiment of FIG. 7 ;
[0019] FIG. 8 is a perspective view of one embodiment of a stand used in accordance with the present invention;
[0020] FIG. 9 is a bottom plan view of a second embodiment of a stand used in accordance with the present invention;
[0021] FIG. 10 is a top perspective view of the stand of FIG. 9 ;
[0022] FIG. 11 is bottom perspective view of the stand of FIG. 9 ;
[0023] FIG. 12 is a top perspective view of one side of a cutting board made in accordance with one embodiment of the present invention; and
[0024] FIG. 13 is a perspective view of one side of yet another embodiment of a cutting board made in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] As shown in FIGS. 1-13 , various embodiments of the present invention comprise one or more cutting boards 10 and 12 , a pan 14 , 15 or 17 and a stand 16 . Preferably each cutting board 10 , 12 has a hole 18 that corresponds, at least in part, to a hole or cutout 19 in the stand 16 . However, since the cutting boards of the present invention can be used without the stand 16 , the hole 18 can be made any size that permits juices and/or cutting scraps to be moved therethrough.
[0026] Preferably the hole in each cutting board has a recessed lip 20 to accommodate the insertion of one or more pans 15 . When a pan 15 is placed in the hole, the pan's peripheral edge 15 engages the recessed lip 20 of the cutting board such that the pan's peripheral edge is even with or below the top surface of the cutting board to facilitate the transfer of juices and or cutting scraps into the pan 15 .
[0027] As shown in FIG. 12 , the cutting boards 10 and 12 of the present invention may also include at least one set of channels or grooves 21 (See FIG. 12 ) on one or both sides to guide juices from the cutting board to the hole 18 so that the juices can run into a pan 15 placed in the hole 18 or a pan 14 placed below the cutting board as shown in FIG. 1 . Preferably, the grooves 21 are recessed into the cutting board at a level above the recessed lip 20 to permit juices to flow freely into a pan 15 if one is placed in the hole 18 . If desired, the grooves 21 can be cut an increasing depth towards hole 18 to more readily insure the flow of juices towards the hole 18 .
[0028] The cutting boards 10 , 12 of the present invention also preferably include a hook 23 in one corner so that they can be hung on a rack when not in use. As shown in FIG. 13 , they may also include an embedded measuring tool 25 and corners 27 with gripping surfaces.
[0029] As shown in FIGS. 1-11 , the stand 16 of the present invention comprises a plurality of support legs 17 preferably having feet 28 that are made from a non-slip material so that the stand does not move when cutting is being done. The stand 16 preferably has retaining lips 22 and/or edges 24 (see FIGS. 6 and 8 ) to hold the cutting board(s) 10 and 12 in place. As shown in FIGS. 3 , 6 and 8 , in another embodiment of the present invention, the majority of the beds 26 and 33 of the stand 16 can be omitted leaving relatively narrow support bands 29 and 31 to support the cutting board 10 .
[0030] Alternatively, the stand can include pegs (not shown) that fit into corresponding holes (not shown) in the cutting boards 10 and 12 or other similar retaining means. Or still further, the beds 26 and 33 or support bands 29 and 31 of the stand 16 may be made from a non-slip material.
[0031] In yet another embodiment of the present invention, the grooves 21 are sized to match the top edges of a pan 14 . In this way, the cutting board 10 can be placed directly on the pan 14 without the use of stand. In this way, without the use of a stand 16 , juices and/or scrap material can be slid directly through hole 18 into the pan 14 .
[0032] While the use of pans 14 , 15 and 17 is facilitated by the use of a stand 16 , the cutting boards 10 and 12 of the present invention can be placed directly over a trash receptacle, hung over the edge of a counter or maintained over a sink (preferably a sink with a garbage disposal) so that scrap juices and materials can be simply slid off the cutting board and through the hole for direct disposal. In such cases, where commercial sized cutting boards are used (typically at least ¾ of an inch thick with a 18 inch by 24 inch footprint) the cutting board weighs enough and is stable enough to extend a significant distance off a counter top in cantilever fashion without tipping. However, where tipping is a concern, the cutting board can be weighted at one end or simply clamped in place. Alternatively, a stand can be created with a cantilever or with appropriate hooks (not shown) to extend out over the end of the counter or to fit tightly on the sink or trash receptacle.
[0033] The present invention may be implemented in a variety of configurations, using certain features or aspects of the several embodiments described herein and others known in the art. Thus, although the invention has been herein shown and described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific features and embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter disclosed herein. | A device for preparing food includes a stand having a plurality of legs for supporting at least one cutting board and lifting it off a work surface. The cutting board has a hole in it. A pan fits in or underneath the hole to catch juices, scraps or finished cut items cut on the cutting board. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of the German patent application No. 10 2012 221 834.3 filed on Nov. 29, 2012, the entire disclosures of which are incorporated herein by way of reference.
BACKGROUND OF THE INVENTION
The invention relates to a method for creating markings, in particular marking lines of highly viscous marking material, in particular a two-component cold plastic, on a surface, which is to be marked, in particular a road surface, wherein the marking material is discharged from a material supply and, before striking the surface, which is to be marked, is fed to a rotational body, which moves relative to the surface in longitudinal direction of the marking, which is to be created, and is applied to the surface so as to be divided into unequal material portions by means of said rotational body, wherein the axis of rotation of the rotational body runs at right angles to the longitudinal direction of the marking and wherein the marking material is fed to the rotational body in the form of a plurality of marking material flows, which, viewed in longitudinal direction of the rotational body, are discharged next to one another.
In addition, the invention relates to a device for creating markings, in particular marking lines of highly viscous marking material, in particular a two-component cold plastic, on a surface, which is to be marked, in particular a road surface, comprising at least one material storage container, comprising at least one conveying device for conveying marking material from the material storage container to a material outlet and comprising a rotational body, which is arranged below the material outlet and through which marking material, which flows from the material outlet, can be divided into unequal material portions and can be applied to the surface, wherein, during operation, the device can be moved relative to the surface in longitudinal direction of the marking, which is to be created, and wherein the axis of rotation of the rotational body runs at right angles to the longitudinal direction of the marking and wherein the marking material can be fed to the rotational body in the form of a plurality of marking material flows, which, viewed in longitudinal direction of the rotational body, flow next to one another.
Structured markings of unequal material portions, thus comprising a stochastic material distribution, encompass increased traffic safety, in particular in the dark and in response to wetness, because rain water can drain and individual areas of the marking protrude from the water film on the road surface. The light from automobile headlights is reflected better through this. In addition, a lower noise development when driving over such markings is advantageous as compared to markings of equal material drops, which are arranged regularly. In the case of markings comprising a stochastic material distribution, the risk that the marking material comes loose when a snowplow drives over it, is also small.
A method and a device of the above-mentioned type are known from document EP 0 665 062 A1. This document shows a device on a vehicle for marking the road by means of color drops. The device has a storage container for color mass, which, on the bottom, encompasses an outlet gap, to which a guide plate, which runs diagonally to the bottom area of the storage container and on which a laminar flow of the color mass takes place, connects. On its bottom edge, the guide plate is provided with notches, which ensure that a plurality of color mass partial flows is created, when the vehicle moves in operating direction. A turbine roller comprising blades for creating an air flow, which acts on the color mass partial flows that drain from the guide plate, is located below the bottom of the storage container. This air flow divides the color mass into color drops and accelerates the color drops, which are flung onto the road surface with great force.
It is considered to be a disadvantage in this state of the art that the volume flow of the color mass from the open storage container through the outlet gap strongly depends on the level of the color mass in the open storage container and fluctuates with this level. The material viscosity, which also fluctuates due to temperature changes, also influences the discharged color mass quantity. As a result, the quantity of the color mass, which is discharged for each unit of stretch of road, which the vehicle covers, is not constant. This leads to irregular road markings, which means a reduced quality. In addition, the marking speed, which can be reached, is limited, because the color mass is dispensed from the storage container solely by means of the force of gravity. This state of the art furthermore encompasses the disadvantage that the marking process needs to be interrupted at relatively short intervals as a function of the hardening time of the marking material, so as to clean the device parts touched by the marking material, in particular the storage container and the guide plate. This means lower daily outputs and a high flushing fluid consumption, which leads to high costs and to environmental pollution. In the case of the slot-shaped material outlet, the material flow can furthermore be hindered easily, e.g. because clumps get caught in the slot, which requires a relatively frequent cleaning of the outlet.
A further method and a device for the above-mentioned purpose are known from document CH 681 904 A5. The device forms an open system herein, comprising a draw box comprising a slot-shaped material outlet and comprising a rotational body arranged therebelow, here in the shape of a roller made of a material having a low adhesiveness. When producing the marking, the marking material, which flows out in the form of a thin curtain, is divided into a plurality of unequally large and irregularly shaped material portions by means of the rotating rotational body, prior to striking the surface, which is to be marked. Structured markings comprising a stochastic material distribution can be created in this manner.
In addition to the above-mentioned disadvantages, this state of the art encompasses the further disadvantage that the marking material, which is applied herein in the form of a flat belt or curtain, has the characteristic that, due to acceleration caused by the force of gravity and wall friction at the outlet walls, the material flow is constricted after leaving the slot-shaped outlet prior to striking the rotational body. The effect of constriction is a function of the material viscosity, among others, which also fluctuates due to temperature changes, and of the type and number of the fillers and solids, which are added to the marking material. As a result, the line width of the marking line is thus always smaller than the slot width of the outlet to an extent, which cannot be determined accurately ahead of time.
A further device is known from document EP 0 148 494 A2. Drops made of marking material are discharged from gap-shaped outlets, which are oriented substantially horizontally and which are arranged next to one another and which are separated from one another by means of separating walls, and are spun onto the surface, which is to be marked, by means of a rotating paddle arrangement. The axis of rotation of the paddle arrangement is thereby located at the same height as the outlets. Marking lines of individual material drops, which are largely identical, can be created with this.
It is considered to be disadvantageous in the case of this state of the art that the marking material, which adheres to the separating walls and which hardens at that location, can relatively easily lead to impairments of the movement of the rotating paddles. A cleaning of the relatively narrow outlets is difficult and time-consuming. Structured markings comprising a stochastic material distribution cannot be created by means of this device.
A device for creating marking lines, which consist of a plurality of individual marking material portions, is known from document DE 10 2009 045 576 A1. The marking material portions herein can be ejected from a nozzle arrangement, which is connected to a marking material source and which comprises a plurality of discharge nozzles, which are arranged at right angles to a direction of movement of the device, by means of blasts of compressed air. Marking lines of individual material drops, which are largely identical, can be created with this, whereas structured markings comprising a stochastic material distribution, however, cannot be created with this.
The instant invention thus has the task of creating a method and a device of the above-mentioned type, which avoids the specified disadvantages and which makes it possible to produce structured markings comprising a stochastic material distribution, of high quality and in a highly cost-efficient manner.
SUMMARY OF THE INVENTION
The part of the task, which relates to the method, can be solved according to the invention by means of a method of the above-mentioned type, which is characterized in that the marking material is discharged from a plurality of discharge nozzles continuously or so as to pulsate or intermittently in a pressurized manner and that the individual marking material flows are turned on or off in accordance with the marking, which is to be created.
Advantageously, the plurality of marking material flows is less susceptible to interferences caused by clumping or foreign objects in the marking material as a single thin band-shaped or curtain-shaped marking material flow, whereby the appearance of interferences and interruptions is rarer. Due to the plurality of marking material flows, which are discharged next to one another, the impact of the material viscosity on the line width of the marking line is also considerably lower than in the case of a band-shaped or curtain-shaped material flow. The method according to the invention can thereby advantageously be carried out in a closed system without the known, above-mentioned disadvantages of open systems comprising draw or feed boxes, which avoids a hardening of marking material prior to being discharged onto the surface, which is to be marked. The fact that the marking material is discharged continuously or so as to pulsate or intermittently from a plurality of discharge nozzles in a pressurized manner will contribute to a reliable process flow. In addition, a high speed can be reached in response to the production of the markings in this manner. Due to the fact that the individual marking material flows are turned on or off in accordance with the marking, which is to be created, the width of a marking, which is to be created, can in particular be changed in a simple manner.
The number of the discharged marking material flows depends in particular on the width of the marking, which is to be created, and can be varied in accordance thereto. Advantageously, the distance between two adjacent marking material flows relative to one another is chosen such that an impact of the individual material flows can be identified in the created marking, thus that an even material distribution is attained in cross direction of the marking.
Preferably, provision is further made for the method according to the invention that the marking material flows are fed to the rotational body with a round or oval or square or rectangular material cross section. A low sensitivity against clumping or foreign objects, which might be contained in the marking material, can be attained by means of these cross sections as compared to a single very wide and thin material cross section according to the above-mentioned state of the art, which boosts an interruption-free process flow.
Finally, provision is made for the method according to the invention that a first connected group of the marking material flows is guided to a first rotational body and/or that a second connected group of the marking material flows is guided to a second rotational body, which can be rotated independent from the first rotational body. In this manner, it is not only possible to create individual lines by means of the method according to the invention, but double lines and combined lines can also be created advantageously in one operation cycle. A high operating speed and an accurate and constant distance of the individual marking lines of the double lines or combined lines is reached hereby, which cannot be reached on practice when creating the lines successively. Due to the fact that the individual discharge nozzles can be turned on and off independent from one another, the parallel lines can be created independent from one another; for example, a continuous first line, to which a second, broken line is created in parallel, can thus be created in one operation cycle.
The solution of the second part of the task, which relates to the device, can be solved according to the invention by means of a device of the above-mentioned type, which is characterized in that the material outlet is formed by means of a plurality of outlet openings, which, viewed in longitudinal direction of the rotational body, are arranged next to one another, that the outlet openings are discharge nozzles, through which the marking material can be discharged continuously or so as to pulsate or intermittently in a pressurized manner, and that the individual outlet openings can be released or locked in accordance with the marking, which is to be created.
The advantages concerning low susceptibility to interference, cost-efficient operation and high quality of the created markings, which have already been explained above in context with the method according to the invention, are attained by means of the device according to the invention. In particular, a high operating speed is ensured, because the outlet openings are discharge nozzles, through which the marking material can be discharged continuously or so as to pulsate or intermittently in a pressurized manner. Due to the fact that the individual outlet openings can be released or locked in accordance with the marking, which is to be created, the width of the created marking can be changed quickly and easily as required.
For the purpose of a low sensitivity against clumping and/or foreign objects in the marking material, the outlet openings preferably have a round or oval or square or rectangular cross section.
So as to be able to not only produce individual lines, but also double lines and/or combined lines in a particularly cost-efficient manner by means of the device according to the invention, it is proposed for a first rotational body to be arranged below a first connected group of the outlet openings and for a second rotational body, which can be rotated independent from the first rotational body, to be arranged below a second connected group of outlet openings. In response to the production of combined lines, the corresponding rotational body can in each case be stopped in line gaps, so that the marking material residues, which are still located on the rotational body, are prevented from being slung off in the line gap as far as possible. In the case of double lines and combined lines, an accurately defined distance between the two marking lines, which are located next to one another, is always ensured due to the simultaneous creation thereof.
In a further embodiment, its own, individually controllable rotary drive, preferably in each case a hydraulic motor, is assigned to each rotational body. Either both rotational bodies or only one of the two rotational bodies can be set into rotation with this, depending on the respective need. In addition, the speed of the rotational bodies can be changed and can be set appropriately due to the controllability, so as to attain a desired structure of the marking. In addition, each rotational body can be stopped individually, as required.
Advantageously, the outer periphery of the/each rotational body is provided with structural elements, it is preferably formed by means of a spiked roller.
To be able to influence the effect, which the/each rotational body has on the marking material flows, which strike it, provision is advantageously made for the position of the/each rotational body to be capable of being adjusted relative to the material outlet, preferably in a horizontal direction parallel to the direction of movement of the device and/or to be capable of being displaced in a vertical direction or to be capable of being pivoted in a vertical plane.
To be able to quickly and easily adapt the device to different needs, in particular to different marking widths, provision is made for the individual discharge nozzles to be located in individual nozzle elements, which can be attached to a nozzle support and which can be removed from the nozzle support and which form a variable nozzle arrangement. Clogging caused by hardened material can also be removed much easier in this manner than in the case of a single slot-shaped material outlet by removing or replacing individual nozzle elements.
The above-mentioned release and locking of the individual outlet openings takes place, for example, by displacing or twisting the individual nozzle elements within the nozzle arrangement, whereby two marking material channel sections of a marking material channel, which leads to the respective nozzle element, can be made to overlap or not to overlap. This arrangement also allows for a simple flushing of the nozzle element by means of a flushing fluid, which is fed through the marking material channel, with a small amount of flushing effort, because, if needed, the flushing fluid and a maximum flushing fluid pressure can be applied separately to the individual nozzle elements in each case.
A further technical possibility for adapting the device to different applications is that the individual nozzle elements can preferably be assembled at a changeable lateral distance to one another so as to form the nozzle arrangement.
The conveying device of the device is preferably formed by means of at least one metering pump. Advantageously, the device forms a closed system, in the case of which, in combination with the metering pump, the discharged marking material quantity can be controlled as a function of the distance, so as to ensure a steady layer thickness of the created marking in response to speed changes of the device relative to the surface, which is provided with markings. In addition, an accurate doubling of the discharged material quantity is possible in the closed system in combination with the metering pump in the case of double lines or combined lines, in that the output of the metering pump is doubled accordingly.
In addition to the metering pump or also instead of the metering pump, a printing medium source can be used as conveying device, which creates an a pressure cushion of a pressure medium, such as air, above the material level in a closed material storage container, so as to convey the marking material. In the case of two-component marking material, the basic component thereof, for example, which comprises the larger volume flow, can be conveyed by means of a pressure medium, and the second component of which, in particular a hardener comprising the smaller volume flow, can be conveyed by means of a metering pump.
An advantageous embodiment of the device according to the invention finally provides for the rotational body/bodies including a rotational body support and, if applicable, one or a plurality of rotational body drives to be embodied as an additional unit, which can be mounted to the remaining device and which can be separated from the remaining device. In this embodiment, the device can be modified quickly and easily between two different versions, wherein, in the first version without the rotational body/bodies, markings can be created, which consist of a plurality of marking material points, which are relatively identical, while in the second version comprising the rotational body or the rotational bodies, markings comprising a stochastic material distribution can be created. The change between the two versions of the device can thereby be realized with little modification effort. In addition, the relatively low acquisition costs and the small expenditure of time for the modification are advantageous, when, in the case of a device, which is already at hand, only the additional unit must be acquired for creating markings of uniform marking materials points, so as to then also be able to create markings comprising a stochastic material distribution. For example, the version of the device, which was mentioned first above, can be embodied according to DE 10 2009 045 576 A1 by applicant, to which reference is made herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention will be explained hereinbelow by means of a drawing.
In the drawing:
FIG. 1 shows a device for creating markings on a surface, which is to be marked, in a schematic side view,
FIG. 2 shows the detail II of the device encircled in FIG. 1 in an enlarged perspective view,
FIG. 3 a shows the device part from FIG. 2 in a schematic cross section, comprising a first work flow direction,
FIG. 3 b shows the device part from FIG. 2 in a schematic cross section, comprising a second work flow direction,
FIG. 4 shows the device part from FIG. 2 in a changed embodiment,
FIG. 5 shows the device part from FIG. 4 in a rear view and
FIG. 6 shows the device part from FIG. 4 in a top view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 of the drawing shows a device 1 for creating markings on a surface 5 , which is to be marked, in a schematic side view. The device 1 is embodied herein as a self-propelled vehicle comprising a frame 10 and four wheels 11 , as well as with a drive unit 16 , such as an internal combustion engine and transmission arranged on the rear, and comprising a driver's cab 15 for an operator. In the alternative, the device 1 can also be embodied as a pulled vehicle without its own propulsion.
In the front part of the device 1 , on the right-hand side in FIG. 1 , at least one storage container 12 for marking material is arranged on the frame 10 . A conveying device 13 , here a metering pump, which, on the input side, is connected to the interior of the storage container 12 via lines, which are not visible herein, and which, on the output side, is connected to a material outlet 2 for discharging marking material to the surface 5 , which is to be marked, such as a road surface, is connected downstream from the storage container 12 . The material outlet 2 is fastened to the bottom side of the frame 10 and is at a predeterminable distance above the surface 5 . In cross direction of the device 1 , that is, viewed vertically to the drawing plane of FIG. 1 , the material outlet 2 consists of a number of separate outlet openings, which are arranged next to one another and which cannot be seen individually herein.
A rotational body 3 , which can be set into rotation and the outer periphery of which is provided with structural elements, is arranged below the material outlet 2 .
During operation of the device 1 , the latter moves across the surface 5 , which is to be provided with a marking, in the direction of movement 14 , which is illustrated by means of the arrow. The conveying device 13 thereby conveys a predeterminable dosage of marking material from the storage container 12 to the material outlet 20 and to the individual outlet openings thereof, through which the marking material initially falls down freely in the form of a plurality of parallel material flows and then hits the rotational body 3 , which is set into rotation, after covering a short distance. The material flows of the marking material, which hit the rotational body 3 , are divided into irregular and uneven material portions and are conveyed to the surface 5 , which is provided with a marking, by means of the structural elements attached thereto.
Glass beads can be removed from a further storage container 17 , which is arranged in the rear part of the device 1 , and can be poured onto the surface of the marking, which has not yet hardened, as it is known per se.
In a perspective view, FIG. 2 of the drawing shows the part II of the device 1 from FIG. 1 comprising the material outlet 2 and the rotational body 3 in an enlarged illustration. In the upper part of FIG. 2 , the material outlet 2 is visible, which is assembled from a plurality of nozzle elements 25 , which are arranged next to one another and which form a nozzle arrangement 27 and which are in each case held on a nozzle support 26 . The nozzle supports 26 , in turn, are connected mechanically to a part of the frame 10 of the device 1 in a suitable manner.
Each nozzle element 25 has a discharge nozzle, which is oriented downwards and through which a material flow of marking material can in each case be discharged.
The rotational body 3 , comprising its structural elements 30 , in the form of a spiked roller herein, is attached to the remaining part of the device 1 , here the frame 10 , at an adjustable distance below the material outlet 2 by means of two lateral consoles 34 , which run in vertical direction. At both of its ends, the rotational body 3 is rotatably supported in bearings 31 . A drive 32 , here a hydraulic motor, by means of which the rotational body 3 can be set into rotation, is attached to the left front side of the rotational body 3 .
At least one material feed line, which is not visible herein and which is in flow connection with all of the nozzle elements 25 , serves to feed the marking material. Each discharge nozzle in the different nozzle elements 25 can be opened or closed individually, so that a desired number of material flows of the marking material can be discharged. The width of the created marking, for example a marking line, can thus be adjusted easily.
FIG. 3 a of the drawing shows the part of the device 1 , which is illustrated in FIG. 2 , in a vertical section. The nozzle arrangement 27 , which comprises the nozzle elements 25 , which are arranged downstream from one another vertically to the drawing plane, is illustrated on the top in FIG. 3 a . A nozzle support 26 and a holder 28 comprising a holding spring are assigned to each nozzle element 25 .
Marking material can be fed to the nozzle element 25 , which is cut in FIG. 3 a , through a material feed channel 21 and through a line, which is connected upstream and which is not illustrated herein, wherein the marking material is initially conveyed into a discharge nozzle 23 , which encompasses an outlet opening 20 at the bottom. An air feed channel 22 , to which compressed air can be fed via an air line, which is not illustrated herein, is connected to the upper end of the discharge nozzle 23 . The compressed air can thereby be fed continuously or so as to pulsate or intermittently, whereby a continuous or pulsating or intermittent marking material flow is discharged accordingly through the outlet opening 20 . This discharge process takes place during the operation of the device 1 in all of the or in selected nozzle elements 25 , the arrangement of which vertically to the drawing plane of FIG. 3 a form the nozzle arrangement 27 .
The rotational body 3 comprising its spiky structural elements 30 is arranged below the nozzle elements 25 and can be driven in work flow direction according to the spinning arrow 33 by means of the rotary drive, which is shown and mentioned in FIG. 2 . By rotating the rotational body 3 , the structural elements 30 thereof divide the material flow 24 of the marking material, which escapes from each outlet opening 20 , into irregular material portions 24 ′ having different sizes, which then end up on the surface 5 and form the marking 4 comprising a stochastic material distribution at that location. Here, the device 1 thereby moves across the surface 5 in the direction of movement 14 from left to right in FIG. 3 a , which is specified by an arrow.
According to FIG. 3 b of the drawing, the device 1 can also encompass a work flow direction, which is opposite compared to the example in FIG. 3 a . According to FIG. 3 b , the part of device 1 shown in FIG. 2 can be assembled to the frame 10 of the device 1 opposite as in FIG. 3 a . The device 1 in FIG. 3 b thereby corresponds completely to the device 1 in FIG. 3 a with regard to its parts, but is now moved in opposite direction according to the motion arrow 14 in FIG. 3 b , that is, from right to left, during operation. During a first run in the one direction, the device 1 can also create a first marking and can then create a further marking during a second run in opposite direction of movement, without having to turn around. With regard to the further reference numerals in FIG. 3 b , reference is made to the description of FIG. 3 a.
By changing the speed of the rotational body 3 and by changing the position of the rotational body 3 relative to the material outlet 2 , the effect of the rotational body 3 on the marking material flows 24 can be changed and adjusted as required. When a division of the material flows 24 by means of the rotational body 3 is not desired, the latter can be moved into a position, in which it no longer meets the material flows 24 , or can be removed completely. As is illustrated in FIG. 2 , the latter can be carried out quickly and easily by releasing the consoles 34 from the remaining device 1 .
FIGS. 4 to 6 of the drawing illustrate a changed embodiment of the device 1 , for which it is characteristic that it encompasses two rotational bodies 3 . 1 and 3 . 2 , which are arranged next to one another and which can be rotated about the same axis of rotation, but independent from one another. The part of the device 1 , which is arranged above the two rotational bodies 3 . 1 , 3 . 2 , corresponds herein to the above-explained embodiment, to the description of which reference is made.
At their respective inner front end, the two rotational bodies 3 . 1 and 3 . 2 are rotatably supported in a bearing 31 so as to capable of being uncoupled from one another. At its left end, the rotational body 3 . 1 on the left-hand side in FIG. 4 is supported in a further bearing 31 and is connected to a first drive 32 . 1 , here also a hydraulic motor, at that location. At its right end, the right rotational body 3 . 2 is accordingly supported in a further bearing 31 , and is connected to a second drive 32 . 2 , also a hydraulic motor, at that location.
Double lines or combined lines can be created with the device 1 according to FIG. 4 with a high quality and high productivity. For example, two groups of material flows are discharged from two groups of nozzle elements 25 for creating a double line, wherein the one group is assigned to the first rotational body 3 . 1 and the second group, which is laterally spaced apart from the first group, is assigned to the second rotational body 3 . 2 , so as to create two parallel, continuous marking lines. When a combined marking line, that is, a continuous line comprising a parallel broken line, is to be created, marking material is discharged continuously from the first group of nozzle elements 25 , while marking material is discharged only periodically from the second group of nozzle elements 25 , which are assigned to the second rotational body 3 . 2 , so that a combination of a continuous line and a broken line, which runs parallel thereto, is created in this manner. The respective rotational body 3 . 1 or 3 . 2 is stopped in the gap lines, so as to prevent that the marking material residues, which are still located thereon, are spun off. In addition, the material residue, which adheres to a splash guard, which may be provided and which partially surrounds the rotational body 3 . 1 , 3 . 2 and which is not illustrated in the drawing, can be blown back to the marking line, which is currently applied, by means of an air pulse from an air syringe.
As is further illustrated in FIG. 4 , the part of the device 1 , which comprises the rotational bodies 3 . 1 , 3 . 2 as well as the bearings 31 and drives 32 . 1 , 32 . 2 thereof, can be embodied as an additional unit 1 ′, which can be attached and removed quickly, so that the device 1 can be modified quickly for different purposes. Without the rotational bodies 3 . 1 , 3 . 2 , the device 1 creates markings from a plurality of marking material points, which are identical and which are arranged regularly; by means of the rotational bodies 3 . 1 , 3 . 2 , the device 1 creates markings from unequal material portions comprising a stochastic material distribution.
FIG. 5 of the drawing shows the part of the device 1 from FIG. 4 in a rear view. The nozzle elements 25 , which, strung together, form the nozzle arrangement 27 , are located in the upper part, while the two rotational bodies 3 . 1 and 3 . 2 with their bearings 31 and their drives 32 . 1 , 32 . 2 are visible in the lower part.
FIG. 6 shows the device part from FIGS. 4 and 5 in top view, wherein the view directed from the top onto the nozzle arrangement 27 comprising the nozzle elements 25 , which are strung together and which are in each case held on a nozzle support 26 . A part of the frame 10 of the device 1 is visible on the top in FIG. 6 . The rotational bodies are covered herein and are not visible; only the two drives 32 . 1 and 32 . 2 are visible on the left and on the right in FIG. 6 .
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
LIST OF REFERENCE NUMERALS
Numeral
Designation
1
device
1′
additional unit
10
frame
11
wheels
12
storage container for marking material
13
conveying device (metering pump)
14
direction of movement of 1
15
driver's cab
16
storage container for glass beads
2
material outlet
20
outlet openings
21
material feed channel
22
air feed channel
23
discharge nozzle
24
material flows
24′
material portions
25
nozzle elements
26
nozzle support
27
nozzle arrangement
28
holder
3, 3.1, 3.2
rotational bodies (spiked roller)
30
structural elements (spikes)
31
bearings
32, 32.1, 32.2
drives
33
rotational work flow direction
34
consoles
4
marking
5
surface | A method and device for creating markings of highly viscous marking material on a surface, in particular a road surface. The marking material is discharged from a material supply and, before striking the surface is fed to a rotational body, which moves relative to the surface in a longitudinal direction of the marking, and is applied to the surface divided into unequal material portions by the rotational body. The rotational body axis of rotation runs at right angles to the marking longitudinal direction. The marking material is fed to the rotational body in a plurality of marking material flows, which, viewed in a longitudinal direction of the rotational body, are discharged next to one another from a plurality of discharge nozzles continuously, pulsatingly or intermittently in a pressurized manner. The individual marking material flows are turned on or off in accordance with the marking to be created. | 4 |
BACKGROUND OF THE INVENTION
A door cutting guide used in conjunction with a saw to cut a door has a slot in it in which the blade of a saw travels and includes surfaces on the guide which interact with the baseplate of the saw in making a straight cut through the door. The door cutting guide is useful in sawing off the bottoms of doors allowing them to freely open and close across rugs or other raised surfaces.
In constructing new structures it is the practice to hang or suspend standard size doors within standard size frames. When the interior decoration of the structure is decided upon, the floor surface of the rooms which the door separates may be covered with a fairly thin material such as a linoleum or a tile, or may be covered with thicker material such as a carpet and its accompanying carpet pad. In order to accommodate the floor covering it may be necessary to cut off the bottom of the door to allow the door to freely open and close without binding against the floor covering.
It used to be standard construction practice to carefully size a door prior to installing it. Because of rising construction costs it is no longer economically feasible to invest the hand labor necessary to custom fit each and every door. For this reason standard size doors and door fittings are used. Once the door is hung, and it is determined that there is insufficient clearance between the bottom of the door and the floor to allow free movement of the door across the floor covering, one of several methods are presently practiced in cutting off the bottom of the door. The first of these would be to remove the door, mark it, and then cut it either freehand or using a strip of wood clamped to the door as a saw guide. The second method is to use the floor as a guide for the baseplate of a circular saw and attempt to cut off the door while it is hanging.
The first method described in the preceding paragraph is disadvantageous because of the expensive labor time it consumes in removing and rehanging the door. The second method is disadvantageous for several reasons. The first of these is that typically cement slab floors or other subfloors are not smooth and level. When a saw is slid across the cement slab or the subfloor any discontinuities or imperfections in its surface are transferred to the saw resulting in either an uneven cut of the door or binding of the saw blade. The second disadvantage of this method is that very few hand-held circular saws are adjustable with respect to the distance of the blade from the edge of the baseplate. Thus, the carpenter has no control over how high the door will be cut off with respect to the floor, but is limited to the particular dimensions achieved in using his saw based on the dimension of the saw blade from the edge of the baseplate. Saw guides or jigs are known which can be used with hand-held circular saws. However, no guides or jigs are known which can be used in cutting off the bottom of a door while the door is hanging.
Further, the known jigs either rely on gravity to retain them in position on a horizontal surface or they must be clamped to the surface of the wood which is being cut if the surface is not horizontal. This, then renders these jigs and guides unusable for vertical surfaces unless clamps are used. Clamps, however, require expenditure of labor time in both mounting and dismounting them and they can mar the surfaces of the door. Further, they can get in the way of the saw which can be dangerous for the operator of the saw.
U.S. Pat. No. 2,614,591 describes an attachment for a plane which allows the door to be planed while it is in a hanging position. However, as anyone skilled with working with wood knows, planing is a very slow technique and as such would never be used by the building industry because of the high labor costs associated with it.
BRIEF SUMMARY OF THE INVENTION
In view of the above discussion it is an object of this invention to provide a door cutting guide or template which can be used on a hanging door. It is a further object to provide a door cutting guide or template which does not require a clamp to be used to maintain it against the surface of the door. Because normally a power saw would be used it is an additional object to provide a guide or template which can be used safely without endangering the carpenter or operator of the saw, and which additionally protects the surface of the door from splintering, etc.
These and other objects as will become evident from the remainder of this specification are achieved by providing a door cutting guide used in conjunction with a saw and a door of the type having two parallel face surfaces separated by two elongated side edges and a top and bottom edge which comprises: an elongated first member sized to fit across the width of one of the face surfaces of said door, said elongated member including two elongated parallel faces, one of which is capable of fitting flush against said face surface of said door, said elongated member including a lower edge capable of resting on a floor and supporting said elongated member above said floor adjacent to said door; said first member including an elongated slot means extending between said two parallel faces along a portion of the length of said elongated member, said slot means forming an opening for the blade of said saw allowing said blade of said saw to pass through said elongated member and contact said door; a retaining means located on one end of said elongated member and capable of retaining said one end of said elongated member in a fixed position with respect to said door with respect to movement of said elongated member in a direction perpendicular to the plane of the face surfaces of the door.
Further, as the saw approaches the end of its cut in the door, the preferred door cutting guide of the invention additionally includes an engagement means located on the same end of the first elongated member as the retaining means and capable of being engaged by a portion of the saw as the saw approaches it to cause the door cutting guide to slide along the face surface of the door in a direction coplanar with the plane of the face surface of the door. Additionally, the door cutting guide includes a second elongated member joined to the first elongated member in a particular arrangement across the length of the lower edge of the first elongated member such that the second elongated member projects outwardly from the first elongated member along the side of the first elongated member which serves as a surface for the baseplate of the saw. The second elongated member serves as a guide plate for the baseplate of the saw as it moves across the first elongated member.
The slot means in the first elongated member can include an elongated cavity which is located parallel to the lower edge of the first elongated member. An elongated insert is sized to fit in this cavity. The elongated insert includes a straight opening which serves as the opening through which the saw blade projects through the first elongated member. After repetitive use which inevitably results in some contact between the saw blade and the elongated insert it is possible to replace the elongated insert by withdrawing it from the cavity and inserting a replacement.
The retaining means preferably includes a retaining member including a plate located on one of the ends of the first member which is held in a parallel relationship with the first member such that the plate fits against the opposite face of the door fixedly retaining the door cutting guide to the door with respect to movement perpendicular to the face of the door, but allowing sliding of the door cutting guide in a direction parallel to the face of the door.
The door cutting guide can include an elevating means located below the second elongated member and therefore positioned between the second elongated member and the floor when the door cutting guide is used. This allows for vertical adjustment of the opening in the door cutting guide with respect to the door resulting in variability of the height of the cut being made in the door.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be better understood when taken in conjunction with the drawings wherein:
FIG. 1 is an isometric view of the door cutting guide as used on a door in conjunction with a hand-held circular saw;
FIG. 2 is a top plan view of the components shown in FIG. 1 with the exception that only the blade of the saw is indicated;
FIG. 3 is a side-elevational view in section about the line 3--3 of FIG. 1; however, only a portion of the blade of the saw is shown;
FIG. 4 is an isometric view of the door cutting guide of this invention;
FIG. 5 is a front elevational view of the door cutting guide shown in FIG. 4; and
FIG. 6 is a front elevational view of an alternate embodiment of the invention.
The invention shown in the drawings and described in this specification utilizes certain principles and/or concepts which are set forth and claimed in the claims appended to this specification. Those skilled in the art to which this invention pertains will realize that these principles and/or concepts could be used in a number of differently appearing embodiments. Because of this the invention is to be construed in light of the claims and is not to be construed as being limited to the exact embodiments shown in the figures and described in the specification.
DETAILED DESCRIPTION
The door cutting guide 10 of this invention is shown alone in FIGS. 4 and 5. FIGS. 1, 2 and 3 show how the guide is used in conjunction with a vertically suspended door and a hand-held circular saw. Before describing the use of the guide 10 its component parts will first be identified.
The guide 10 has a first elongated member 12 having two parallel faces 14 and 16. In use as hereinafter explained face 16 is placed next to one of the face surfaces of the door and face 14 serves as a support for the baseplate of a circular saw. A second elongated member, or base member 18, is perpendicularly attached to the first elongated member 12 along its lower edge 20. The base member 18 has a particular shape, the function of which will be hereinafter described. Attaching to end 22 of first elongated member 12 is a horizontally oriented plate 24. Attaching to plate 24 is a plate 26. Plate 26 is spaced from first member 12 at a distance which is slightly greater than the thickness of a door. In any one usage, most of the doors will be of a standard thickness and thus the position of plate 26 from first member 12 can be fixed. It is to be realized of course that in special circumstances wherein exceedingly thin or thick doors are used, the distance of plate 26 from first member 12 will be modified to reflect any deviation from a normal thickness.
First member 12, base member 18 and plates 24 and 26 are all suitably joined to other members of this group by gluing, screws, nails, nuts and bolts, or other common fastening means. In the embodiment depicted in FIG. 5 these components are shown as attached to one another with suitable nails and screws.
Plate 24 extends outwardly from face 14 of first elongated member 12 by a short distance. Attaching to plate 24 adjacent to face 14 is an engagement block or member 28. Engagement block 28 is adapted to engage the front end of the baseplate of a circular saw and allows movement of the baseplate of the saw to be transmitted to the first elongated member 12. It is not mandatory to use the engagement block 28 for this purpose. The segment 30 of plate 24 which extends beyond face 14 will serve the same function, i.e., an engagement means, as engagement block 28; however, in actual use in the construction industry it is preferred to use the engagement block 28 because it is replaceable and after multiple uses, if the edge of the baseplate 12 of the circular saw is sharp, this sharp edge tends to abrade the engagement block 28. Thus, the replaceability of the engagement block 28 results in longer service life of the door cutting guide 10.
Extending horizontally across the first elongated member 12 between faces 14 and 16 is an elongated cavity 32. The cavity 32 includes a series of notches, collectively identified by the numeral 34, cut into face 14. The cavity 32 is formed in the elongated member 12 such that it is parallel to lower edge 20 and extends almost across the total length of elongated member 12 from end 22 to the other end 36.
An elongated saw blade guide insert 38 fits into the cavity 32. The insert 38 includes a plurality of ears identified collectively by the numeral 40 equal in number to the notches 34. Further, the ears 40 are spaced along the insert 38 such that when the cutting guide 38 is placed within the cavity 32 the ears 40 align with the notches 34. A plurality of nuts and bolts attach the ears 40 to the portion of the first elongated member 12 located between the notches 34 and face 16. In the place of the nuts and bolts appropriate screws or other fastening means could be used. In addition to the notches 34, two identical notches 42 located at the respective ends of cavity 32, receive the ends of the insert 38. These ends are attached in the notches 42 in the same manner as the ears 40 are attached.
Since the insert 38 is in close proximity to or at times in direct contact with a spinning saw blade, it is preferredly made out of wood. Generally a hard wood would be used which would hold up under repeated use, but would still give should the saw blade inadvertently come in contact with it. After many repeated uses, it is inevitable that the saw insert 38 will be enlarged and notched a few times detracting from its usefulness. When the insert 38 is deemed no longer serviceable it simply is removed from the saw cutting guide 10 and a new insert 38 inserted. The remainder of the components, that is the first elongated member 12, the base member 18, the plates 24 and 26, and the engagement block 28 could be constructed of a variety of material. The simplest of these would be a wood material, either a hard wood or a soft wood. Alternately, any or a portion of these components could be constructed of metal, plastic or the like.
Referring now to FIGS. 1, 2 and 3, a door 44 having two parallel faces 46 and 48 separated by two elongated side edges 50 and 52 and a top edge 54 and bottom edge 56 is shown suspended by hinges collectively identified by numeral 58. The hinges 58 fit onto the surface of a door facing 60 placed between two walls 62 and 64. The door cutting guide 10 is slid against face 46 of door 44 along face 16 of elongated member 12. The edge 50 of the door is slid into the U-shaped cavity 66 formed between plates 26, 24 and elongated member 12. The other end 36 of the door cutting guide 10 is fixedly held against the face 46 of door 44 using one hand 68 as a clamp between the other face 48 of the door 44 and the face 14 of the elongated member 12. A circular saw 70 is rested against the door cutting guide 10 such that edge 72 of its baseplate 74 rests against base member 18 and the bottom surface 76 of the baseplate 74 is directed toward face 14 of elongated member 12. This positions the saw blade 78 in the straight opening 80 in the insert 38. At this point it is noted that the length of the door cutting guide 10 is somewhat greater than the width of the door 44; thus, the elongated insert 38 extends beyond edge 52 of the door 44. This allows the saw blade 78 to slide into the straight opening 80 in insert 38 until the bottom surface 76 of the baseplate 74 is flush against the face 14 of elongated member 12. The saw is then started and slowly slid toward end 22 of the door cutting guide 10.
As viewed from above in FIG. 2 the rotation of the saw blade 78 is clockwise. The teeth of the saw blade 78 therefore are cutting the door as they move in the direction from face 48 toward face 46. Face 46 is firmly supported against face 16 of the elongated member 12. This serves to prevent face 46 of door 44 from splintering as the saw moves through it. Thus, the guide in addition to assisting in sawing the door 44 also assists in preventing splintering of the door 44.
As can be seen in FIG. 1 the edge 50 of the door 44 projects beyond end 82 of the opening 80 in the elongated insert 38. Because of this, the segment of the door between end 82 and edge 50 could not be cut without cutting into that portion of the elongated member 12 between end 32 of the insert 38 and plate 24. However, before the saw blade 78 cuts through end 82 of insert 38 the front edge 84 of the baseplate 74 contacts the engagement block 28. Further, movement of the saw 70 in a direction toward edge 50 of door 44 causes the door cutting guide 10 to slide along the door 44 in a direction toward the left hand side of FIG. 1. While this is happening the operator loosens his grip of his hand 68 slightly allowing the door cutting guide 10 to slide along his hand. The door cutting guide 10 continues to slide until the saw blade 78 completely cuts through the door 44 exiting out of edge 50.
The whole cutting operation of the door 44 can be done in one smooth continous manner. The door cutting guide 10 is simply positioned next to the door 44 and slid along the door 44 until edge 50 is safely within the U-shaped channel 66. The saw is inserted, moved along the door cutting guide 10 and smoothly exits edge 50.
Because of the ease of operation in using the door cutting guide 10 a carpenter can rapidly trim the bottom of a succession of doors 44 in a house. Aside from the accurate trimming of the door the ease of operation results in economy because of the decrease in labor expended.
The opening 80 in the elongated insert 38 can be preformed during manufacture of the door cutting guide 10. Any such preforming of the opening 80 would be done in light of utilizing standard dimensions of a particular circular saw. It is preferable, however, that the opening 80 be custom-made to each individual circular saw because of small variations in the dimensions of the saw and also in the thickness of the saw blade 78, etc.
To custom form the opening 80, the first time the door cutting guide 10 is to be used the carpenter or other operator positions the door cutting guide 10 on an appropriate support surface and then positions the circular saw 70 such that its front edge 84 is against face 14 of elongated member 12 and the edge 72 of the baseplate 74 is against the base member 18. The saw is turned on and pivoted about the front edge 84 which brings the blade 78 into contact with the elongated insert 38. When the blade has completely cut through the insert 38 the saw is moved along the door cutting guide 10 toward end 36. When the saw 70 approaches end 36 the operator shuts off the saw and withdraws it. This custom forms the opening 80 in the elongated insert 38. The opening 80 is thus very precisely aligned with the individual dimensions of the saw 70 and the blade 78. If a new elongated insert 38 is later substituted in the door cutting guide 10 a custom opening 80 is likewise formed in the new insert 38. The ease of changing the insert 38 also allows the owner of a door cutting guide 10 to have a series of custom inserts 38, each individually tailored to the dimensions of a series of circular saws 70. In place of circular saw 70 inserts 38 could also be cut to correspond to the dimensions of a power sabre or reciprocating saw. While the door cutting guide 10 would normally be used with a power tool, alternatively it could also be used as a guide for a hand saw.
The shape of base member 18 is designed to allow use of the door cutting guide in very tight spaces and without regard to which side of the door the hinges are placed. The base member 18 is cut at an angle near end 36 forming oblique surface 86. The oblique surface 86 allows the guide to be used even though the door 44 lies very close to a wall 62. In FIG. 2 the door 44 makes approximately a 45 degree angle with wall 62. However, it is evident from looking at FIG. 2 because of the shape of oblique surface 86 the door 44 could be brought much closer to wall 62 and still allow use of the door cutting guide 10. Depending exactly on the angle which the oblique surface is cut, the door 44 need be positioned from the wall 62 by only a very slight amount such that the angle between the door 44 and the wall 82 is only a few degrees, as, for example, approximately 10 degrees.
In FIG. 2 the door cutting guide 10 is shown in relationship to the door 44 such that edge 50 of the door 44 fits within U-shaped channel 66 of the door cutting guide 10. If the hinges 58 supporting the door 44 were mounted along edge 50 instead of edge 52, as depicted in FIG. 2, it would be necessary in cutting the door 44 to reverse the placement of the door cutting guide 10 as might be expected. This is because of the shape of the base member 18 near end 22. Near end 22 the base member 18 has a notched surface 88 which allows for placement of the door cutting guide 10 such that the U-shaped channel 66 is located at the side of the door wherein the door is hinged. When the guide 10 is slid near the end of the cutting operation the notch surface 88 allows the guide to slide past the door facing 60 and any molding thereon a distance sufficient to allow the saw blade 78 to cut through edge 52. The unique shape of the base member 18 as defined by oblique surface 86 and notched surface 88 allows the user of the door cutting guide 10 to use the cutting guide 10 on any door regardless of which side it is hinged on, and in which direction it opens or closes.
In the embodiment of the door cutting guide 10 illustrated in FIG. 4 the height of the cut made in the door 44 is determined by the spatial relationship between the opening 80 and the base member 18. If it is desired to increase the height of the cut--that is, make a bigger space between the bottom of the door and the floor--this can easily be done by simply inserting a shim between the base member 18 and the floor. Thus, if a quarter-inch piece of plywood was first layed on the floor and then the door cutting guide positioned over the plywood, the cut in the door would be one-quarter inch higher than the cut without the piece of plywood. As is evident, any height of cut can be achieved by inserting appropriately spaced shims.
In the alternate embodiment shown in FIG. 6 the door cutting guide 90 is identical in all respects to the door cutting guide 10 as previously described except that it includes an elevating means allowing for infinite variety of adjustment with respect to the distance of the opening 80 above the surface of the floor. Positioned below the base member 18 is a sub-base member 92 identical in shape to the base member 18. Interspaced between base member 18 and sub-base member 92 is an elevating member 94.
Elevating member 94 is composed of two identical scissoring members 96. The scissoring members 96 are appropriately hinged to the base member 18 and the sub-base member 92 by hinge pins 98 appropriately journaled. Connecting the scissoring members 96 is a linking rod 100 having an adjustment knob 102 located thereon. The scissoring members 96 are each constructed of four identical levers 104 which are either pivotally hinged to each other at hinge pins 106, pivotally hinged to either base member 18 or sub-base member 92 at hinge pins 98, or hinged to adjusting nuts 108.
The rod 100 has right hand threads on one of its ends and left hand threads on its other end. One of the nuts 108 is threaded to receive the right hand threads and the other nut 108 is threaded to receive the left hand threads of rod 100. The result of this is that as rod 100 is turned by turning knob 102, the nuts 108 move toward and away from each other depending on the direction of rotation of adjustment knob 102. If the nuts 108 move away from each other the scissoring members 96 are expanded vertically lifting base member 18 with respect to sub-base member 92 and if the nuts 108 move toward each other the scissoring members 96 are expanded horizontally bringing base member 18 and sub-base member 92 closer together. | A template used in assisting in cutting off a bottom of a door so that the bottom of the door is parallel with the floor, but is raised a sufficient distance from the floor to allow a floor covering to be installed on the floor has an elongated member sized to fit across the width of one of the face surfaces of the door. The elongated member includes an elongated slot or opening extending across it and this slot or opening is normally parallel to the bottom edge of the elongated member. A retaining member located on one end of the elongated member fixedly holds the elongated member to the door in respect to movement of the elongated member away from the door in a direction perpendicular to the door face but allows movement of the elongated member across the surface of the door in a direction coplanar with both the face of the door and the elongated member. When a saw, preferredly a hand-held circular saw, is fitted to the elongated member, one edge of the baseplate of the saw follows either the floor or a second member mounted on the bottom edge of the elongated member and the blade of the saw follows the slot. The saw cuts the door parallel then to either the floor or the baseplate. | 8 |
FIELD OF THE INVENTION
The present invention relates to novel flame retardant compositions, to a method for rendering flammable synthetic resins flame-resistant, and to flame-resistant plastic compositions comprising them.
BACKGROUND OF THE INVENTION
It has been known for some time that petabromobenzylester polyacrylate (PBB-PA) is a valuable flame-retardant material, useful in a number of synthetic resins. PBB-PA is prepared by the polymerization of pentabromobenzylester monoacrylate (PBB-MA), e.g., by the process described in DE 25 27 802. The so-obtained PBB-PA polymeric flame-retardant material is then incorporated into the synthetic resin to which it is desired to impart flame-retardant properties, by techniques known to the skilled engineer.
SUMMARY OF THE INVENTION
It has now been most surprisingly found, and this is an object of the invention, that the monomer pentabromobenzylester monoacrylate also by himself can be employed as a flame-retardant agent as such, and can be incorporated into the synthetic resin, without first polymerizing it to obtain PBB-PA.
It has further been found, and this is another object of the invention, that synthetic resins which incorporate PBB-MA present substantially shorter total and maximal flaming times in the UL94 test.
Various advantages deriving from the use of PBB-MA, as compared to PBB-PA, are self evident, e.g., an entire reaction step--the polymerization of PBB-MA to PBB-PA--can be dispensed with. The precise nature of the product obtained when PBB-MA is incorporated into the synthetic resin is not known. Thus, it is unclear whether a mere dispersion of PBB-MA in the polymer matrix is obtained, or whether a partial graft polymer results, or whether part of the monomer polymerizes, or copolymerizes with the matrix. Any one of the above-noted processes, or the combination of two or more of them, may occur, and different behavior may be involved with different polymeric matrices.
Thus the present invention is directed to flame-retardant compositions which comprise, as an active ingredient, pentabromobenzyl monoacrylate, or the product of its in situ reaction. As will be apparent to those skilled in the art, the said compositions may further comprise additional additives, such as conventionally employed flame-retardant synergists, fillers, heat and UV stabilizers, antioxydants, lubricants, plasticizers, etc., and may be provided in substantially pure form, or in different compositions thereof, or in master batches. It should also be understood that the exact mechanism by means of which PBB-MA imparts flame retardancy to synthetic resins has not been elucidated, but the exact understanding of this phenomena is not critical. However, PBB-MA may at least partly react with other compounds or additives in the polymeric matrix, to give grafts or other types of compounds. However, as long as the result of such a reaction still provides an improvement of the flame retardancy, the goals of the invention are achieved. It should be therefore understood that the term "the product of the in situ reaction" of PBB-MA refer to any such compound formed during plastic processing, storage, handling or the like.
Also encompassed within the present invention is a method for imparting flame-retardant properties to a flammable synthetic resin, which method comprises incorporating into the said synthetic resin pentabromobenzyl monoacrylate. The incorporation method can be any of those commonly employed in the art, e.g., PBB-MA can be blended with the synthetic resin before processing thereof in the plastic processing apparatus, or mixed during processing. The actual incorporation method may affect the precise nature of the resulting dispersion of PBB-MA in the matrix, as hereinbefore detailed, but is not critical to the invention. The flame retarded plastic composition which incorporates PBB-MA, and which is obtained by the aforesaid method, also forms part of the invention. The invention is directed not only to compositions, methods and processes, but also to the use of PBB-MA as a flame retardant agent.
DETAILED DESCRIPTION
The above and other characteristics and advantages of the invention will be better understood from the following examples, in which non-limiting embodiments of the invention are described for the purpose of illustration.
EXAMPLE 1
In this and the following examples, contents of active material are given as percent of bromine in the product, to permit a comparison between PBB-MA- and PBB-PA-containing specimens.
Concentrates of PBB-PA and PBB-MA containing 10% bromine were prepared in the BUSS extruder compounder, according to the following formulations:
______________________________________Component (%) (%)______________________________________PBB-PA 14.3 --PBB-MA -- 14.3Antimony 7.15 7.15TrioxidePBT - VALOX 420 78.55 78.55(ex General Electric)Bromine 10 10______________________________________
The processing temperature profile was: CO-kneader: 220° C.; pellettizer: 215° C.; die: 207° C. The concentrates were "diluted" with pure PBT to the required bromine level, and specimens were prepared for the different tests with an Arburg injection-molding machine, at the following conditions:
Processing Temperature Profile: inlet: 210° C.; middle zone: 235° C., final zone: 250° C.; nozzle: 275° C.
Working Pressure: Injection Pressure: 60 Atm.; Holding Pressure: 40 Atm.; Back Pressure: 10 Atm.
Timing: Injection Time: 0.1 sec.; Holding Time: 4.0 sec.; Cooling Time: 14.0 sec.; Mould Opening Time: 0.1 sec.; Injection Delay: 0.5 sec..
A 5% Br PBT (polybutyleneterephthalate) specimen (Valox-420) was prepared, using commercially available PBB-PA (FR 1025--Eurobrom, Holland) and PBB-MA (prepared by IMI, Haifa, Israel).
The data and results of tests carried out with these specimens are set forth in Table I below. The virtually zero flaming time of the composition of the invention should be noted.
EXAMPLE 2
Two HIPS (High Impact Polystyrene) specimens (10% Br and a 14% Br) were prepared according to the following procedure, and using the same PBB-MA as in Example 1. The formulation employed was the following:
______________________________________ Thickness [mm]Component 1.6 3.2______________________________________HIPS/Huels VESTYRON 638 74.4 81.5ANTIMONY TRIOXIDE 5.1 3.6(Blue Star - Campine)Mg-Stearate (ex WITCO) 0.5 0.5TINUVIN P 0.5 0.5(ex CIBA-GEIGY)PBB-PA/PBB-MA 19.5 13.9Br/Sb Atomic Ratio 5 5Bromine 14 10______________________________________
The formulations were compounded in a Brabender Plastograph at 200° C. for 4 minutes at 40 RPM, and subsequently cooled to 130° C. at 20 RPM (total processing time: 15-16 mins.). The resulting melt was pressplated 1 min. at 200° C. at 1 Atm., and during another minute at 100 Atm., after which it was cooled during 4 mins. to 120° C.
Specimens were prepared with a ribbon saw.
The results are shown in Table II below.
EXAMPLE 3
Example 2 was repeated, but using ABS (Acrylonitrile-Butadiene-Styrene) as the matrix, to give final 10, 12 and 14% Br contents. The results are detailed in Table III below.
EXAMPLE 4
Flame-retarded Nylon 6 specimens (Capron 8200 MS) were prepared, following the procedures of Example 1, to give a final 9% Br content. The results are set forth in Table IV.
The above description and examples have been given for the purpose of illustration and are not intended to be limitative. Many different synthetic resins, compounding conditions and additives can be employed, together with PBB-MA, without exceeding the scope of the invention.
TABLE I______________________________________5% Br in PBT (Valox-420) Flame-retardant Additive PBB-PA PBB-MA None______________________________________Flame-Retardancy(UL 94 - 3.2 mm)Max Flam. (sec) 5 0 >180Total Flam. (sec) 10 0 >900Drip no no 5Rating V0 V0 NRHDT (°C.)* 198 ± 2 201 ± 0.4 205Mechanical PropertiesIZOD Notched (J/m) 87 ± 4 91 ± 6 100Tensile strength at 104 ± 3 109 ± 1 115break (MPa)Elongation at break (%) 2.4 ± 0.3 2.4 ± 0.0 3Tensile Modulus (MPa) 9500 ± 470 9910 ± 530 8000Flexural Strength (MPa) 175 ± 8 172 ± 2 190Flexural Modulus (MPa) 6910 ± 380 7560 ± 220 7500CTI (V) 240-260 250-270 460-520______________________________________ *Heat Distortion Temperature at 264 psi.
TABLE II______________________________________FR - HIPS Formulation No.Component 1 2 3 4______________________________________Bromine (%) 10 10 14 14HIPS - VESTYRON 638 81.5 81.1 74.4 73.9(ex Huels)PBB-PA (ex Eurobrom) -- 14.3 -- 20PBB-MA ex IMI 13.9 -- 19.5 --Antimony Trioxide 3.6 3.6 5.1 5.1(ex Campine)Mg-Stearate (ex WITCO) 0.5 0.5 0.5 0.5TINUVIN P 0.5 0.5 0.5 0.5(ex Ciba-Geigy)PROPERTIES:UL-941.6 mm thickness -- -- V0 V03.2 mm thickness V0 V0 -- --IZOD NOTCHED 49 38 -- --IMPACT [J/m]HDT [°C.] at 1.82 KPa load 73 79 -- --______________________________________
TABLE III______________________________________FR - ABS Formulation No.Component 1 2 3 4______________________________________Bromine (%) 14 12 12 10ABS (ex Borg-Warner) 75.8 79.3 79.7 83.1PBB-PA (ex Eurobrom) 20.0 17.1 -- --PBB-MA ex IMI -- -- 16.7 13.9Antimony Trioxide 4.2 3.6 3.6 3.0(ex Campine)PROPERTIES:UL-94 V0 V0 V0 V0/V1(1.6 mm thickness)IZOD NOTCHED 85 -- -- --IMPACT [J/m]HDT [°C.] at 1.82 KPa load 61 -- -- --______________________________________
TABLE IV______________________________________FR - Nylon 6 (CAPRON 8200 HS) Formulation No.Component 1 2 3______________________________________Bromine (%) 10 9 9CAPRON 8200 HS 79.5 81.3 81.3(ex Allied Chem. Corp)PBB-PA (ex Eurobrom) 14.3 12.9 --PBB-MA ex IMI -- -- 12.9Antimony Trioxide 4.8 4.3 4.3(ex Campine)Mg-Stearate (ex WITCO) 0.5 0.5 0.5HOSTAFLON TF 9202 1.0 1.0 1.0(ex Hoechst)PROPERTIES:UL-941.6 mmMax. Flam. [sec] 8 11 5Total. Flam. [sec] 33 36 14DRIP no 1 noRATING V0 V0/V1 V0______________________________________ | Novel flame-retardant composition incorporate as an active ingredient pentabromobenzylester monoacrylate, of a product of its in situ reaction.
Articles made of flammable synthetic resins can be rendered flame-retarded by the incorporation of the novel flame-retandant compositions. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application No. 61/488,831, filed May 23, 2011, entitled TRANSPARENT CONDUCTIVE FILMS, METHODS, AND ARTICLES, which is hereby incorporated by reference in its entirety.
BACKGROUND
Transparent conductive films are finding widespread use in such applications as electronic and optical devices that exploit the films' transparency, conductivity, and stability. Providing transparent conductive films as coatings on flexible transparent substrates broadens their range of use.
Some flexible substrates that may be in common use in other coatings applications have found limited use for transparent conductive film applications. Standard grades of polyethylene terephthalate (PET) films, for example, can exhibit excessive migration of oligomers to film surfaces, often leading to increased haze due to the powdered deposits that can develop during processing.
Flexible films based on polyethylene naphthalate (PEN) are reported to exhibit low levels of oligomer migration and haze development relative to standard grades of PET film. See, for example, U.S. Pat. No. 4,725,479 to Utsumi, which is hereby incorporated by reference in its entirety. However, PEN films have higher raw material costs and can be more costly to manufacture than standard grades of PET films; they are generally sold at a premium.
Specialty grades of PET films that have low oligomer content are known. See, for example, U.S. Pat. No. 5,498,454 to Kuze et al. and U.S. Pat. No. 6,020,056 to Walker et al., both of which are hereby incorporated by reference in their entirety. Resin oligomer content can be reduced after melt-phase polymerization, for example, by thermally processing the resin at temperatures between the resin's glass transition and melting temperatures, such as during solid-state polymerization processes, resin annealing processes, oligomer extraction processes, and the like. Further oligomer development after such processing can be limited by, for example, reducing film processing temperatures and dwell times. Such grades of PET film tend to be more costly to manufacture than standard grades of PET films and are generally sold a premium.
SUMMARY
Applicants have discovered compositions and methods that provide flexible transparent conductive films that exhibit low levels of oligomer migration and haze development, without having to use costly substrates based on PEN film or low-oligomer content grades of PET film. Such flexible transparent conductive films can be used in electronic and optical applications.
At least a first embodiment provides flexible transparent conductive films comprising a transparent substrate comprising at least one first polyester comprising at least about 70 wt % ethylene terephthalate repeat units, the substrate further comprising a front side surface and a back side surface; at least one barrier layer disposed on the front side surface, the at least one barrier layer comprising at least one thermoplastic resin, and the at least one thermoplastic resin comprising at least one first cellulose ester polymer; and at least one transparent conductive layer disposed on the at least one barrier layer, the transparent conductive layer comprising at least one second cellulose ester polymer, where the film comprises a Delta Haze measurement less than about 1%.
In some such embodiments, the at least one first polyester may comprise polyethylene terephthalate with at least about 0.6 wt % extractable oligomer content, the at least one first cellulose ester polymer may comprise at least one cellulose acetate butyrate polymer, or the at least one thermoplastic resin may comprise at least one second polyester having less than one unsaturated carbon-carbon bond per ten repeat units. In some cases, the at least one transparent conductive layer may comprise at least one silver nanowire. The at least one second cellulose ester polymer may, for example, comprise at least one cellulose acetate butyrate polymer.
In some cases, such films may further comprise at least one hardcoat layer disposed on the back side surface comprising at least one radiation curable monomer.
Such films may comprise a Delta Haze measurement less than about 0.5%. In some cases, such films comprise Delta Haze measurements that are about the same as those of polyethylene naphthalate films.
At least a second embodiment provides flexible transparent conductive films comprising: a transparent substrate comprising at least one first polyester comprising at least about 70 wt % ethylene terephthalate repeat units, where the substrate further comprises a front side surface and a back side surface; at least one barrier layer disposed on the front side surface, where the at least one barrier layer comprises at least one thermoplastic resin; and at least one transparent conductive layer disposed on the at least one barrier layer.
The at least one first polyester may, for example, comprise polyethylene terephthalate (PET), such as, for example, PET with at least about 0.6 wt % extractable oligomer content.
The at least one thermoplastic resin may, for example, comprise at least one cellulosic polymer, such as, for example, at least one cellulose acetate butyrate polymer. Or the at least one thermoplastic resin may, for example, comprise at least one second polyester, such as, for example, at least one linear substantially saturated polyester. Or the at least one thermoplastic resin may, for example, comprise at least one cellulosic polymer and at least one second polyester.
The at least one transparent conductive layer may, for example, comprise at least one metal nanostructure, such as, for example, at least one silver nanowire. Or the at least one transparent conductive layer may, for example, comprise at least one cellulosic polymer, such as, for example, at least one cellulose acetate butyrate polymer. Or the at least one transparent conductive layer may, for example, comprise at least one metal nanostructure and at least one cellulosic polymer.
In at least some embodiments, the flexible transparent conductive film further comprises at least one hardcoat layer disposed on the back side surface of the transparent substrate. The at least one hardcoat layer may, for example, comprise at least one radiation curable monomer. Or the at least one hardcoat layer may, for example, comprise at least one cellulosic polymer, such as, for example, at least one cellulose acetate butyrate polymer.
Some embodiments provide flexible transparent conductive films comprising Delta Haze measurements less than about 5%, or less than about 1%, or less than about 0.5%. In some cases, such films comprise Delta Haze measurements that are about the same as those of polyethylene naphthalate films.
Still other embodiments provide articles comprising such flexible transparent conductive films. Non-limiting examples of such articles include electronic displays, touch screens, portable telephones, cellular telephones, computer displays, laptop computers, tablet computers, point-of-purchase kiosks, music players, televisions, electronic games, electronic book readers, transparent electrodes, solar cells, light emitting diodes, other electronic devices, medical imaging devices, medical imaging media, and the like.
These embodiments and other variations and modifications may be better understood from the description, exemplary embodiments, examples, and claims that follow. Any embodiments provided are given only by way of illustrative example. Other desirable objectives and advantages inherently achieved may occur or become apparent to those skilled in the art.
DESCRIPTION
All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference.
U.S. provisional application No. 61/488,831, filed May 23, 2011, entitled TRANSPARENT CONDUCTIVE FILMS, METHODS, AND ARTICLES, is hereby incorporated by reference in its entirety.
Transparent Substrates
At least some embodiments provide flexible transparent conductive films comprising transparent substrates that comprise at least one first polyester. The at least one first polyester may, for example, comprise at least about 70 wt % ethylene terephthalate repeat units. Or it may comprise at least about 75 wt %, or at least about 80 wt %, or at least about 85 wt %, or at least about 90 wt % or at least about 95 wt % ethylene terephthalate repeat units.
Such polyesters may, for example, be made through condensation polymerization of one or more monomers comprising acid or ester moieties with one or more monomers comprising alcohol moieties. Non-limiting examples of monomers comprising acid or ester moieties include, for example, aromatic acids or esters, aliphatic acids or esters, and non-aromatic cyclic acids or esters. Exemplary monomers comprising acid or ester moieties include, for example, terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isothphalate, phthalic acid, methyl phthalate, trimellitic acid, trimethyl trimellitate, naphthalene dicarboxylic acid, dimethyl naphthalate, adipic acid, dimethyl adipate, azelaic acid, dimethyl azelate, sebacic acid, dimethyl sebacate, and the like. Exemplary monomers comprising alcohol moieties include, for example, ethylene glycol, propanediol, butanediol, hexanediol, neopentyl glycol, diethylene glycol, cyclohexanedimethanol, and the like.
Such polyesters may, for example, comprise repeat units comprising a first residue from a monomer comprising acid or ester moieties joined by an ester linkage to a second residue from a monomer comprising alcohol moieties. Exemplary repeat units are, for example, ethylene terephthalate, ethylene isophthalate, ethylene naphthalate, diethylene terepthalate, diethylene isophthalate, diethylene naphthalate, cyclohexylene terephthalate, cyclohexylene isophthalate, cyclohexylene naphthalate, and the like. Such polyesters may comprise more than one type of repeat group and may sometimes be referred to as copolyesters.
Such polyesters generally comprise polymer chains that have a distribution of chain lengths. Some chains may be linear, others non-linear. Some chains may be cyclic, that is, comprised of several repeat units that form at least one cycle, or they may be acyclic, where the repeat units between any two chain ends do not form a cycle.
Chains comprising a relatively small number of repeat units, whether cyclic or acyclic, are often referred to as oligomers, or they may be referred to by a specific name, such as “trimer” to refer to oligomers with three repeat units or “tetramer” to refer to oligomers with four repeat units. Such oligomers may, for example, be the natural product of chemical equilibration during high temperature melt-phase polymerization or high temperature manufacture of a polyester film.
The polyester may, in some cases, exhibit at least about 0.6 wt % extractable oligomer content. Polyester oligomeric content may be directly measured by chemically extracting low molecular weight species from a film. For example, U.S. Pat. No. 6,020,056 to Walker et al., which is hereby incorporated by reference in its entirety, discloses gravimetric determination of extractable oligomer content by comparing the weights of a polyester film before and after immersing the film in boiling xylene for 24 hrs.
Barrier Layers
At least some embodiments provide at least one barrier layer disposed on the front side surface of the transparent substrate, where the barrier layer comprises at least one thermoplastic resin.
The at least one thermoplastic resin may, for example, comprise at least one cellulosic polymer. Cellulosic polymers are polysaccharides or derivatives of polysaccharides, that may have degrees of polymerization of, for example, 100, 1000, 10,000, or more. These include derivatives of cellulose, such as, for example, esters and ethers of cellulose. Cellulose ester polymers (also referred to as “cellulosic esters”) include cellulose acetates, such as, for example, cellulose acetate, cellulose triacetate, cellulose propionate, cellulose acetate propionate, cellulose acetate butyrate (CAB), and the like. Cellulosic ether polymers (also referred to as “cellulose ethers”) include, for example, methylcellulose, ethylcellulose, ethyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethyl methyl cellulose, hydroxypropyl methyl cellulose, ethyl hydroxyethyl cellulose, carboxymethyl cellulose, and the like. These and other such cellulosic polymers will be understood by those skilled in the art.
The at least one thermoplastic resin may, for example, comprise at least one second polyester. Polyester resins may comprise, for example, aliphatic polyesters, aromatic polyesters, aliphatic copolyesters, aromatic copolyesters, or copolyesters having a combination of aliphatic and aromatic repeat units. Exemplary polyester resins are polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, poly(ε-caprolactone), poly(glycolide), poly(lactide), poly(lactide-co-glycolide), and the like.
In at least some embodiments, the thermoplastic resin may, for example, comprise at least one linear substantially saturated polyester. Some polyester resins may possess some extent of unsaturation, with double or triple carbon-carbon bonds being included for polymerization or crosslinking by thermal or radiation curing. Other polyester resins may be substantially saturated, and may, for example, comprise less than one unsaturated carbon-carbon bond for every ten or more of its repeat units.
Transparent Conductive Layers
At least some embodiments provide at least on transparent conductive layer disposed on the at least one barrier layer. In at least some embodiments, the transparent conductive layer may comprise at least one metal nanostructure.
In at least some embodiments, the at least one metal nanostructure may comprise at least one nanowire, nanocube, nanorod, nanopyramid, or nanotube, or the at least one metal nanoparticle comprises at least one nanowire. The at least one metal nanostructure may, for example, comprise at least one coinage metal, such as, for example, silver. An exemplary metal nanostructure is a silver nanowire. Conductive layers comprising nanowires are described in, for example, European Patent Application Publication EP 1 965 438, published Sep. 3, 2008, which is hereby incorporated by reference in its entirety.
The at least one transparent conductive layer may, for example, comprise at least one cellulosic polymer. Cellulosic polymers are polysaccharides or derivatives of polysaccharides, that may have degrees of polymerization of, for example, 100, 1000, 10,000, or more. These include derivatives of cellulose, such as, for example, esters and ethers of cellulose. Cellulosic esters include cellulose acetates, such as, for example, cellulose acetate, cellulose triacetate, cellulose propionate, cellulose acetate propionate, cellulose acetate butyrate (CAB), and the like. Cellulosic ethers include, for example, methylcellulose, ethylcellulose, ethyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethyl methyl cellulose, hydroxypropyl methyl cellulose, ethyl hydroxyethyl cellulose, carboxymethyl cellulose, and the like. These and other such cellulosic polymers will be understood by those skilled in the art.
In at least some embodiments, the at least one transparent conductive layer may have a surface resistivity of less than about 150 ohms/sq, or less than about 125 ohms/sq, or less than about 100 ohms/sq, or less than about 75 ohms/sq, or less than about 65 ohms/sq, such as, for example, a surface resistivity of about 110 ohms/sq or a surface resistivity of about 60 ohms/sq.
Hardcoat Layers
At least some embodiments provide at least one hardcoat layer (“hardcoat”) disposed on the back side surface of the transparent substrate. At least some hardcoats may be radiation curable hardcoats, such as, for example, an ultraviolet (UV) curable hardcoat. Such UV curable hardcoats are known. See, for example, Koleske, J. V., Coatings Technology, 1997, 69(866), 29; U.S. Pat. No. 7,339,793; and US patent application publication 2009/0274902; each of which is hereby incorporated by reference in its entirety. UV curable hardcoats may, for example, comprise monomeric or functional acrylates. Monomeric and functional acrylates can have molecular weights of 10,000 g/mol or less, typically 5,000 g/mol or less. UV curable hardcoats may, for example, comprise unsaturated polyesters. Unsaturated polyesters can attain high molecular weights and high crosslink densities upon exposure to ultraviolet radiation, which can result in improved coating durability.
In at least some embodiments, the at least one hardcoat layer comprises at least one radiation curable monomer. Radiation curable monomers are known. These may, for example, comprise monomers with one or more acrylic or methacrylic groups, such as, for example, polyfunctional monomers with two, three, four, five, six, or more polymerizable groups. At least some unsaturated polyesters or their oligomers may be radiation curable monomers. In some cases, radiation curable monomers may be polymerized or crosslinked in the presence of light, such as, for example, ultraviolet light at wavelengths of, for example, about 246 nm or about 280 nm. Dipentaerythritol pentaacrylate (DPPA) is an exemplary radiation curable monomer. These and other such monomers will be understood by those skilled in the art.
Curing may be aided through use of photoinitiators, such as, for example, 1-hydroxycyclohexylphenyl ketone, or crosslinkers, such as, for example hexamethoxymethylmelamine. These and other curing aids will be understood by those skilled in the art.
In at least some embodiments, the at least one hardcoat layer comprises at least one cellulosic polymer. Cellulosic polymers are polysaccharides or derivatives of polysaccharides, that may have degrees of polymerization of, for example, 100, 1000, 10,000, or more. These include derivatives of cellulose, such as, for example, esters and ethers of cellulose. Cellulosic esters include cellulose acetates, such as, for example, cellulose acetate, cellulose triacetate, cellulose propionate, cellulose acetate propionate, cellulose acetate butyrate (CAB), and the like. Cellulosic ethers include, for example, methylcellulose, ethylcellulose, ethyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethyl methyl cellulose, hydroxypropyl methyl cellulose, ethyl hydroxyethyl cellulose, carboxymethyl cellulose, and the like. These and other such cellulosic polymers will be understood by those skilled in the art.
Films Comprising Low Delta Haze
In at least some embodiments, the transparent conductive film has a total light transmission of at least about 80%, or of at least about 85%. Or the transparent conductive films have ASTM D-1003 haze values of less than about 10%, such as, for example, haze values of about 9.38% or haze values of about 5.22%.
Percent haze of films may be measured, for example, using a BYK Gardner Hazegard instrument, according to ASTM method D-1003. Films may be hung in a 150° C. oven under an air atmosphere for 60 minutes. Percent haze may then be measured after the heat treatment and a Delta Haze measurement calculated as the difference of the post-treatment and pre-treatment percent haze numbers.
In at least some embodiments, the transparent conductive film has a Delta Haze measurement less than about 5%, or less than about 1%, or less than about 0.5%.
In some cases, the Delta Haze measurement is about the same as that of polyethylene naphthalate (PEN) film. Comparative Example 4, below, presents Delta Haze measurements for four commercial PEN films that range from 0.06% to 0.44%. Examples 1-3, below, show numerous examples of films that exhibit Delta Haze measurements from −0.06% to 0.35%. Performance of these films would be considered to be about the same as that of PEN films.
Articles Comprising Transparent Conductive Films
Some embodiments provide articles comprising flexible transparent conductive films. Such articles may, for example, comprise electronic displays, touch screens, and the like, for use in such applications as portable telephones, cellular telephones, computer displays, laptop computers, tablet computers, point-of-purchase kiosks, music players, televisions, electronic games, electronic book readers, and the like. These and other such articles will be understood by those skilled in the art.
EXEMPLARY EMBODIMENTS
U.S. provisional application No. 61/488,831, filed May 23, 2011, entitled TRANSPARENT CONDUCTIVE FILMS, METHODS, AND ARTICLES, which is hereby incorporated by reference in its entirety, disclosed the following 21 non-limiting exemplary embodiments:
A. A flexible transparent conductive film comprising:
a transparent substrate comprising at least one first polyester comprising at least about 70 wt % ethylene terephthalate repeat units, said substrate further comprising a front side surface and a back side surface;
at least one barrier layer disposed on the front side surface, said at least one barrier layer comprising at least one thermoplastic resin; and
at least one transparent conductive layer disposed on the at least one barrier layer.
B. The film according to embodiment A, wherein the at least one first polyester comprises polyethylene terephthalate. C. The film according to embodiment A, wherein the at least one first polyester comprises polyethylene terephthalate with at least about 0.6 wt % extractable oligomer content. D. The film according to embodiment A, wherein the at least one thermoplastic resin comprises at least one cellulosic polymer. E. The film according to embodiment A, wherein the at least one thermoplastic resin comprises at least one cellulose acetate butyrate polymer. F. The film according to embodiment A, wherein the at least one thermoplastic resin comprises at least one second polyester. G. The film according to embodiment A, wherein the at least one thermoplastic resin comprises at least one linear substantially saturated polyester. H. The film according to embodiment A, wherein the at least one transparent conductive layer comprises at least one metal nanostructure. J. The film according to embodiment A, wherein the at least one transparent conductive layer comprises at least one silver nanowire. K. The film according to embodiment A, wherein the at least one transparent conductive layer comprises at least one cellulosic polymer. L. The film according to embodiment A, wherein the at least one transparent conductive layer comprises at least one cellulose acetate butyrate polymer. M. The film according to embodiment A, further comprising at least one hardcoat layer disposed on the back side surface. N. The film according to embodiment M, wherein the at least one hardcoat layer comprises at least one radiation curable monomer. P. The film according to embodiment M, wherein the at least one hardcoat layer comprises at least one cellulosic polymer. Q. The film according to embodiment M, wherein the at least one hardcoat layer comprises at least one cellulose acetate butyrate polymer. R. The film according to embodiment A comprising a Delta Haze measurement less than about 5%. S. The film according to embodiment A comprising a Delta Haze measurement less than about 1%. T. The film according to embodiment A comprising a Delta Haze measurement less than about 0.5%. U. The film according to embodiment A comprising a Delta Haze measurement that is about the same as that of polyethylene naphthalate film. V. An article comprising the film according to embodiment A. W. The article according to embodiment V comprising at least one of an electronic display, a touch screen, a portable telephone, a cellular telephone, a computer display, a laptop computer, a tablet computer, a point-of-purchase kiosk, a music player, a television, an electronic game, an electronic book reader, a transparent electrode, a solar cell, a light emitting diode, an electronic device, medical a medical imaging device, or a medical imaging medium.
EXAMPLES
Materials
Unless otherwise noted, materials were available from Sigma-Aldrich, Milwaukee, Wis.
CYMEL® 303 is a hexamethoxymethylmelamine crosslinker (Cytec).
DESMODUR® BL 3370 MPA is a 70% solution of a blocked aliphatic polyisocyanate based on hexamethylene diisocyanate in propylene glycol monomethyl ether acetate (Bayer).
EASTMAN® CA 398-50 is a cellulose acetate polymer (Eastman Chemical).
EASTMAN® CAB 171-15i is a cellulose acetate butyrate polymer (Eastman Chemical).
EASTMAN® CAB 551-0.2 is a cellulose acetate butyrate polymer (Eastman Chemical).
EASTMAN® CAP 482-20 is a cellulose acetate propionate polymer (Eastman Chemical).
EPON™ 1031 is an epoxy resin (Momentive).
PIOLOFORM® PVB BL16 is a polyvinyl butyral resin (Kuraray).
POLYFOX™ PF-3320 is a fluorinated oxetane acrylate polymer surfactant (Omnova).
SARTOMER® SR399 is a dipentaerythritolpentaacrylate monomer (Sartomer Industries).
SKYNEX® NH10S and NX10 are polyethylene naphthalate films (SKC).
TEGO® Glide 410 is a polyether modified polysiloxane (Evonik).
TEONEX® Q65F and Q65FA are polyethylene naphthalate films (Teijin DuPont Films).
UCAR™ VYNS is a 90/10 vinyl chloride-vinyl acetate copolymer having an average molecular weight of 44,000 g/mol. (Dow Chemical).
VITEL® PE2200B is an amorphous, thermoplastic, high molecular weight, aromatic, linear saturated polyester resin. (Bostik).
VITEL® PE2700B is an amorphous, thermoplastic, linear saturated polyester (Bostik).
VITEL® PE2700B-LMW is a linear saturated polyester resin having a weight average molecular weight of 30,000-70,000 g/mol. (Bostik).
VITEL® PE5833 is a polyester resin (Bostik).
X-CURE™ 184 is a 1-hydroxycyclohexylphenone photoinitiator. (Dalian).
Example 1
Preparation of Hardcoat Coated PET Substrates
To a room temperature mixing vessel was charged 4625 g of methyl ethyl ketone (MEK) and 4625 g of butyl acetate, with moderate agitation. 750 g of EASTMAN® CAB 551-0.2 was slowly added to the vessel, taking care to avoid clumping. The vessel was covered to minimize evaporation and its contents were allowed to mix for 4 hrs. Mixing continued until samples of the vessel contents were homogeneous. The vessel contents were then filtered for use as Mixture A.
To a room temperature mixing vessel was charged 993.4 g of Mixture A. To this mixture was added 239.2 g of MEK, 239.2 g of butyl acetate, 172.0 g of SARTOMER® SR399, 224.0 g of CYMEL® 303, 69.2 g of a 16.7% solution of X-CURE™ 184 in 1 part benzophenone (Dalian) and 9 parts MEK, and 3.6 g of a 10% solution of POLYFOX™ PF-3320 in MEK, with agitation. To this mixture, 59.6 g of a 20% solution of p-toluenesulfonic acid monohydrate (Fisher) in denatured ethanol was slowly added. The vessel contents were allowed to mix for 30 min and then were filtered for use as the hardcoat coating mix.
The hardcoat coating mix was then coated on the back side of a 7-mil polyethylene terephthalate (PET) web, dried briefly under a hot air blower, and then cured under ultraviolet radiation, to provide a hardcoat layer with a dry coating weight of about 9 g/m 2 . The coated web was slit to 10-inch width films having hardcoat layers on their back sides.
Preparation of Silver Nanowire Coating Mix
To a room temperature mixing vessel was charged 1296.25 g of n-propyl acetate (>99% purity) and 82.92 g cyclohexanone (>99% purity), with moderate agitation. The set-point temperature of the mixing vessel was increased to 52° C. 119.33 g of EASTMAN® CAB 171-15i was slowly added to the vessel, taking care to avoid clumping. To the vessel was then charged 0.598 g of phthalazone (99% purity, Aldich). The vessel was covered to minimize evaporation and its contents were allowed to mix for 4 hrs. Mixing continued until samples of the vessel contents were homogeneous. The vessel contents were then filtered for use as Mixture B.
To a room temperature mixing vessel was charged 1499.11 g of Mixture B, to which was added a mixture of 34.98 g of DESMODUR® BL 3370 MPA and 40 g of n-propyl acetate, with moderate agitation. To the agitated vessel was then charged a mixture of 10.88 g of bismuth neodecanoate (>99% purity, Aldrich) and 20 g of n-propyl acetate, followed by a mixture of 2.04 g of TEGO® Glide 410 and 10 g of n-propyl acetate, and then by 140 g of n-propyl acetate. The contents of the vessel continued to be mixed for 15 min. To the vessel was then added 150 g of ethyl lactate (>99% purity), which was allowed to mix for 10 min. Over ten minutes, 1500.0 g of a 2.5% slurry of silver nanowires in isopropanol (>98% purity) was added to the vessel and dispersed. After 15 min, the vessel contents were filtered for use as the silver nanowire coating mix.
Preparation of Coated Films
Either uncoated 7-mil PET films or the PET films having hardcoat layers on their backsides were used as substrates.
Barrier layer coating mixes were prepared as 5% solutions of various resins in methyl ethyl ketone (MEK), using the resins listed in Table I. On the front sides of some of the substrates, barrier layer coating mixes were coated using a #6 Mayer rod and dried to achieve a dry coating weight of 0.4 g/m 2 . The front sides of the remaining substrates had no barrier layer coating applied.
The silver nanowire dispersion was then applied on the front sides of the substrates, either over the barrier layer or over the uncoated substrate, and dried at 135° C. for five minutes to produce coated films for evaluation. The dry coating thickness of the barrier layers was 0.7 μm.
Coated Film Evaluation
Percent haze of the coated films was measured using a BYK Gardner Hazegard instrument, according to ASTM method D-1003. The films were then hung in a 150° C. oven under an air atmosphere for 60 minutes. Percent haze was then measured after the heat treatment and a Delta Haze measurement calculated as the difference of the post-treatment and pre-treatment percent haze numbers.
Table I summarizes the results. Sample 1-13, which had no barrier layer, no silver nanowire layer, and no backcoat layer, had the highest Delta Haze measure, followed by Sample 1-12, which had a backcoat layer, but no barrier layer and no silver nanowire layer, followed by Sample 1-11, which had a backcoat layer and a silver nanowire layer, but no barrier layer. The uncoated side of Sample 1-12 was very dusty and cloudy. Coated films having barrier layers, silver nanowire layers, and backcoat layers exhibited low Delta Haze measurements, with the films with barrier layers comprising cellulosic polymers or polyesters exhibiting the smallest Delta Haze measurements.
TABLE I
Sample ID
Barrier Layer Resin
Backcoat Layer
Delta Haze (%)
1-1
EASTMAN ® CAB 171-
Hardcoat
−0.01
15i
1-2
EASTMAN ® CA 398-60
Hardcoat
0.20
1-3
EASTMAN ® CAP 482-20
Hardcoat
0.15
1-4
VITEL ® PE2700B-LMW
Hardcoat
0.13
1-5
VITEL ® PE5833
Hardcoat
0.34
1-6
VITEL ® PE2200B
Hardcoat
0.07
1-7
VITEL ® PE2700B
Hardcoat
0.34
1-8
EPON ™ 1031
Hardcoat
0.35
1-9
UCAR ™ VYNS
Hardcoat
0.83
1-10
PIOLOFORM ® PVB
Hardcoat
1.37
BL16
1-11
No Barrier Layer
Hardcoat
5.00
1-12
No Barrier Layer
Hardcoat
5.49
No Nanowire Layer
1-13
No Barrier Layer
No Backcoat
8.53
No Nanowire Layer
Layer
Example 2
Barrier layer coating mixes were prepared from EASTMAN® CAB 171-15i and VITEL® PE2700B-LMW in methyl ethyl ketone (MEK), as listed in Table II. A resin-free MEK coating mix was prepared, as well.
The barrier layer coating mixes were coated on the front sides of 7-mil polyethylene terephthalate (PET) supports that also had hardcoat layers applied to their reverse sides, which were prepared according to the procedure of Example 1. Various barrier layer coating weights were used, as shown in Table II. Samples 2-1 through 2-9 were coated using a #4 Mayer rod, while the remaining samples were coated using a #6 Mayer rod. The barrier layer coatings were dried at 121° C. for 3 minutes.
Delta Haze was determined according to the procedure of Example 1. All barrier layer coatings containing the cellulosic polymer and polyester exhibited improved Delta Haze measurements relative to the 100% MEK control sample, even those with very light coating weights.
TABLE II
Barrier
Barrier
Barrier
Barrier
Layer
Layer
Layer
Layer Dry
Barrier
Cellulosic
Polyester
Total
Coating
Layer
Content
Content
Solids
Weight
Dry
Delta
Sample
Dry Basis
Dry Basis
Content
(g/sq.
Thickness
Haze
ID
(wt %)
(wt %)
(wt %)
m.)
(μm)
(%)
2-1
70
30
4
0.358
0.4
0.01
2-2
70
30
3
0.227
0.3
0.17
2-3
70
30
1
0.032
0.01
0.25
2-4
80
20
4
0.358
0.4
0.29
2-5
80
20
3
0.227
0.3
0.26
2-6
80
20
1
0.032
0.01
0.31
2-7
90
10
4
0.358
0.4
0.18
2-8
90
10
3
0.227
0.3
0.17
2-9
90
10
1
0.032
0.01
−0.06
2-10
90
10
1
0.042
0.2
0.12
2-11
80
20
0.50
0.021
0.08
0.17
2-12
80
20
0.20
0.008
0.03
0.09
2-13
80
20
0.10
0.004
0.02
0.07
2-14
80
20
0.05
0.002
0.008
0.14
2-15
80
20
0.01
0.0004
0.002
0.21
2-16
0
0
0
n/a
n/a
7.55
Example 3
Barrier-coated PET substrates were prepared according to the procedure of Example 2. The coating compositions and coating weights are shown in Table III. For three of the six samples, a silver nanowire coating mix was prepared and applied according to the procedure of Example 1.
Delta Haze was measured according to the procedure of Example 1, as summarized in Table III. Delta Haze was low compared to the control samples of Examples 1 and 2. The results also show that the performance of the barrier layers was not significantly adversely affected by the application of silver nanowire layers over the barrier layers.
TABLE III
Barrier
Barrier
Barrier
Barrier
Layer
Layer
Layer
Layer Dry
Cellulosic
Polyester
Total
Coating
Content
Content
Solids
Weight
Silver
Delta
Sample
Dry Basis
Dry Basis
Content
(g/sq.
Nanowire
Haze
ID
(wt %)
(wt %)
(wt %)
m.)
Coating?
(%)
3-1
80
20
3.0
0.2270
No
0.21
3-2
80
20
1.5
0.1135
No
−0.05
3-3
80
20
0.2
0.0084
No
0.14
3-4
80
20
3.0
0.2270
Yes
0.28
3-5
80
20
1.5
0.1135
Yes
0.12
3-6
80
20
0.2
0.0084
Yes
0.13
Example 4
Comparative
Four different polyethylene naphthalate (PEN) films were evaluated for Delta Haze according to the procedure of Example 1. No coatings were applied to the films as received.
SKYNEX® NH10S 7-mil PEN film exhibited a Delta Haze of 0.44%.
SKYNEX® NX10 2-mil PEN film exhibited a Delta Haze of 0.06%.
TEONEX® Q65F 4-mil PEN film exhibited a Delta Haze of 0.45%.
TEONEX® Q65FA 4-mil PEN film exhibited a Delta Haze of 0.28%.
A comparison of these results to those of Tables I-III demonstrates the ability of the inventive barrier-coated PET films to achieve similar Delta Haze levels as those exhibited by these PEN film samples.
The invention has been described in detail with reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein. | Disclosed are compositions and methods that provide flexible transparent conductive films that exhibit low levels of oligomer migration and haze development, without making use of costly substrates based on PEN film or PET films having low oligomer content. Such flexible transparent conductive films are useful in electronic and optical applications. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Ser. No. 60/519,907, filed Nov. 14, 2003, which is herein incorporated by reference in its entirety, including all Tables, Figures, and claims.
FIELD OF THE INVENTION
[0002] The field of the invention relates to diagnostic devices for collecting and evaluating environmental or biological samples.
BACKGROUND OF THE INVENTION
[0003] The following Background of the Invention is intended to aid the reader in understanding the invention and is not admitted to be prior art.
[0004] There are a variety of medical and environmental diagnostic devices currently on the market. Most are designed to work in conjunction with a rapid analysis test device, such as a chemical or immunological test card. Some are used in clinical settings to test for indicators of health or disease. Others are used in non-clinical settings, such as by employment agencies, athletic commissions and prison facilities, to test for illicit drugs. Most if not all are complicated to use, requiring the technician to perform several steps to accomplish the analysis, or do not promote hygiene or the maintenance of sample purity. Most if not all existing devices simply are not designed to separate an aliquot of sample for testing, simultaneously preserving the remaining sample in an unadulterated state for confirmation or other testing at a later or earlier time.
SUMMARY OF THE INVENTION
[0005] The present invention provides a sample testing device and methods for use. In one embodiment the device is a urine cup for detecting the presence or amount of analytes in urine. In one embodiment the analyte is one or more drugs of abuse. In one embodiment the device is configured in a “cup within a cup” format, where a first cup is positioned or disposed within a second cup. Between the two cups is present one or more reservoirs. In one embodiment there is one reservoir present between the bottoms of the first and second cups, which is sealed at its base with an O-ring. A valve mechanism is present and regulates flow between the interior of the first cup and the reservoir(s). When a sample (e.g., urine) is added to the device, the sample flows from the interior of the first cup through an aperture therein and into one or more reservoirs or chambers between the cups, and remains in the reservoir due to the O-ring seal present at the base of the reservoir. When the first cup is moved from a first position into a second position, the reservoir seal is broken and sample is shunted from the reservoir or chamber through a passageway and into contact with a test element. Also, a valve member is actuated and seals the aperture so that no further sample is passed from the interior of the cup to the one or more reservoirs. The sample in the interior of the first cup is therefore preserved for confirmation testing.
[0006] In a first aspect the present invention provides a device for determining the presence or amount of an analyte in a sample. The device has a first cup which has an interior for holding a liquid sample, a top, one or more sidewalls, and a bottom. The device also contains a second cup having a top, one or more sidewalls, and a bottom. The first cup of the device is disposed within the second cup. The device also has at least one reservoir for containing an aliquot of sample which is located between the first and second cups, and the first cup has an aperture venting from the interior of the first cup into the at least one reservoir. The device also contains a valve assembly interfacing with the at least one reservoir for regulating communication of the aliquot of sample from the interior of the cup to the reservoir, and one or more test elements which have a sample application zone, and which are for determining the presence or amount of an analyte in the liquid sample. A passageway connects the at least one reservoir and the sample application zone.
[0007] The term “cup” as used in the claims is not limited to a particular geometric shape. Thus, the cup can have a square or oval shape, or any shape consistent with the function of the invention. Moreover, there is no requirement that the two cups need be of the same shape, although they certainly may be. The terms “top” and “bottom” also not limited to a particular geometric shape. A top may have a ledge, ridge, or lip, or the top may simply be the end of the upper portion of the cup. The “bottom” also may take a variety of shapes, such as flat, conical, or another shape consistent with its function as described herein. A “reservoir” refers to an volumetric area where an aliquot of sample is segregated from the remaining portion of the sample placed into the device. The term “aliquot” refers to a selected volume of sample. An aliquot need not be any particular volume but will be an amount of sample sufficient to perform an assay for the presence or amount of an analyte.
[0008] The term “valve assembly” refers to a component that regulates the flow of liquid by opening, shutting, or partially obstructing an aperture. The valve may be mobile itself, or may be an immobile component that is moved into a position to open, close, or partially obstruct the aperture by the relative movement of the cups or other parts of the device. In one embodiment the valve is a type of slide valve composed of an immobile component constructed of plastic, rubber, or another material. In various other embodiments the valve assembly can be a ball valve, mitral valve, butterfly valve, check valve, or another type of valve. Devices of the invention can have more than one valve and more than one reservoir.
[0009] In one embodiment the first cup is rotatably disposed within the second cup, where the first cup has first and second positions within the second cup. The valve assembly can be a valve member that seals the reservoir from liquid communication with the interior of the first cup when the first cup is located in the second position. In one embodiment the device also has a lid that contains at least one key element, and the first cup contains at least one engagement mechanism. The at least one key element is inserted into the at least one engagement mechanism when the lid is placed onto the first and second cups. The first cup has a first position where liquid communication occurs between the reservoir and the interior of the first cup, and a second position where the valve member seals the at least one reservoir from liquid communication with the interior of the first cup. In one embodiment the one or more test elements are lateral flow test elements, for example, test strips, which can produce a calorimetric signal when an analyte of interest is present.
[0010] In another embodiment the valve member is located on the second cup and can be placed in a first position where the aperture is open, and a second position where the aperture is closed. In one embodiment liquid communication does not occur between the reservoir and the test elements when the valve member is located in the first position, but liquid communication between the reservoir and the test elements does occur when the valve member is located in the second position. Thus, the passageway is closed when the first cup is in the first position, and open when the first cup is in the second position. The first and second positions can be conveniently located about 90 degrees radially apart. The lid can be rotatably sealable about the top of the second cup.
[0011] In one embodiment the device contains a seal that prevents liquid communication between the reservoir and the test element when the first cup is located in the first position. The seal can be a second valve or O-ring or another type of seal located at a base of the one or more sealable reservoirs. In one embodiment a seal is an O-ring situated at the base of the reservoir. The second valve or O-ring seals the reservoir to prevent liquid communication between the reservoir and the test elements when the first cup is in the first position. But when the first cup is moved into the second position, the seal provided by the valve or O-ring is broken, and liquid communication then occurs between the reservoir and the test elements. In other embodiments the seal can be a caulking, rubber seal, or other water impermeable material. In other embodiments liquid communication occurs between the reservoir and the one or more test elements, through the passageway, when the first cup is located in the second position. An “O-ring” is a gasket which seals the reservoir from liquid communication with the passageway. It is usually made of rubber or plastic, but any material able to fulfill the function of sealing the reservoir from liquid communication is suitable. The O-ring usually is in the form of a flat ring or loop, but may take any shape or form consistent with its function. The “passageway” is the space between the reservoir and the sample application zone of the test element, which space can take any form. In other embodiments no O-ring is used, but a second valve seals the reservoir from liquid communication with the test element when the first cup is in the first position, and allows liquid communication between the reservoir and test elements when the first cup is in the second position.
[0012] In another embodiment the invention can have an access opening. An “access opening” refers to an opening on the top or side of the device which can be opened without spilling the contents of the device, and which allows the operator to gain access to the sample within without the need to remove the top of the device. The access opening will typically take the form of an opening large enough for a pipette or other sampling device to be inserted to remove an aliquot of sample, but the opening can take any shape or size consistent with its function.
[0013] In another aspect the present invention provides methods of determining the presence or amount of an analyte in a sample. The methods involve placing the sample into a device of the present invention as described herein, placing the lid on the first and second cups and engaging the key elements in the engagement mechanisms; turning the lid so that the first cup is moved from the a first position to a second position, thereby sealing the aperture and preventing fluid flow from the interior of the first cup to the reservoir, and thereby breaking a seal at the reservoir and permitting fluid flow from the reservoir to the testing elements through the passageway; and determining the presence or amount of analyte in the sample. In embodiments using an O-ring or other type of seal, fluid flows from the reservoir due to breaking of the seal of the reservoir provided by the O-ring or other seal. In embodiments using a second valve, fluid flows from the reservoir by opening of the second valve.
[0014] In one embodiment the key elements are comprised on the underside of the lid. For example, the lid can contain a circular portion in the center bottom of the lid which contains the key elements that protrude from the circular portion. At least two key elements are desirably present, but four will result in a more stable turning mechanism. Of course six or any number of key elements can also be used. The lid can be rotatably sealable about the top of the first and second cups. The lid can fit over the top of the two cups together and form a seal. In one embodiment the O-ring is located at a base of the one or more reservoirs and seals the reservoir from liquid communication with the passageway when the first cup is in the first position. The O-ring seal is broken and opened when the first cup is turned to the second position, thereby allowing liquid communication between the reservoir and the test elements. The liquid communication occurs between the reservior and the test elements through the passageway.
[0015] In another aspect the present invention provides kits including a device of the invention as described herein, and instructions for use of the device in the determination of the presence or amount of an analyte in a fluid sample.
[0016] The summary of the invention described above is not limiting and other features and advantages of the invention will be apparent from the following detailed description, as well as from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIGS. 1 A-F are various orthogonal and perspective views of one device embodiment of the invention. FIG. 1A is a top orthogonal view of the lid or cap. FIG. 1B is a horizontal side orthogonal view. FIG. 1C is a vertical orthogonal view of another side. FIG. 1D is a sectional side view. FIG. 1E is an orthogonal view of the bottom of the device. FIG. 1F is a perspective view. In this embodiment, an elliptical O-ring is used to provide the barrier between the reservoir and the test elements.
[0018] FIG. 2 is an exploded side view of the embodiment in FIG. 1 .
[0019] FIG. 3 is a sectional perspective side view of the embodiment of FIG. 1 without the lid, showing elliptical component alignment between the bottoms of the two cups.
[0020] FIG. 4 is another cross sectional perspective side view including lid of the embodiment of FIG. 1 , showing the first and second cups 90 degrees out of alignment (after rotation of the first cup). This Figure shows the elliptical O-ring used in this embodiment.
[0021] FIGS. 5A and B are, respectively, horizontal and vertical sectional views of the device embodiment of FIG. 1 , showing the elliptical O-ring used in this embodiment aligned relative to one another, thereby allowing flow of fluid sample from the interior of the first cup to the reservoir.
[0022] FIGS. 6A and 6B are, respectively, horizontal and vertical sectional views of the device embodiment of FIG. 1 , showing the elliptical O-ring used in this embodiment offset by 90 degrees, thereby sealing the reservoir from fluid communication with the first cup, and allowing flow of fluid sample from the reservoir to the test elements.
DETAILED DESCRIPTION
[0023] Among other aspects, the invention provides a new diagnostic device. The hardware of the device provides for collection of sample, an assay capability, as well as a preservation area for the preservation of an uncontaminated aliquot of sample in one area of the device. Thus, a portion of the collected sample is segregated so that it remains intact and unadulterated relative to the portion assayed. The device can be disposable or reusable and can be made out of a translucent water-resistent plastic or polymer such that the sample and assay results can be visualized or monitored from outside the device, for example, with the unaided eye.
[0024] While the devices will normally be disposed of after use, in one embodiment the device utilizes modular components and chambers that are provided preassembled for use, and in another embodiment can be provided in reversible format such that disassembly is also convenient, and so that the assay component of the device can be readily cleaned, changed and/or the sample aliquot previously assayed removed to ready the device for a second assay or batch of assays of the same or different type. Test elements can be provided in a cartridge format providing for ease of replacement.
[0025] The invention allows assays to be conducted with easier maintenance of sample purity/minimization of sample adulteration, and facile sample storage for later use. The valve assembly of the device permits sample aliquot shunting toward the test element when the operator is prepared to conduct the assay. The device features simplistic manual operation of the valve assembly or assemblies to effect aliquot segregation and analysis while maintaining intact the balance of originally collected sample, which may be conveniently retained or stored thereafter for later testing.
[0026] The following discussion describes one embodiment of the invention. With reference to the present disclosure, the person of ordinary skill in the art will realize other embodiments within the scope of the present disclosure.
[0027] With reference to FIGS. 1-5 , an inner cup 1 fits within an outer cup 2 , the relative dimensions of each sufficiently compatible for the outer (second) cup to receive the inner (first cup) and for the inner cup to rotate within the outer cup. The cups each have a flanged rim ( 1 a and 2 a , respectively), bottom ( 1 b and 2 b , respectively), and side walls ( 1 c and 2 c , respectively). A valve assembly 3 interfaces with the reservoir 4 for regulating fluid communication of the sample between the interior of the cup 1 and the test elements 8 , which in this embodiment are test strips. The test elements 8 can be located in a test element support 8 a and provided with a cover 8 b , which can indicate the analytes being tested for. Similarly, the device can be provided with adulterant indicators 9 , which can also be present on an adulterant element support 9 a . In this embodiment the valve assembly is a structure made of rubber that is positioned to allow fluid communication between the interior of the first cup and the reservoir when the first cup is in the first position. When the first cup is moved into the second position the valve structure will block the aperture 5 in the first cup, thereby blocking fluid communication between the interior of the first cup and the reservoir.
[0028] When the sample 10 is collected a portion of the sample flows into the reservoir 4 through an aperture 5 or slot in cup bottom 1 b . In this embodiment the reservoir 4 is formed of a raised portion of cup bottom 1 b providing the volume of the reservoir. This embodiment also uses an O-ring 4 b as the seal at the base of the reservoir, preventing liquid communication between the reservoir 4 and the passageway and test elements. The O-ring is present in an elliptical groove in the inside bottom of the second cup 2 b , thereby providing the seal ( FIG. 3 ). The bottom of cup 1 b can also have a corresponding elliptical groove or ledge to assist in seating the O-ring. During sample collection, the elliptical components are all aligned, and the aperture 5 is open.
[0029] Following sample collection, the lid is applied and the key elements on the underside of the lid are engaged in the engagement mechanisms 1 d . The key elements and engagement mechanisms will provide support for an applied force that rotates the inner cup 1 within the outer cup 2 . The inside lip of the lid can have screw threads that are complementary to screw threads located on the outside rim 2 g of the second cup 2 . The lip of the first cup turns downward, and on the underside of the exterior rim 1 a of the first cup 1 are retaining teeth 1 e (not visible). On the periphery of the underside of the rim is a rubber gasket 1 f . The retaining teeth 1 e are designed to be received by recesses (not visible) in the outer cup rim 2 a . Thus, the first cup fits over the rim of the second cup 2 a , and the retaining teeth are engaged with the recesses present on the rim of the second cup. In this embodiment, the rubber gasket 1 f is held in place by the retaining teeth. When the cups are mated, the retaining teeth fit into the recesses, and the rubber gasket seals the space between the rims of the two cups. When the first cup is seated into the second cup, the parts are mated so that the lip on the rim of the first cup covers the lip 2 f on the rim of the second cup, and together provide a surface on which the lid may be screwed onto the two cups.
[0030] When lid 7 is placed onto the two cups (the cup within a cup), the key elements engage the engagement mechanisms. The screw threads on the inner lid 7 a also engage the complementary screw threads on the outer rim of the second cup. Lid 7 is of suitable dimension to fit over each of the cup rims 1 a and 2 a , engaging each cup—the first cup through the key elements being placed within the engagement mechanisms, and the second cup through the complementary screw threads.
[0031] During use, inner lid threads 7 a engage threads of the rim of the second cup 2 g in screw-type fashion to effectively seal cups 1 and 2 from the exterior environment. Lid key elements 7 d (two of four visible in FIG. 5A ) simultaneously engage the engagement mechanisms 1 d on the rim of the inner cup. Thus, the lid is “locked” onto the cup within a cup. This allows the cups 1 and 2 to not only be sealed from the external environment, but also to be manipulated relative to one another to actuate the valve assembly 3 and thereby perform the assay.
[0032] When a force is applied to tighten the lid 7 onto the cup within a cup, the retaining teeth are dislodged from the recesses, thus causing the first cup to be turned within the second cup. This occurs under a normal turning force easily applied by hand. As the first cup turns within the second cup, the seal provided by the O-ring 4 b is broken and the aliquot held in the reservoir 4 is shunted to a passageway 6 . At the same time, the aperture 5 of the first cup is closed and sealed by the new (second) position of the valve assembly 3 . Thus, the remaining contents of the first (inner) cup 1 are therefore sealed and can be used at a later time for confirmation testing.
[0033] Upon shunting, the sample portion in the reservoir 4 flows into the passageway 6 . Lateral flow test elements 8 are affixed to the outer cup's side walls 2 b or to another chamber in fluid communication with the passageway, and upon breaking of the O-ring seal are thereby placed in fluid communication with the sample in the passageway 6 .
[0034] In another embodiment the lid 7 can contain a suitably dimensioned recesses on the underside of the lid to fit cup bottom 1 b , either prior to placement of cup 1 within cup 2 , or after concluding an assay and separating cup 1 from 2 , e.g., in prelude to cleaning and/or the preparation and running of another assay or series of assays, e.g., in identical or alternatively configured outer cups harboring identical or different test elements 8 a,b . Further, the lid outer side surface may be suitably textured so as to enhance the end-user's “grip” on the device.
[0035] The individual components of the device are readily produced, e.g., by standard injection-molding techniques and may assume a wide range of shapes, resiliencies and geometries so long as functionally compatible with one another in furtherance of the principles discussed above. Depending on the exact embodiment and configuration, the device may consist of one or more flexible or rigid components, depending on the specific material used. The device may be constructed of any suitable material such as, for example, pressed hardboard, metals, ceramics, plastics, and polymers. Suitable polymers include, but are not limited to, polycarbonate, polypropylene and cycloolifins.
[0000] Valve Assembly
[0036] The valve assembly functions by rotation of one cup relative to the other cup, such as by a lid having key elements that fit into engagement mechanisms on the first cup providing a location to apply the force to turn the first cup within the second. In one embodiment, the lid seals the top of the second cup so as to prevent sample from leaking out of the cups. In another embodiment, the valve assembly (or assemblies) can be driven by handles on the lateral exterior of the outer cup, such that turning the handle shunts an aliquot sample into another chamber where it may then be tested using a test element or component as described above. In still other embodiments, one or more valve assemblies may be electrically operated and responsive to an external electric impulse routed to the valve assembly.
[0037] The valve can be a rubber or plastic tab situated at the bottom of the inside of the second cup, so that it will be positioned in the reservoir when the first cup is placed into the second cup. Because it is rigid and water impermeable, it can be positioned such that when the first cup is rotated within the second cup, the valve will be moved into position to block the aperture present in the first cup, thereby preventing fluid communication between the interior of the first cup and the reservoir.
[0000] Key Element
[0038] Some embodiments of the device utilize one or more key elements for manipulating the valve assembly (or assemblies). The key elements engage the engagement mechanisms, which in one embodiment are located on the top inside rim of the first cup, and provide a location for applying force to rotate the first cup within the second cup. In some embodiments the key element is integral to the lid, which fits over and rotatably engages the engagement mechanisms on the inside rim of the first cup, such that (a) the valve assembly is moved into position to block the aperture and prevent fluid communication between the interior of the first cup and the reservoir.
[0039] In various embodiments one or more gaskets may be used to prevent leaking between the different parts of the device. These gaskets can take the form of O-rings, seals of water impermeable materials, etc.
[0000] Samples, Sample Aliquots, and Sample Analytes
[0040] A “sample” is any material to be tested for the presence or amount of an analyte. Examples of liquid samples that may be tested using a test device of the present invention include bodily fluids such as urine, blood, serum, plasma, saliva, sputum, sweat, ocular fluid, semen, and spinal fluid; water samples, such as samples of water from oceans, seas, lakes, rivers, and the like, or samples from home, municipal, or industrial water sources, runoff water or sewage samples; and food samples, such as milk or wine. Viscous liquid, semi-solid, or solid specimens may be used to create liquid solutions, eluates, suspensions, or extracts that can be samples. For example, throat or genital swabs may be suspended in a liquid solution to make a sample. Samples can include a combination of liquids, solids, gasses, or any combination thereof, as for example a suspension of cells in a buffer or solution. Samples can comprise biological materials, such as cells, microbes, organelles, and biochemical complexes. Liquid samples can be made from solid, semisolid or highly viscous materials, such as soils, fecal matter, tissues, organs, biological fluids or other samples that are not fluid in nature. For example, these solid or semi-solid samples can be mixed with an appropriate solution, such as a buffer, diluent, extraction buffer, or reagent. The sample can be macerated, frozen and thawed, or otherwise extracted to form a fluid sample. Residual particulates can be removed or reduced using conventional methods, such as filtration or centrifugation. By “sample aliquot” is meant a portion of the sample that undergoes testing by the test element.
[0041] An “analyte” is a compound or composition of interest within the sample that is to be detected and/or measured by the test element. Any analyte can be detected using the present invention for which there is a suitable test element. In one embodiment the analyte sought to be detected is a drug of abuse. A “drug of abuse” (DOA) is a drug that is taken for non-medicinal reasons (usually for mind-altering effects). The abuse of such drugs can lead to physical and mental damage and (with some substances) dependence, addiction and/or death. Examples of DOAs include cocaine; amphetamines (e.g., black beauties, white bennies, dextroamphetamines, dexies, beans); methamphetamines (crank, meth, crystal, speed); barbiturates (Valium®, Roche Pharmaceuticals, Nutley, N.J.); sedatives (i.e. sleep-aids); lysergic acid diethylamide (LSD); depressants (downers, goofballs, barbs, blue devils, yellow jackets, ludes); tricyclic antidepressants (TCA, e.g., imipramine, amitriptyline and doxepin); phencyclidine (PCP); tetrahydrocannabinol (THC, pot, dope, hash, weed, etc.); and opiates (e.g., morphine, opium, codeine, heroin, oxycodone). But any analyte can be detected using the invention.
[0042] An analyte can also relate to measuring or determining the adulteration of a sample, such as by dilution or other tampering, e.g., supplying a sample from another species, subject or non-human source, or by adding an agent that can alter the composition of a sample and defeat the purpose of the assay. Such adulteration analytes can be chosen based on the particular application and sample type being analyzed, and the sources or types of possible adulteration. Such analytes are optionally referred to herein as adulteration analytes or adulteration indicators.
[0043] Analytes can also be specific binding molecules, such as antibodies or derivatives or fragments or active fragments thereof. Specific binding molecules bind to another molecule or complex with greater affinity or avidity relative to other sample or analyte compounds. The antibody can be monoclonal or polyclonal and can be prepared by techniques that are well known in the art such as, for example, immunization of a host and collection of sera or hybrid cell line, e.g., hybridoma, technology.
[0000] Test Elements
[0044] A “test element” is the component containing the reagents that form the basis of the assay, and provides a detectable signal when an analyte is present in a fluid sample. In one embodiment the test element is a test strip (e.g., a lateral flow test strip). In other embodiments the test element can be a slide, or a bibulous paper (e.g., filter paper) with a reagent applied thereon. Test elements typically contain one or more reagents that bind and/or react with one or more analytes of interest in a sample. Many different test elements and assays are commercially available that can be used in the devices and methods of the invention.
[0045] When the test element is a test strip, it may be made of bibulous or non-bibulous material. A test strip can include more than one material, which are then in fluid communication. One material of a test strip may be overlaid on another material of the test strip, such as for example, filter paper overlaid on nitrocellulose. Alternatively or in addition, a test strip may include a region comprising one or more materials followed by a region comprising one or more different materials. In this case, the regions are in fluid communication and may or may not partially overlap one another. The material or materials of the test strip can be bound to a support or solid surface such as a supporting sheet of plastic, to increase its handling strength.
[0046] In embodiments where the analyte is detected by a signal producing system, such as by one or more enzymes that specifically react with the analyte, one or more components of the signal producing system can be bound to the analyte detection zone of the test strip material in the same manner as specific binding members are bound to the test strip material, as described above. Alternatively or in addition, components of the signal producing system that are included in the sample application zone, the reagent zone, or the analyte detection zone of the test strip, or that are included throughout the test strip, may be impregnated into one or more materials of the test strip. This can be achieved either by surface application of solutions of such components or by immersion of the one or more test strip materials into solutions of such components. Following one or more applications or one or more immersions, the test strip material is dried. Alternatively or in addition, components of the signal producing system that are included in the sample application zone, the reagent zone, or the analyte detection zone of the test strip, or that are included throughout the test strip, may be applied to the surface of one or more test strip materials of the test strip as was described for labeled reagents.
[0047] The zones can be arranged as follows: sample application zone, one or more reagent zones, one or more test results determination zones, one or more control zones, one or more adulteration zones, and fluid absorbing zone. If the test results determination zone includes a control zone, preferably it follows the analyte detection zone of the test result determination zone. All of these zones, or combinations thereof, can be provided in a single strip of a single material. Alternatively, the zones are made of different materials and are linked together in fluid communication. For example, the different zones can be in direct or indirect fluid communication. In this instance, the different zones can be jointed end-to-end to be in fluid communication, overlapped to be in fluid communication, or be communicated by another member, such a joining material, which is preferably bibulous such as filter paper, fiberglass or nitrocellulose. In using a joining material, a joining material may communicate fluid from end-to-end joined zones or materials including such zones, end-to-end joined zones or materials including such zones that are not in fluid communication, or join zones or materials that include such zones that are overlapped (such as but not limited to from top to bottom) but not in fluid communication. In addition to these embodiments of test strips, many other embodiments can be made.
[0048] It is also useful to provide test elements indicating the presence of adulteration contaminants. For example, an adulteration element can be included indicating the specific gravity of the urine sample, so that adulterants that would change the specific gravity of the urine will be detected. It is a common technique among those who would seek to defeat the results of an assay for drugs of abuse to add glutaraldehyde and other chemicals, and many other contaminants to a urine sample. Further, it is useful to include a test element for the physical parameter of temperature. If the sample provided is not of a normal temperature expected, it may provide an indication that the sample was carried to the test site and does not originate with the test subject. Many adulterants can be added to urine to defeat the purpose of drug screening, and as many test elements as thought desirable can be incorporated into the device. These adulterants and corresponding test elements are known in the art.
[0049] When a test strip includes an adulteration control zone, the adulteration control zone can be placed before or after the results determination zone. When a control zone is present in the results determination zone on such a test strip, then the adulteration control zone is preferably before the control zone, but that need not be the case. In the embodiment of the present invention where a test strip is a control test strip for the determination of an adulteration analyte and/or a control, then the adulteration control zone can be placed before or after the control zone, but is preferably before the control zone.
[0050] Samples that can be tested with the device of the present invention include liquids of biological origin (e.g., casing fluids and clinical samples). Liquid samples may be derived from solid or semi-solid samples, including feces, biological tissue, and food samples. Such solid or semi-solid samples can be converted into a liquid sample by any suitable method, for example by mixing, chopping, macerating, incubating, dissolving or enzymatically digesting solid samples in a suitable liquid (e.g., water, phosphate-buffered saline, or other buffers). “Biological samples” include samples derived from living animals, plants, and food, including for example urine, saliva, blood and blood components, cerebrospinal fluid, vaginal swabs, semen, feces, sweat, exudates, tissue, organs, tumors, tissue and organ culture, cell cultures and conditioned media therefrom, whether from humans or animals. A preferred biological sample is urine. Food samples include samples from processed food components or final products, meat, cheese, wine, milk and drinking water. Plant samples include those derived from any plant, plant tissue, plant cell cultures and conditioned media therefrom. “Environmental samples” are those derived from the environment (e.g., a water sample from a lake or other casing of water, effluent samples, soil samples, ground water, ocean water, and runoff water. Sewage and related wastes can also be included as environmental samples.
[0051] Any analyte can be tested for utilizing the present invention and a suitable test element. In particular, the present invention can be utilized for the detection of a drug of abuse in oral fluid. A “drug of abuse” (DOA) is a drug that is taken for non-medicinal reasons (usually for mind-altering effects). The abuse of such drugs can lead to physical and mental damage and (with some substances) dependence, addiction and/or death. Examples of DOAs include cocaine; amphetamines (e.g., black beauties, white bennies, dextroamphetamines, dexies, beans); methamphetamines (crank, meth, crystal, speed); barbiturates (Valium®, Roche Pharmaceuticals, Nutley, N.J.); sedatives (i.e. sleep-aids); lysergic acid diethylamide (LSD); depressants (downers, goofballs, barbs, blue devils, yellow jackets, ludes); tricyclic antidepressants (TCA, e.g., imipramine, amitriptyline and doxepin); phencyclidine (PCP); tetrahydrocannabinol (THC, pot, dope, hash, weed, etc.); and opiates (e.g., morphine, opium, codeine, heroin, oxycodone).
[0052] For example, analytes that can be tested using the present invention include but are not limited to creatinine, bilirubin, nitrite, protein (nonspecific), hormones (e.g. human chorionic gonadotropin, luteinizing hormone, follicle stimulating hormone, etc.), blood, leukocytes, sugar, heavy metals or toxins, bacterial components (e.g. proteins or sugars specific to a particular type of bacteria, such as E. coli 0157:H7, S. aureus, Salmonella, C. perfringens, Campylobacter, L. monocytogenes, V parahaemolyticus , or B. cereus ) and physical characteristics of the urine sample, such as pH and specific gravity. Any other clinical urine chemistry analyte that can be adapted to a lateral flow test format may also be incorporated into the present device.
EXAMPLE 1
A Sample Collection Container with Activatable Integrated Test Element
[0053] The devices of the invention can be utilized in a variety of contexts, for example, for pre-employment drug screening. The person to be tested provides a sample of urine in the inner (first) cup. In embodiments for pre-employment drug screening the device contains test strips for several common drugs of abuse, in this embodiment cocaine, methamphetamine, phencyclidine, THC, morphine, and amphetamines. These test strips utilize a competitive immunoassay format where labeled specific binding molecules (antibodies in this embodiment) for each drug being tested are present on the label zone of the test strip. The test lines contain the antigen being tested for. If analyte is present in the sample it is bound by labeled specific binding molecules in the label zone, thereby preventing the labeled antibody from binding to the test line. Thus, no signal occurs on the test line when analyte is present. Conversely, when no antigen is present in the saliva, the labeled antibodies bind to the test line providing the signal on the test line.
[0054] The test subject receives a device and provides a urine sample in the device. By the time the technician receives the device filled with urine sample, the reservoir will already have filled with urine sample. After receiving the device with the urine sample, the testing technician applies the lid, and engages the key elements in the engagement mechanisms. The retaining teeth of the first cup were previously seated in the recesses on the lip of the second cup. When the testing technician is prepared to begin the assay, the lid is screwed onto the device. This dislodges the retaining teeth from the recesses as the first cup turns within the second cup. When the technician rotates the first cup within the second cup, the valve assembly is moved into position to block the aperture in the first cup, thereby stopping fluid communication between the interior of the first cup and the reservoir. Also, as the first cup is rotated within the second cup, the seal located at the base of the reservoir is broken, and fluid communication occurs between the reservoir and the passageway, and finally the test strips.
[0055] Within about 30 seconds, the urine has flowed through the test strip and the control indication are present, signaling that the assay is complete. The technician then reads the results of the assay. If a positive result is found for any analyte, the device can be retained for a confirmatory test on the remaining sample, which is safely sealed and sequestered in the interior of the first cup.
[0056] The foregoing Example is not limiting of the invention and is merely representative of various aspects and embodiments. All documents cited are indicative of the levels of skill in the art to which the invention pertains, although none is admitted to be prior art. One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The Example merely describes one embodiment, is exemplary, and is in no way intended as a limitation on the full scope of the invention. Certain modifications and other uses will occur to those skilled in the art, and are encompassed within the spirit of the invention as defined by the scope of the claims.
[0057] The reagents and test elements described herein are either commercially available or else readily producible without undue experimentation using routine procedures known to those of ordinary skill in the art, or else described in the documentation cited herein. For example, illustrative test elements usable in the devices of the invention are available, e.g., from Acon Laboratories (San Diego, Calif., USA) as per http://www.aconlabs.com/products.html.
[0058] The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other two terms, endowing a different meaning under the patent laws.
[0059] The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described, or portions thereof. It is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments, optional features, modifications and variations of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the description and the appended claims.
[0060] In addition, where features or aspects of the invention are described in terms of Markush groups or other grouping of alternatives, those skilled in the art will recognize that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group or other group, and exclusions of individual members as appropriate.
[0061] Other embodiments are apparent from the following claims. | Medical and environmental diagnostic devices are described and claimed. Preferred embodiments feature cup within cup configurations wherein one cup is dedicated, for the most part, to sample collection and another cup is dedicated, for the most part, to assay performance. Communication between the cups is afforded by what is believed to be a unique valve assembly and lid tandem. | 1 |
[0001] This specification claims the benefit of and expressly incorporates by reference provisional application Ser. No. 60/189,944, entitled “Secure Internet Gateway For Web Enabling Legacy Applications,” filed Mar. 16, 2000.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates generally to computer interfaces and in particular to secure data access systems.
BACKGROUND
[0003] As the Internet has become the ubiquitous medium for telecommunications and the transport of data, the software industry at large and companies in the technology business have developed so-called “e-commerce” solutions. E-commerce solutions have transformed the Internet into a global storefront. Web pages advertise goods and services that consumers and businesses can purchase on-line. This growth in on-line commercial activity has created a substantial need to make the data and applications that companies have on their existing host computers (e.g., legacy systems) accessible via the Internet. Unfortunately, a redesign of these host computer applications and databases would be prohibitively expensive, running in the billions, perhaps trillions of dollars.
[0004] Access alone is not the only important consideration when creating on-line access to host computers. The data and applications that run on these machines typically must be protected from undesired or unauthorized access. Information systems managers go to considerable lengths and expense to ensure that the systems which run their businesses are not exposed to the risk of software malfunctions or computer hackers. Before putting their mission-critical systems and databases on-line, these managers need assurance that these systems and databases will be secure. Unfortunately, conventional security schemes—especially those that rely alone on firewalls to prevent unauthorized users from getting access to the secure data—are not sufficiently reliable.
[0005] Accordingly, what is needed is an improved system and method for implementing secure Internet access to a host computer.
SUMMARY OF THE INVENTION
[0006] The present invention addresses both the problem of Internet access and security by providing an interface to a host computer that does not utilize a direct network connection between the host computer and the internet. In one embodiment, a computer system is provided that comprises two servers that interact through a shared-file database. One server is connected to the Internet and makes requests to the other through the shared-file database. The second server is connected to a host computer, and only performs the requests if they are among a predefined set of allowable transactions corresponding to a permissible set of request commands. The shared-file database is the substantially only resource shared by the two servers, and it thus serves as a secure buffer between Internet users and the host computer. Because the host computer is not connected to the Internet, it is not susceptible to many forms of unauthorized use. The transactions that can be initiated on the web server and performed on the host computer are restricted to a pre-defined set of transactions. By funneling requests for host transactions through a database buffer, and by limiting access to a pre-defined set of transactions, the computer system provides a secure method of enabling Internet users to access host computers.
[0007] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0009] [0009]FIG. 1 depicts a block diagram of one embodiment of a secure host computer—internet interface system of the present invention.
[0010] [0010]FIG. 2 depicts a block diagram of a web server from the system of FIG. 1.
[0011] [0011]FIG. 3 shows one embodiment of a routine for providing request files to a shared-file database in the system of FIG. 1.
[0012] [0012]FIG. 4 shows one embodiment of a routine used by the web server of FIG. 2 to retrieve response files from a shared-file database in the system of FIG. 1.
[0013] [0013]FIG. 5 shows example portions of an HTML page used in a web application in one embodiment of the present invention.
[0014] [0014]FIG. 6 shows an Active Server code segment used to make the HTML page depicted in FIG. 5 interactive.
[0015] [0015]FIG. 7 depicts an example of an Internet API for reading from and writing to the shared file database.
[0016] [0016]FIG. 8 depicts a block diagram of one embodiment of the host-side server and shared-file database from the system of FIG. 1.
[0017] [0017]FIG. 9 shows a routine used by a host-side agent in the host-side server of FIG. 8 .
[0018] [0018]FIG. 10 shows a routine used by the host-side agent to retrieve request files from the shared-file database.
[0019] [0019]FIG. 11 displays a portion of the code used in an example for illustrating one aspect of the present invention.
[0020] [0020]FIG. 12 displays a portion of the code used in the example of FIG. 11.
[0021] [0021]FIG. 13 depicts a block diagram of the host-side server containing a shared-file database.
[0022] [0022]FIG. 14 depicts a block diagram of another specific embodiment of an interface system of the present invention.
DETAILED DESCRIPTION
[0023] System Overview
[0024] The computer system, according to a preferred embodiment of the present invention, comprises a web server, a shared-file database, and a host-side server, operable to allow an Internet user to access a host computer. The web server is connected to the Internet and provides Internet access to the system. The host-side server is connected to a host computer and enables the system to perform a definable set of host computer transactions. The shared-file database is accessible to both the web server and the host-side server. It provides a secure interface between the two servers. The shared-file database may reside on the host-side server, or on another computer connected to the system.
[0025] In a preferred embodiment, both the web server and the host-side server provide and retrieve files from the shared-file database. The web server provides request files to the shared-file database. The host-side server retrieves these request files, determines whether the requested service is among the defined set of host computer transactions that are permitted, and directs the host computer to process appropriate transactions. Once a transaction is completed, the host-side server receives data from the host computer and generates a response file which the server provides to the shared-file database. The web server retrieves this response file and processes its contents, making them available to Internet users through a web application. Because the shared-file database is the substantially only shared resource between the two servers, the host-side server is protected from a direct attack via the Internet.
[0026] [0026]FIG. 1 shows one embodiment of a computer system 100 of the present invention. System 100 communicatively links a host computer 80 to at least one user PC 60 via the Internet 65 . The connection to the host computer may use SNA, Asynchronous protocols, protocols that connect through LAN gateways, or any other protocol for connecting to the host computer. For the purposes of this invention, the Internet, which is commonly considered to comprehend the network of networks known as the World Wide Web, should also be construed to include private networks, corporate extranets, and other networks that operate to connect computers together. The host computer 80 can be any hardware platform, including but not limited to a mainframe, server, workstation, personal computer, or a network of computers that contain data that may be stored in databases. The user PC 60 can be any form of Internet access device, including a computer or Internet appliance.
[0027] In the embodiment depicted in FIG. 1, the computer system 100 comprises a web server 160 , a host-side server 110 , and a shared-file database 150 . The web server 160 and the host-side server 110 are operably connected to the shared-file database 150 . The web server 160 and the host-side server 110 can be implemented with any suitable computer, including but not limited to a mainframe, workstation, or personal computer, running an operating system that may be Windows NT, UNIX, LINUX, or any other computer operating system. The web server has at least one web application 165 and Internet enabling software 185 . The host-side server has a host-side agent 115 and host communications enabling software 135 .
[0028] The web application 165 provides request files 153 to and retrieves response files 157 from the shared-file database 150 . It may be any application that performs these tasks and is accessible to the Internet. The web application 165 is connected to the Internet via Internet enabling software 185 , also installed on the web server 160 . Internet enabling software 185 facilitates the web site for providing Internet users with access to Web application 165 . Internet enabling software 185 may be implemented with any suitable Internet enabling software such as Apache, Microsoft IIS, and Netscape Enterprise Server.
[0029] The shared file database 150 is operably connected to the web application 165 (as well as to the host-side agent 115 ) and holds request files 153 and response files 157 . A request file contain the commands and/or instructions for carrying out pre-defined, allowable tasks on the host computer 80 responsive to a request from a web user. In turn, a response file 157 contains data, generated from the host computer 80 , that is responsive to a processed request file. Other types of databases, including but not limited to flat-file, hierarchical, relational, and object-oriented databases may also be used to hold the commands, instructions, and data that the web application 165 provides and retrieves through the request and response files 153 , 157 , respectively. In addition, the shared-file database may be implemented using a custom block of code, or by implementing a commercial database product, including but not limited to MS-ACCESS, ORACLE, INFORMIX databases. In one implementation in which the shared-file database resides on the host-side server, the web server accesses the database through a connection which may be implemented using a hub, by placing the shared-file database on a dual-ported disk drive connected to both servers, or through another physical connection.
[0030] The host-side agent 115 may be a program or a set of programs that retrieve and process request files 153 , initiate host computer transactions, process host computer responses, and provide response files 157 to the shared-file database 1 - 50 . The host-side agent 115 is installed on the host-side server 110 and is operably connected to the host communications enabling software 135 . The host communications enabling software 135 may be a script, routine, program, or set of programs that exchange data and instructions between the host-side agent 115 and the host computer 80 . For example, the host communications enabling software 135 may be a terminal emulator. In one embodiment, the host communications enabling software 135 is a screen scraper, providing data elements to the screen coordinates that an application running on the host computer 80 expects as input, and extracting output from the screen coordinates that the host computer 80 generates. This screen scraper functions by emulating a ‘dumb’ terminal. The host communications enabling software may also be an interface written to a specific host application, database interconnectivity software such as ODBC, or an interface that is appropriate to the type of host computer 80 used in the computer system 100 .
[0031] The computer system 100 operates when a user PC 60 attached to the Internet 65 initiates a request for services on the web server 160 , by invoking the web application 165 that is running on the Internet enabling software 185 . Before reaching the web server 160 , the user's request may pass through an Internet firewall or other security device. The web application 165 communicates with the host-side agent 115 running on the host server 110 through the shared file database 150 . The web application 165 does this by providing a request file 153 containing one or more request commands and required data to the shared-file database 150 .
[0032] The host-side agent 115 , running on the host-side server 110 , retrieves the request file 153 and processes the request for service. The host-side agent 115 is programmed to recognize a defined set of request commands that correspond to host computer services that the computer system 100 is authorized to execute. If the host-side agent 115 recognizes the request command, the host-side agent 115 communicates the request to the host computer 80 through the host-communications enabling software 135 . If the request command is not recognized, then the hostside agent does not process the request. This denial of unauthorized service provides security for the host computer 80 .
[0033] When the host-side server directs the host computer 80 to perform a transaction (i.e. execute a request command), the host computer 80 performs the service and communicates the results to the host-side agent 115 through the host communications enabling software. The host-side agent 115 communicates with the web application 165 by providing a response file 157 to the shared-file database 165 . The web application 165 retrieves and processes the response file 157 , then communicates with the user PC 60 through the Internet 65 .
[0034] Web Side Server and Sub-Elements
[0035] [0035]FIG. 2 depicts a block diagram of the web server 160 , illustrating the interaction between the elements of the web application 165 and the shared file database 150 . The web application 165 is comprised of web pages 171 , translation logic 169 , and an Internet API 167 . The web pages 171 may include input pages, output pages, and transaction pages. Input pages collect requests from the web server 160 . Output pages display information that had been retrieved from the host computer 80 . Transaction pages define the set of host computer transactions that are enabled for a given configuration of the computer system 100 . An important feature of the invention is the ability to specify these transaction pages to limit host computer access to a defined set of transactions.
[0036] The web pages 171 are typically formatted in a hypertext mark-up language (HTML) but may be formatted using other technologies. Web pages 171 may be further enabled with programs or scripts implemented using a common gateway interface (CGI) written in Perl, C, C++, Java, or another language that supports CGI, or using a web-enabling toolkit such as Active Server. These programs or scripts can be used to make the web pages 171 interactive. The web pages 171 are the interface through which the user PC 60 requests computer system 100 to perform a host computer transaction.
[0037] The translation logic 169 may consist of a script, routine, program, or set of programs that receives data and instructions in one format and translates them into another format. The translation logic may be embedded in the web pages 171 , the Internet API 167 , or implemented as a distinct body of computer code. In the embodiment of FIG. 2, the translation logic 169 is operably connected to the web pages 171 and the Internet API 167 . The translation logic 169 is bi-directional. Data coming from the web pages 171 is translated into the format of the shared-file database 150 , and data in the shared-file database format is translated into the format of the web pages. In addition to reformatting data and instructions, the translation logic may contain functionality to disallow transaction requests that are not part of the pre-defined set of transactions allowed for the host computer system 100 .
[0038] The Internet API 167 may consist of a function, set of functions, program, or set of programs that provide request files 153 and retrieve response files 157 from the shared-file database 150 for processing. Additional processing of files, including but not limited to file encryption and error correction may also be provided by the Internet API. The Internet API 167 is operably connected to the shared-file database 150 , and may be connected to the web pages 171 or to the translation logic 169 of the web application 165 . The Internet API 167 may also be attached to a pre-existing web application to integrate it into the computer system 100 .
[0039] When a transaction request is made by a User PC 60 , the web application 165 captures the request and any required data from the web pages 171 . Next, the application uses the translation logic 169 to structure the request into a format that conforms with the shared-file database 150 . If the transaction request is recognized as an allowable request by the web application 165 , then the web application 165 provides a request file 153 corresponding to the transaction request to the shared-file database 150 by invoking the Internet API 167 . Conversely, if the transaction is not authorized, the web application 165 does not generate the request file 153 . By providing request files only for authorized transactions, the web application protects the host computer 80 , its applications, and data from unauthorized access. Additional protection may be provided in the host-side server 110 and the host computer 80 itself.
[0040] When a response file 157 is created by the host-side server 110 , the Internet API 167 receives the response file and copies its contents into a data structure that can be processed by the web application 165 . In a computer system 100 in which multiple requests are processed simultaneously, the contents of this file may include identifiers used to match response files 157 to the specific web pages 171 and users that requested them. The Internet API 167 is the single interface between the web application 165 and the shared-file database, thus ensuring that transaction requests and host responses are processed in a consistent manner.
[0041] [0041]FIG. 3 illustrates one embodiment of a routine used by the web application 165 to provide request files 153 to the shared-file database 150 . At step 210 , the routine to provide request files 153 begins. At step 215 , the routine waits until there is a request from a web client. When there is a request, the routine initiates step 220 which identifies which service is requested and identifies any data from the web application 165 . After the requested service is known, the routine identifies the relevant request command for processing at step 225 . If the requested service is not available to the web application then there will be no request command. The computer system 100 may be configured to log these unauthorized transaction requests. When the service requested is of a type that is known to the application, the routine continues to formulate the request file 153 in step 230 . This formulation of the request file 153 based on a knowledge of the relevant request command and the data identified from the web application in step 220 is an embodiment of the translation logic 169 described in FIG. 2. Next, at step 235 , the web application 165 provides the request file 153 to the shared-file database 150 . This final step invokes the Internet API to write or otherwise establish the file in the shared-file database.
[0042] [0042]FIG. 4 illustrates an embodiment of a routine used by the web application 165 to retrieve and process response files 157 . At step 250 , the routine to retrieve and process response files begins. At step 255 , the routine waits for the host-side server 110 to provide a response file 157 to the shared-file database. At step 260 , the routine retrieves the response file 157 . This is accomplished by using the Internet API 167 to read the file. At step 265 , the routine verifies that the response file 157 contains valid data. If there is not a response containing valid data or if the system has timed out because there was not a response within a defined time interval, the routine returns a value of ‘false’ at step 290 . If the response file 157 contains valid data, then at step 275 , the routine matches the response data to the appropriate request.
[0043] Next, at step 280 , the routine processes the response file. The nature of this processing may vary depending on the nature of the transaction processed. Processing includes translating the file into a format that is accessible to the web pages 171 . Therefore, step 280 is also, in part, an embodiment of the web application's translation logic 169 . Finally, at step 285 , the routine deletes the response file 157 and returns to step 255 to wait for the next response file 157 to arrive. In this way, the shared-file database 150 does not overflow with response files 157 that are no longer required.
[0044] FIGS. 5 - 7 show code segments from a portion of a specific example of a web application. This example, applicable in a banking system or other application involving a PIN secured account number, captures user information and submits it to the host computer. FIG. 5 shows an example of an HTML web page. Specifically shown is an example of an input page 300 and the code segments 304 - 325 that created it. A ‘submit’ button 302 and a ‘cancel’ button 304 are elements of the web page created by those code segments. HTML code segment 305 formats the page and displays the heading “Internet Financial Transaction” in the center of the page. The next code segment 310 links the web page to the Active Server code segments 355 - 370 (shown on FIG. 6 which will be discussed later). The next segment 315 captures a user account number and code segment 320 captures the PIN number. Finally, the HTML code segment 325 captures a command, either ‘submit’ or ‘cancel’.
[0045] [0045]FIG. 6 contains code segments 355 - 370 that form the Active Server page mentioned above. When the user selects ‘submit’ the Active Server code segments that are linked to the HTML page are activated. Code segment 355 assigns the user account number and PIN to variables. Next, in code segment 360 , two sequential calls are made to the Internet API 167 . These function calls insert the two variables into a data structure that can be read by the host-side server. In this specific example, since there are only two variables, the two sequential function calls represent an embodiment of translation logic which takes the data from the web page and structures it into the format of the request files in the shared-file database.
[0046] Code segment 365 of FIG. 6 calls the Internet API 167 to provide a request file to the shared file to the shared-file database. If the request is successfully serviced, the return value of the variable “ret” will be ‘true’ and if the request is not successfully serviced, the value will be ‘false’. Next, at code segment 370 , calls are made to Active Server output pages. If the request is successfully processed, then the routine “AccountInfo.asp” will process and display the results. If the request is not processed, then the routine “AccountError.asp” will perform appropriate error processing which may include presenting an account error message.
[0047] [0047]FIG. 7 contains code segments 410 - 460 which illustrate a specific example of a portion of the Internet API. Code segment 410 processes data from the web page by placing it in an array that can be written to a request file. Code segment 420 provides the request file to the shared file database. It opens a file of type “Request” with a definable filename and writes the request command, indicated by the variable ‘ProcessNumber’ to the file. Then it writes the array of variables, which in this case includes two elements, to the file and closes the file. Code segment 430 waits in a ‘do-loop’ until the host-side server has written a response file. In this specific example the Internet API waits indefinitely for a response file to appear. Once the file is written, code segment 440 receives the response file. If the host computer successfully processes the request, then the first element of the response file reads ‘Success’, code segment 440 reads the response data into an array, and code segment 450 returns a value of ‘True’. If the file indicates that the host computer is unsuccessful in processing the request, then code segment 450 returns a value of ‘False’. Finally, code segment 460 closes and deletes the response file.
[0048] Host Side Server and Sub-Elements
[0049] [0049]FIG. 8 depicts a block diagram of the host-side server 110 , illustrating the interaction between the host-side agent 115 and the shared-file database 150 . The host-side server 110 can be any kind of computer, including but not limited to a mainframe, workstation, or personal computer, that is capable of supporting a physical connection to the host computer 80 and has sufficient capacity to run host communication enabling software 135 and a host-side agent 115 . The purpose of the host-side server 110 is to receive requests, (through request files 153 ) for host computer services from the shared-file database 150 , process those requests, and provide a response file 157 containing the appropriate data. The host-side server 110 provides an added layer of security for the host computer because only transactions that the host-side server 110 is authorized to process will be transmitted to the host communication enabling software 135 and on to the host computer 80 .
[0050] The host communications enabling software 135 is installed on the host-side server. This software is operatively connected to the host-side agent and the host computer 80 to transmit data and transaction requests to and receive data and error messages from the host computer 80 . In one application, the host computer 80 is a mainframe computer running a transactional system, and the host communications enabling software 135 is a terminal emulator and screen-scraper application. This screen-scraper application operates by convincing the host computer 80 that the host-side server 110 is a dumb terminal. The host communications enabling software 135 may also be an interface written to a specific host application, database interconnectivity software such as ODBC, or an interface that is appropriate to the type of host computer 80 used in the system.
[0051] In one embodiment, the host side agent 115 primarily contains two elements: a shared-file database manager 117 , and a host process manager 119 . The shared-file database manager 117 may be a script, routine, program, or set of programs that are operatively connected to the shared-file database 150 so that it may retrieve request files, provide response files, and perform database management functions on the shared-file database 150 . These database management functions may include, but are not limited to functions to create, read, write, and delete files, functions to allocate space, and functions to remove files that have persisted in the database beyond a defined time interval. The shared-file database manager 117 is also operatively connected to the host process manager 119 . The host process manager may be a script, routine, program, or set of programs that process data retrieved from the request files 153 and structure and process data going to the response files 157 . The shared-file database manager 117 and the host process manager 119 may be embodied in discrete code segments or integrated together in a common body of code. In the event that the shared-file database 150 is encrypted, encryption routines, such as an implementation of PGP or DES encryption software, may be linked to the shared-file database manager 117 , the host process manager 119 , or both.
[0052] In its operation, the shared-file database manager 117 retrieves request files 153 from the shared-file database 150 . The shared-file database manager 117 communicates the contents of these files to the host-process manager 119 . If the file includes a valid transaction request command, then the host process manager 119 initiates the appropriate processes on the host computer 80 . The host process manager 119 communicates the necessary data and instructions to the host computer 80 by invoking the host communications enabling software 135 .
[0053] When the host computer 80 has completed a transaction, the host communications enabling software 135 receives any return data and error messages and communicates them to the host process manager 119 . From there, the host process manager 119 processes the data and error messages, putting the information into the format required by the web server 160 . The formatted information is sent to the shared-file database manager 117 which provides (e.g., generates and conveys) a response file 157 to the shared-file database 150 .
[0054] [0054]FIG. 9 illustrates one embodiment of a routine 505 performed by the host-side agent 115 to retrieve and process request files 153 . In step 510 , the routine retrieves (or waits for) a next request file to be processed. In step 520 , the routine opens a shared request file. Authorized request files are written by the Internet API 167 and may contain a request command and data required for the request. At step 525 , the routine reads the request command and any data in the file. Next, at step 530 the routine closes the file and at step 535 deletes it. By deleting files after they are read, the routine performs part of the function of the shared-file database manager 117 by ensuring that the shared-file database 150 does not overflow with files that are no longer needed.
[0055] Next, at step 545 , the routine checks to see whether or not the transaction requested is valid. One of the security features of this computer system 100 is that it only permits a defined set of transactions to be run on the host computer 80 . If the request command is invalid, the routine does not process the request, and the host computer 80 is protected. If the request is valid, the routine advances to step 550 , which processes the request command and data. Performing this step is a part of the function of the host process manager 119 and involves initiating host computer transactions through the host communications enabling software 135 . From here, the routine proceeds back to step 510 for processing a next request file.
[0056] [0056]FIG. 10 illustrates one embodiment of a routine executed by the host-side agent 115 to provide response files 157 to the shared-file database 150 . At step 560 , the routine to provide response files to the shared file-database 150 begins. First, at step 565 , the routine waits for a response from the host computer 80 . When there is a response, the routine creates the response file at step 570 . This involves recognizing whether or not the host computer 80 successfully processes the transaction. If the transaction is successfully processed, then any data returned by the host is processed so that it can be read by the web server 160 . If the transaction is not successful, then the response file will contain any appropriate error messages indicating transaction failure. After the response file 157 is created, the routine advances to step 575 where the data in the file is written to the shared-file database 150 . Finally, in step 580 , the routine closes the response file 157 and returns to step 565 to wait for the next host response.
[0057] [0057]FIG. 11 contains code segments 605 - 620 that illustrate a portion of a specific example of host process manager. In this example, the shared-file database manager and the host process manager are merged into a single block of code comprising two functions labeled “Poll” and “DoHostLinkProcess”. The function “Poll” uses code segment 605 to wait in a do loop until there is a request file. When there is such a file, code segment 610 opens the file, reads the process number and data, then closes and deletes the file. After the data is read, code segment 615 makes a call to the “DoHostLinkProcess” function. This function begins by executing process “ 1 ” in code segment 620 . In this specific example, “ 1 ” is the only allowable transaction request command. After initiating the transaction, code segment 620 waits for a response and creates a response file. If the transaction is processed successfully, the response file will contain the value “Success” and any appropriate data. If the transaction is not successful, the response file will contain the value “Fail” and an error message. By combining the functionality of accessing the shared-file database with the functionality to process a transaction request, the code segments 605 - 620 in this example combine some the functions of the shared-file database manager with the host process manager into a single block of code.
[0058] [0058]FIG. 12 shows code segments 650 and 655 which illustrate a portion of an example of a terminal emulator running a screen scraper. In this example, the terminal emulator functions as host communications enabling software. The terminal emulator convinces the host computer that the host-side server is a dumb terminal by converting transaction requests and input data into screens that are recognized by the host computer. Code segment 650 enters the account number and PIN into the appropriate fields on a mainframe computer screen. Code segment 655 ‘scrapes’ the response data from the screen. If the transaction is successful, two data items are captured from the screen. If the transaction is unsuccessful, an error message is captured. Together, these code-segments enable the host-side agent to communicate with the mainframe host computer used in this example.
[0059] Alternative Embodiments
[0060] [0060]FIG. 13 shows an embodiment of a host-side server 610 in which a shared-file database 650 resides on the server. Although the shared file database 650 can be physically located on another computer, in the preferred embodiment it is placed on the host-side server 610 . By placing the shared-file database 650 on the host-side server 610 , the database is isolated from the Internet. This increases the security of the shared-file database 650 because an unauthorized Internet user does not have a direct connection to the host-side server.
[0061] [0061]FIG. 14 shows an embodiment in which the physical connection through which the web server 760 accesses the shared-file database 750 is a hub 790 . In this embodiment, the hub is connected to the web server 760 and to the host-side server 710 . Because the shared-file database 750 in this embodiment resides on the host-side server 710 , the hub 790 provides a path for the web application 765 to provide and retrieve files in the shared-file database 750 . In an alternative embodiment, the shared-file database could be installed on a multi-ported storage device that forms a part of or is connected to the host-side server 710 . This multi-ported storage device may be a dual-ported disk drive, operably connected to the host-side server 710 and to the web-server 760 . In this embodiment, the web application 765 has a direct path to the shared-file database 750 through the port of the storage device that is connected to the web server 760 . It is obvious to one who is skilled in the art that other means to provide a connection between the web-server and the shared-file database, such as a serial or parallel interconnect, could also be used to enable the web application 765 to provide and retrieve files from the shared-file database 750 .
[0062] 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. | The present invention addresses both the problem of Internet access and security by providing an interface to a host computer that does not utilize a direct network connection between the host computer and the internet. In one embodiment, a computer system is provided that comprises two servers that interact through a shared-file database. One server is connected to the Internet and makes requests to the other through the shared-file database. The second server is connected to a host computer, and only performs the requests if they are among a pre-defined set of allowable transactions corresponding to a permissible set of request commands. The shared-file database is the substantially only resource shared by the two servers, and it thus serves as a secure buffer between Internet users and the host computer. Because the host computer is not connected to the Internet, it is not susceptible to many forms of unauthorized use. The transactions that can be initiated on the web server and performed on the host computer are restricted to a pre-defined set of transactions. By funneling requests for host transactions through a database buffer, and by limiting access to a pre-defined set of transactions, the computer system provides a secure method of enabling Internet users to access host computers. | 6 |
FIELD OF THE INVENTION
[0001] The invention relates to a membrane material for energy storage devices such as a lithium-ion secondary battery and a preparation method thereof, which belongs to the field of manufacturing battery and capacitor.
DESCRIPTION OF THE RELATED ART
[0002] Microporous polymer membrane is one of the three essential materials for manufacturing lithium-ion battery. The characteristic, pore structure, physicochemical property of material are closely related to electric performance, safety and cycle life of lithium-ion battery. Membrane used for traditional liquid battery is mainly microporous polyolefin membrane, microporous polyvinylidene fluoride membrane and microporous polyolefin membrane/polyvinylidene fluoride membrane composite membrane.
[0003] Microporous polyolefin membrane is mainly polyethylene membrane, polypropylene membrane and polyethylene-polypropylene composite membrane. Mechanical two-way stretch method (dry method) and solvent extraction method (wet method) process technology are used to prepare microporous polyolefin membrane. As polyolefins are non-polar materials, the compatibility of polyolefin with electrolyte solution (polar organic solvent) is poor. It plays only the role of a simple mechanical isolation between cathode and anode. The membrane has no fixation to electrolyte which makes most of electrolyte solution exist in the battery in a free state. During charge-discharge cycles, redox side-reaction occurs inevitably between the free electrolyte with anode and cathode materials to consume the electrolyte in battery which results in poor lithium battery. It leads to polarizations increase of battery and easy to form lithium deposition crystal in charge-discharge cycles, which results in membrane piercing phenomenon. It is easy to form dry areas of electrolyte which leads to the phenomenon of electrostatic breakdown caused by the poor absorption of membrane to electrolyte. The two phenomena above-mentioned can easily result in combustion and explosion of lithium-ion battery in severe case. The potential safety hazard of lithium-ion battery constrains its development space used in large-capacity and high-power dynamic-power electrical source.
[0004] Polyvinylidene fluoride and its derivatives possess film-forming ability only in the presence of plasticizer. The PVDF membrane containing plasticizer has high performance of self-adhered and relatively low mechanical strength which result in poor process operability. It can not be separately prepared to be microporous polymer membrane like polyolefin resin. The preparation method of such microporous polymer membrane basically adopts the following procedure. The PVDF membrane containing plasticizer and battery electrode of anode and cathode are prepared to be dry battery cell by thermal bonding. Then, organic solvent is used to extract the dry battery cell to form PVDF microporous polymer membrane bonded with anode and cathode. In order to solve the technical difficulty to allow the PDVF microporous polymer membrane to be formed like microporous polyolefin membrane and enhance the operability in preparation of battery, the PVDF solution is coated on microporous polyolefin membrane, and then solvent extraction or phase inversion method is used to prepare microporous polyolefin/polyvinylidene fluoride composite membrane.
[0005] In addition, other types of microporous polymer membrane are being researched and developed. For example, Degussa Corporation in Germany uses polymer non-woven as supporter to prepare inorganic microporous ceramic membrane. This non-woven support membrane contains a lot of inorganic fillers which bonded to non-woven through silane adhesive. During drying and use, inevitable piercing phenomenon caused by vibration, bending and folding lead to membrane-coating rugged. Due to uneven current distribution, local voltage increase may lead to current breakdown phenomenon in charge or discharge. S. S. Zhang, et al. prepared P (AN-MMA) microporous polymer membrane using phase inversion method.
SUMMARY OF THE INVENTION
[0006] The object of the present invention is to provide a kind of novel membrane, i.e., microporous polymer membrane, used for energy storage devices such as a lithium-ion battery. The membrane has some merits such as low-cost, simple preparation method and green environmental protection. The prepared membrane has good high temperature resistance. It has good security and long cycle life used for secondary battery and other energy storage devices.
[0007] In the present invention, water is used as reaction medium. Polymer colloidal emulsion is obtained through polymerization reaction generated by polyvinyl alcohol and multicomponent monomers with different polarities (such as the hydrophobic monomer or hydrophilic monomer). Coating the polymers colloidal emulsion on a plastic baseband using tape-casting techniques, peeling the membrane after drying, the microporous polymer membrane is obtained.
[0008] In the present invention, the micropores of membranes are formed under different interaction parameters of each component, because different evaporation rate of various components can form micro-phase separation during film-forming process. Specifically, the microporous polymer membrane provided in the invention is from a colloidal emulsion obtained by polymerization reaction between polyvinyl alcohol and hydrophobic monomer (a certain amount of hydrophilic monomer can also be added) with an initiator in water medium.
[0009] The weight ratio of materials for preparing microporous polymer membrane is as follows: 100 parts of polyvinyl alcohol, 0-100 parts of hydrophilic monomer 30-100 parts of hydrophobic monomer, 1-5 parts of initiator. The polyvinyl alcohol has a polymerization degree of 1700-2400 and a hydrolysis degree of 55-99. Preferably, polyvinyl alcohol has a polymerization degree of 1700 and a hydrolysis degree of 99, i.e., PVA1799.
[0010] The structure formula of hydrophobic (lipophilic) monomer is CH 2 ═CR 1 R 2 , wherein, R 1 =—H or —CH 3 ; R 2 =—C 6 H 5 , —OCOCH 3 , —COOCH 3 , —COOCH 2 CH 3 , —COOCH 2 CH 2 CH 2 CH 3 , —COOCH 2 CH(CH 2 CH 3 )CH 2 CH 2 CH 2 CH 3 , —CN; the hydrophobic monomer comprised at least one of the above-mentioned hydrophobic monomer.
[0011] In order to improve the swelling properties of the membrane to electrolyte and enhance affinity of the membrane to electrolyte, etc., the hydrophilic monomer can also be added in the reaction. The preferable amount of the hydrophilic monomer added is 10-100 parts by weight.
[0012] The structure formula of the hydrophilic monomer is as follows:
[0000] CHR 3 ═CR 4 R 5 , wherein,
R 3 =—H, —CH 3 or —COOLi;
R 4 =—H, —CH 3 or —COOLi;
R 5 =—COOLi, —CH 2 COOLi, —COO(CH 2 ) 6 SO 3 Li, —CONH 2 , —CONHCH 3 ,
[0013]
[0000] —CONHCH 2 CH 3 , —CON(CH 3 ) 2 , —CON(CH 2 CH 3 ) 2 ; the hydrophilic monomer comprised at least one selected from the above-mentioned hydrophilic monomer.
[0014] The initiator may be ammonium peroxydisulphate, potassium peroxydisulfate, hydrogen peroxide, azobis (2,2′-Azobisisobutyronitrile) which are water soluble initiator, or redox system consisted by the above-mentioned initiator with Na 2 SO 3 and FeSO 4 and so on.
[0015] Not more than 3 parts by weight of auxiliary is used as emulsifier which can enhance the stability of colloidal emulsion. The auxiliary can be selected from laurylsulfate, dodecyl benzene sulfonate and vinyl-sulfonate.
[0016] The preparation method of microporous polymer membrane described in the present invention comprised the following steps:
[0017] (a) Adding polyvinyl alcohol to water, heating and stirring until the solids completely dissolved. If hydrophilic monomer or/and auxiliary is used, simultaneously dissolving in water together with the polyvinyl alcohol.
[0018] (b) Then holding the reactor at the required reaction temperature (30-90° C.), adding the hydrophobic monomers containing different components to the reactor at one time or in batches or dropwise, and adding the initiator to initiate the polymerization reaction for 4-35 h to obtain the polymer colloidal emulsion; the initiator can be added dropwisely or in batches.
[0019] (c) Adding 5-20% of filler and 50-100% of plasticizer on the basis of 100% solid content of the polymer colloidal emulsion, grinding the mixture with a ball grinder for 5 h to obtain the slurry. Coating the polymer colloidal emulsion on plastic baseband such as BOPP, PET, PE, PP and other plastic baseband using tape-casting techniques, drying and peeling the membrane to obtain the microporous polymer membrane.
[0020] The hydrophilic monomer described above can also be added dropwisely or in batches together with hydrophobic monomer and initiator in Step b to allow a stepwise polymerization reaction.
[0021] The filler can be extra fine inorganic filler with high specific surface area and strong adsorption capacity that will benefit electrolyte absorption and ion conduction, meanwhile the filler can increase the rigidity of membrane so that in favor of production of energy storage devices. The inorganic filler is mainly selected from oxide, such as silicon dioxide, aluminum oxide, titanium dioxide, zirconium dioxide, magnesia, calcium oxide and fiberglass and so on.
[0022] In order to enhance the dispersion of inorganic filler in polymer colloidal emulsion, silane coupling agent can be added. The silane coupling agent can be added during the polymerization reaction by adding the amount of 0.5-5 parts by weight. The silane coupling agent can also be added while adding filler and plasticizer after polymer colloidal emulsion obtained. The addition amount of silane coupling agent added is 0.5-3.0% on the basis of 100% solid content of the polymer colloidal emulsion, The silane coupling agent can be selected from 3-aminopropyltriethoxysilane, [3-(2-Aminoethyl)aminopropyl]trimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-(methacryloyloxy)propyltrimethoxysilane, vinyltriethoxysilane, vinyltrimethoxysilane and vinyl tri (2-methoxyethoxy) silane.
[0023] To enhance the strength and toughness of membrane, micron-sized organic filler can also be added to modify the membrane. The organic filler can be selected at least one from polyethylene powder, polyethylene wax powder or oxidized polyethylene wax powder.
[0024] The plasticizer can be glycerol, propylene glycol, polyethylene glycol, benzyl alcohol, isopropanol, phosphate ester and so on.
[0025] The microporous polymer membrane described in the present invention is developed on the basis of traditional liquid lithium battery membrane. Neither two-way stretch nor solvent extraction is required to create pores. Instead, it is a completely different pore-forming theory (micro-phase separation method). The phase separation theory is firstly used to prepare microporous polymer membrane in the field of battery membrane. In the present invention, the chemical composition of basic materials of traditional battery membrane is changed. Water is used as reaction medium. Polymer colloidal emulsion with micro-phase separation structure can be obtained by graft copolymerization of multi-component in different polar monomer. The process is environmental friendly and pollution-free. The prepared lithium-ion battery has a good stability and long life cycle.
[0026] The characteristics of microporous polymer membrane described in the present invention are as follows:
[0027] (1) Having high absorbency, high absorption rate and good hydrophilicity, absorbing and holding the electrolyte of a rated capacity of the battery, and holding higher absorption rate during the whole service life;
[0028] (2) having large surface area and high porosity;
[0029] (3) being capable of effectively prevent the battery from short-circuit and dendrite penetration due to its small aperture;
[0030] (4) having stronger resistance to oxidation and low resistivity;
[0031] (5) having higher ion penetrability and good mechanical strength; and
[0032] (6) having good thermal stability (less thermal shrinkage and less size distortion), and having good electrochemical stability.
[0033] Microporous polymer membrane described in the present invention has abundant and cheap material sources which are processed by the conventional equipment, and has simple operation, stable property and commercial value.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The invention is further described in details by reference to Examples, but the invention is not limited to the following embodiments.
Example 1
Preparation of Microporous Polymer Membrane
Step 1: Synthesis of Polymer Colloidal Emulsion
[0035] In this example, water-soluble polymer emulsion used for lithium-ion battery membrane was prepared through polymerization reaction generated by hydrophilic polymer polyvinyl alcohol (PVA) 1750 and lipophilic monomer vinyl acetate (VAC)/ethylacrylate (EA)/acrylonitrile (AN) in water solution. The composing of copolymer was PVA:VAC:EA:AN=10:2:2:5 (weight ratio, the same hereinafter). The content of copolymer is 17%. The product was white opaque emulsion.
[0036] The polymer emulsion was prepared through following steps: 1000 g distilled water and 100 g polyvinyl alcohol (PVA) 1750 were added to four-neck reaction vessel fixed condenser. The temperature of the reaction vessel was heated to 75° C. under stirring at 100 rpm. After 3 h, the material was transparent like can be regarded as dissolved finished. After natural cooling to 55° C., 40 g mixture of lipophilic monomer vinyl acetate (VAC) and ethyl acrylate (1:1) was added in one time. After stirring for 10 min, 0.5 g of water-soluble initiator (ammonium peroxydisulphate) was added. About 20 minutes later, the material was light blue. The color of the mixture changed into a white emulsion after 30 minutes. The reactive intermediate was obtained after 2 h copolymerization.
[0037] The above reaction mixture and 50 g of lipophilic monomer Acrylonitrile (AN) were mixed. 1.5 g of initiator and 0.5 g weakly acidic lithium vinyl sulfonic acid were added. After 10 h reaction, polymer colloidal emulsion was obtained.
Step 2: Preparation of Slurry
[0038] 19 g of filler (zirconium dioxide) and 160 g of plasticizer (benzyl alcohol) were added to the polymer colloidal emulsion prepared according to Step 1. The mixture was grinded with a ball grinder for 5 h. The viscosity of the slurry at the temperature T slurry of 35° C. was 2500 mpa·s measured at the temperature of 20.6° C. and the relative humidity (RH) of 64%.
Step 3: Coating
[0039] Tape-casting equipment was used. Polymer colloidal emulsion was coated on BOPP plastic baseband. The microporous polymer membrane was obtained after the water and plasticizer of the BOPP baseband coated the polymer colloidal emulsion was volatilized through the heated-air drying tunnel. The temperature of heated-air drying was 60-130° C., preferably, 80-100° C.
Example 2
Preparation of Microporous Polymer Membrane
Step 1: Synthesis of Polymer Colloidal Emulsion
[0040] The reaction steps are basically the same as EXAMPLE 1 The only difference is that the lipophilic monomer ethyl acrylate (EA) was replaced by acrylamide (AM). The composing of copolymer was PVA:VAC:AM:AN=10:2:1:8.
[0041] The concrete preparation method of the polymer emulsion is as follows:
[0042] All monomers were added in one time. The concentrations of materials were adjusted to about 13%. Initiator was added directly. The slurry experienced colorless-light blue-white emulsion process. The reaction rate was faster than EXAMPLE 1. After 12 h reaction, polymer emulsion used for lithium batteries was obtained.
Step 2: Preparation of Slurry
[0043] The amount of filler is the same as EXAMPLE 1. The materials are titanium dioxide and benzyl alcohol. The mixture was grinded with a ball grinder for 5 h. The viscosity of the slurry was kept at 2500 mpa·s by adjusting the solid content at the temperature T slurry of 35° C.
Step 3: The Process is the Same as Example 1
Example 3
Step 1: Synthesis of Polymer Colloidal Emulsion
[0044] In this example, polyvinyl alcohol 1788 (PVA) was added to lipophilic monomer styrene (St)/butyl acrylate (Ba)/acrylonitrile (AN). Water-soluble polymer emulsion used for lithium-ion battery membrane was prepared by ternary polymerization in aqueous phase. The composing of copolymer was PVA:St:Ba:AN=10:2:4:5 (weight ratio, the same hereinafter). The content of copolymer is 17%. The product was white opaque emulsion.
[0045] The polymer emulsion was prepared through following steps: 1000 g distilled water and 100 g polyvinyl alcohol (PVA) 1788 were added to four-neck reaction vessel fixed condenser. The temperature of the reaction vessel was heated to 90° C. under stirring at 100 rpm. After 3 h, the material was transparent like can be regarded as dissolved finished. After natural cooling to 65° C., styrene monomer and a little initiator were added. About 20 minutes later, the mixture became a white emulsion. In the meantime, butyl acrylate (Ba) was added. The reaction was continued for 2 h.
[0046] Acrylonitrile monomer was added dropwisely to the above prepared emulsion (The dropwise speed was controlled by peristaltic pump. The material was added to the emulsion during 5 h). 1.5 g of initiator was replenished and the polymerization reaction was continued for 12 h to obtain polymer membrane emulsion used for lithium battery.
Step 2: Preparation of Slurry
[0047] 15% of filler (silicon dioxide) and 100% of plasticizer (tributyl phosphate) were added to the prepared polymer colloidal emulsion. The mixture was grinded with a ball grinder for 5 h. The viscosity of the slurry was kept at 2500 mpa·s by adjusting the solid content at the temperature T slurry of 35° C.
Step 3: The process is the same as Example 1
Example 4
Step 1: Synthesis of Polymer Colloidal Emulsion
[0048] In this example, polyvinyl alcohol 1788 (PVA), hydrophilic monomer N-vinyl pyrrolidone (NVP), lipophilic monomer butyl acrylate (Ba) and acrylonitrile (AN) were used as materials for preparation of water-soluble polymer emulsion used for lithium battery membrane. The composing of copolymer was PVA:NVP:Ba:AN=10:2:4:5 (weight ratio).
[0049] The polymer emulsion was prepared by one-step polymerization. The monomers and initiators were added simultaneously. The redox system of ammonium sulfite-potassium peroxydisulfate was used as initiator. The reaction temperature was 72° C. and the reaction time was 12 h. The concentration of copolymer is 19.5%. The product was white colloidal emulsion.
Step 2: Preparation of Slurry
[0050] 15% of filler (silicon dioxide treated with 3-aminopropyltriethoxysilane) and 100% of plasticizer (tributyl phosphate) were added to the prepared polymer colloidal emulsion. The viscosity of the slurry was kept at 2500 mpa·s by adjusting the solid content.
Step 3: The Process is the Same as EXAMPLE 1
Example 5
Step 1: Synthesis of Polymer Colloidal Emulsion
[0051] In this example, PVA, hydrophilic monomer lithium acrylate (MAALi) and lipophilic monomer acrylonitrile (AN) were polymerized in aqueous phase to form water-soluble polymer emulsion used for lithium battery membrane. The composing of copolymer was PVA:MAALi:AN=10:2:5 (weight ratio).
[0052] The polymer emulsion was prepared through following steps: First, polyvinyl alcohol 1788 was dissolved in water at 50° C. Lithium acrylate (MAALi) and acrylonitrile (AN) were added in one time. The polymerization method is the same as foregoing EXAMPLE. After 12 h, polymerization reaction was completed.
Step 2: Preparation of Slurry
[0053] 30% of filler (aluminum oxide) and 120% of plasticizer (triethyl phosphate) were added to the prepared polymer colloidal emulsion. In order to improve the adhesiveness of membrane with BOPP substrate, 35% of oxidized polyethylene wax emulsion was added. The mixture was grinded with a ball grinder for 5 h. The viscosity of the slurry was kept at 2500 mpa·s by adjusting the solid content.
Step 3: The Process is the Same as EXAMPLE 1
Example 6
Step 1: Synthesis of Polymer Colloidal Emulsion
[0054] In this example, aqueous polymer emulsion used for lithium battery membrane was obtained by graft polymerization of polyvinyl alcohol 1799 (PVA), hydrophobic monomer vinyltriethoxysilane (151)/acrylonitrile (AN) in aqueous phase. The composing of copolymer was PVA:151:AN=10:4:5 (weight ratio).
[0055] The polymer emulsion was prepared through following steps: 1000 g distilled water and 100 g polyvinyl alcohol (PVA) 1799 were added to four-neck reaction vessel fixed condenser. The temperature of the reaction vessel was heated to 90° C. under stirring at 100 rpm. After 3 h, the material was transparent like can be regarded as dissolved finished. After natural cooling to 60° C., 40 g of vinyltriethoxysilane 151, 50 g of acrylonitrile (AN) and 1.9 g of ammonium peroxydisulphate were added. The graft polymerization time was 12 h. The concentration of copolymer is 17.4%. The product was white colloidal emulsion.
Step 2: Preparation of Slurry
[0056] The polymer colloidal emulsion is adjusted to be weakly acid by diluted hydrochloric acid. 20% of filler (silicon dioxide) filler and 100% of plasticizer (triethyl phosphate) was added. In order to improve the shrinkage performance of membrane, 30% alkali free fiberglass (micron-sized) was attempted added. The fiberglass was sintered at temperature 500° C. before use, then natural cooling. The mixture was grinded with a ball grinder for 5 h. The viscosity of the slurry was kept at 2500 mpa·s by adjusting the solid content.
Step 3: The Process is the Same as EXAMPLE 1
[0057] Absorption Amount of the Membrane Prepared by example 1-6
[0058] The microporous polymer membranes prepared by EXAMPLE 1-6 were dried for 3-8 h in a vacuum at 90° C. The whole testing process was carried out in dry air atmosphere (the relative humidity of dry air atmosphere was below 3%). The membranes were taken out after 2, 4, 6, 12 h dipping in electrolyte, respectively. The residual electrolyte on surface was blotted up by filter paper. The sample was weighed using analytical balance of 0.01 g accuracy. The weight difference before and after dipping in the electrolyte is the absorption amount. After 12 h dipping in electrolyte, the membranes were taken out and deposited for 3 h. The electrolyte conservation rate of water-soluble polymer membranes was determined (the absorption amount to the weight difference of 12 h dipping). The results of contrast experiment of EXAMPLE and PP membrane are shown in Table 1.
[0000]
TABLE 1
Data of liquid absorption rate
Electrolyte LB305
Dry
Wet
Soak
film
film
Absorption
Absorption
Type
time
weight
weight
amount
rate
PP
2
23
35
12
52%
4
23
37
14
60%
6
23
38
15
65%
12
23
38
15
65%
EXAMPLE 1
2
25
44
19
76%
4
25
49
24
96%
6
25
53
28
112%
12
25
53
28
112%
EXAMPLE 3
2
24
40
16
67%
4
24
44
20
83%
6
24
49
23
95%
12
24
50
25
96%
EXAMPLE 4
2
25
43
18
72%
4
25
48
23
92%
6
25
50
25
100%
12
25
50
25
100%
EXAMPLE 6
2
24
39
15
62%
4
25
44
19
76%
6
25
45
20
83%
12
25
46
21
84%
Example 7
A Lithium-Ion Battery Containing the Microporous Polymer Membrane of Invention
[0059] The microporous polymer membrane prepared in EXAMPLE 6 was assembled into a lithium-ion battery. The battery was composed of the LiMn 2 O 4 cathode material, graphite anode materials, and electrolyte LiPF 6 consisting of ethylene carbonate/diethyl carbonate. The battery is subject to a DOD 100% charge-discharge cycle under a condition of 1 C. The results of experiments showed that the capacity of battery remained over 75% than initial capacity after 1500 charge-discharge cycle. The increase of internal resistance in battery was less than 10%. As a contrast, the lithium-ion battery assembled by commercial microporous polypropylene film under the same conditions has the capacity about 75% of initial capacity and the internal resistance increases more than 35% after 400 cycles under the same condition.
[0060] The lithium-ion battery assembled by microporous polymer membrane prepared in present invention has long cycle life and smaller battery polarization attributed to the microporous polymer membrane has excellent affinity with the polar electrolyte solution and excellent liquid retention property which is made from a high-polarity polymer material. | Provided are separators used in power accumulators such as lithium ion secondary batteries and a preparation method thereof. The said separators are obtained through following steps: providing a polymer colloidal emulsion through a polymerization reaction of polyvinyl alcohol, hydrophobic monomer and hydrophilic monomer in water solution initiated by an initiator; coating a plastic substrate with the said polymer colloidal emulsion using tape-casting method; drying the plastic substrate coated with the polymer colloidal emulsion, and then obtaining the said separators by delaminating them from the substrate. The said separators have good liquid absorbability, high liquid absorption rate and retention, low resistivity, good mechanical strength and good thermal stability (little thermal shrinkage and little size distortion) as well as electrochemical stability. The prepared lithium ion batteries have good cycle stability and long service life. | 2 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a U.S. national stage application of International Application No. PCT/FI00/00821, filed Sep. 26, 2000, and claims priority on Finnish Application No. 19992086 filed Sep. 29, 1999, the disclosures of both of which applications are incorporated by reference herein.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to the calendering of a fibrous web.
Calendering is a method by means of which the properties, in particular the thickness profile, smoothness, gloss, surface porosity and translucence of a web-like material, such as a paper web, are sought to be generally improved. In calendering the paper web is passed into a nip which is formed between rolls pressed against each other and in which the paper web is deformed by the action of temperature, moisture and nip pressure, in which connection the physical properties of the paper web can be affected by controlling the above-mentioned parameters and the time of action. The good physical properties attained by calendering lead to better print quality, thereby bringing a competitive advantage to the manufacturer of paper.
The so-called shoe rolls known in prior art are usually hydraulically deflection-compensated, zone-controlled rolls in which the shell is supported from a non-rotating central shaft of the roll by means of hydrostatic loading arrangements, such as rows of loading shoes, which transfer the nip force acting on the shell rotating around the central shaft so as to be carried by the central shaft. The loading element is generally also divided into zones, in which connection the loading pressure can be regulated as required by profiling. The zoning in this kind of zone-controlled shoe roll may comprise individual elements in the loading arrangement, in which connection the number of zones in the roll and in the loading arrangement may exceed 60—as examples may be mentioned the shoe rolls marketed by Metso Paper, Inc. under the trademarks SymCD™ and SymCDS™, or the zoning may comprise a group of elements in the loading arrangement, in which connection the roll and the loading arrangement normally comprise eight zones—as examples may be mentioned the shoe rolls marketed by Metso Paper, Inc. under the trademarks SymZ™, SymZS™, SymZL™, and SymZLC™. Extended-nip calendering accomplished by means of a shoe roll has generally been found to be good for producing low-gloss paper grades, i.e. grades having a Hunter gloss % below 40. When higher gloss is required, the nip pressure of extended-nip calendering is, however, not any more sufficient to provide gloss.
In the papermaking art, grades of ever higher quality are required today. As the running speeds required of paper machines are continuously increasing, the direction in calendering technology is more and more towards on-line solutions. When the aim is to make higher quality printing paper grades, such as, for example, SC-A and LWC-roto grades and glossy coated paper grades, a substantial problem is that this kind of grades can be produced in practice only by using, after drying a fibrous web, intermediate winding and off-line supercalenders, several of said supercalenders, usually two or three, being used side by side to meet production capacity.
Supercalendering is calendering in a calender unit in which nips are formed between a smooth-surface press roll, such as a metal roll, and a roll covered with a resilient coating, such as a paper or polymer roll. The resilient-surface roll adapts itself to the contours of the surface of paper and presses the opposite side of paper evenly against the smooth-surface press roll. Today, the supercalender typically comprises 10-12 nips and for the purpose of treating the sides of the web, the supercalender comprises a so-called reversing nip in which there are two resilient-surface rolls against each other. Linear load increases in the supercalender from the top nip to the bottom nip because of the force of gravity. This increase in load can be compensated for by using the relieving of the rolls. Supercalendering is an off- and on-line calendering method, and at the moment it provides the best paper qualities, such as, for example, WFC, LWC-roto and SC-A.
Soft calendering is calendering in a calender unit in which nips are formed between a smooth-surface press roll, such as a metal roll, and a roll covered with a resilient coating, such as a paper or polymer roll. In a soft calender, the nips are formed between separate roll pairs. In order to treat both sides of the web in the soft calender, the order of the roll pairs forming the successive nips is inverted with respect to the web so that the resilient-surface roll may be caused to work on both surfaces of the web. Soft calendering is an on- or off-line calendering method, and grades, such as, for example, MFC and film coated LWC as well as SC-C can be produced by means of it.
Multi-roll on-line, off-line calendering is calendering in a calender unit in which the number of rolls is higher than in soft calenders, most commonly 6-16. Multi-roll calenders are soft-nip calenders. The resilient-surface roll conforms to the contours of the surface of paper and presses the opposite side of paper evenly against the smooth-surface press roll. Linear load increases in the multi-roll calender from the top nip to the bottom nip because of the force of gravity. By using the relieving of rolls, this increase in load can be compensated for. This kind of relieving of the rolls is provided in Metso Paper, Inc.'s OptiLoad™ calender. Multi-roll on-line, off-line calendering is a calendering method, allowing grades from WFS up to uncoated fine paper to be produced.
SUMMARY OF THE INVENTION
The primary object of the present invention is
to improve calendering of a fibrous web in connection with a papermaking process,
to improve control of the moisture gradient of a fibrous web, such as a paper or board web,
to diminish the process problems now associated with the manufacture of high quality paper grades, such as WFC, LWC-roto and SC-A, and
to enable the manufacture of high quality paper grades, such as WFC, LWC-roto and SC-A by on- or off-line calendering.
Thus, the invention is based on the new and inventive idea that an on- or off-line multi-roll calender comprising separate sets of rolls is used for calendering, and that the fibrous web is subjected to intermediate moistening between the sets of rolls. In accordance with an advantageous embodiment of the invention, the multi-roll calender comprises two sets of rolls, in which connection the moisture content of the fibrous web coming from the drying process is raised to a level of 3-10% by means of pre-moistening preceding the first set of rolls, the fibrous web is dried to a level of 1-6% in the first set of rolls, the moisture content of the fibrous web is raised to a level of 6-14% by means of intermediate moistening after the first set of rolls, and the fibrous web is dried in the second set of rolls to a desired final moisture level, which is advantageously in a range of 4.5-7.5%.
With respect to the benefits of the invention, it maybe mentioned that by means of the multi-stage moistening and gradient calendering according to the invention it is possible to better and more accurately affect only the surface layers of the fibrous web and to leave the inner layers of the fibrous web substantially untouched, which allows higher quality paper grades to be produced by on- or off-line calendering.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention will be described in more detail by means of one of its embodiments considered advantageous with reference to the accompanying patent drawing whose figure FIG. 1 schematically shows a multi-roll calender according to an embodiment of the invention regarded as advantageous.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The calender in the embodiment shown in FIG. 1 is a multi-roll calender comprising two sets of rolls A and B in accordance with the invention.
Both sets of rolls A and B of the multi-roll calender are formed of smooth-surface press rolls 3 , such as metal rolls, rolls 4 covered with a resilient coating, such as paper or polymer rolls, and reversing or guide members 5 guiding the run of a web W to be calendered, placed alternately one after the other in the machine direction. The successive nips N of the multi-roll calender are thus always formed between a roll 3 having a rigid shell and a roll 4 having a resilient shell.
Since the multi-roll calender is an on- or off-line calender, the fibrous web W which is calendered is passed from a drying process D without any intermediate winding directly to the calendering process. In the calendering process accomplished by means of the multi-roll calender with two sets of rolls in accordance with the invention, the run of the fibrous web W to be calendered is as follows. The fibrous web W is passed by means of a guide roll 1 through pre-moistening into the topmost nip N of the first set of rolls A in the multi-roll calender, from which nip the fibrous web W is passed around a reversing member 5 , for example a reversing roll, into the next lower nip. After that, the fibrous web W meanders around a reversing member 5 and runs through the nips situated one underneath the other until the fibrous web W has been passed through the bottom nip in the first set of rolls A. After that, the fibrous web W is passed into the topmost nip N of the second set of rolls B, from which the fibrous web W is passed again around a reversing member 5 into the following lower nip. The fibrous web W meanders again around a reversing member 5 and runs through the nips N situated one underneath the other until the fibrous web W has been passed through the bottom nip N in the second set of rolls B. After the bottom nip of the second set of rolls B, the fibrous web W is passed to a process stage after calendering, which is, for example, reeling R.
In accordance with the invention, this run of the fibrous web is affected such that the fibrous web to be calendered is dried in the drying process D so that it is overdried, i.e. to a moisture content that is lower than the equilibrium moisture content dependent on the ambient operating conditions, and the moisture content of the fibrous web W passed from the drying process D to the calendering is raised by means of a pre-moistening unit 2 preceding the first set of rolls A, the fibrous web W is dried in the first set of rolls A, the moisture content of the fibrous web W is raised after the first set of rolls A by means of an intermediate moistening unit 7 , and the fibrous web W is dried to a desired final moisture level in the second set of rolls B.
In that connection, in accordance with the invention it is advantageous that the first drying with the pre-drying unit 2 raises the moisture content of the fibrous web W, which is advantageously overdried according to the invention, to a level of 3-10%, in which connection the first set of rolls A can dry the fibrous web W to a level of 1-6%, and that the second moistening with the intermediate moistening unit 7 raises the moisture content of the fibrous web W to a level of 6-14%, in which connection the second set of rolls B can dry the fibrous web W to a desired final moisture level, which is advantageously in a range of 4.5-7.5%. This kind of multi-stage moistening allows the moistening to be applied substantially only to the surface layers of the fibrous web and enables the moisture gradient of the fibrous web to be controlled with fewer problems and more quickly than before, thereby allowing provision of higher quality paper grades, such as, for example, WFC, LWC-roto and SC-A.
To control the amount of the intermediate moistening of the fibrous web W and/or the penetration of moisture into the fibrous web and to thereby control the moisture gradient, the intermediate moistening unit 7 , which is either a water moistener or an electricity-aided moistener, can be arranged optionally either to moisten the fibrous web W on one side or to moisten the fibrous web on both sides.
In order to minimize the formation of drop marks, the surface energy of the fibrous web W is lowered prior to the intermediate moistening unit 7 by manipulating the surface energy of the fibrous web, whereby the spreading of water on the surface of the fibrous web is accelerated because of the reduced surface energy of the fibrous web.
In one embodiment of the invention regarded as advantageous, a unit 6 for reduction and/or manipulation of the surface energy of the fibrous web W comprises a unit for corona treatment of the fibrous web, which unit is linked with the intermediate moistening unit 7 composed of a water moistener.
Above, the invention has been described only by way of example by means of one of its embodiments regarded as advantageous. This is naturally not intended to limit the invention and, as is clear to a person skilled in the art, a variety of alternative arrangements and modifications are feasible within the inventive idea and within the scope of protection thereof defined in the accompanying claims. | A method for a multi-roll calender and a multi-roll calender for controlling the moisture gradient of a fibrous web and for enabling the manufacture of high quality paper grades, such as WFC, LWC-roto and SC-A by on- and off-line calendering. An on- or off-line multi-roll calender formed of separate sets of rolls is used for calendering, and the fibrous web (W) is subjected to intermediate moistening between the sets of rolls (A, B). | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of U.S. Ser. No. 10/172,181, filed Jun. 14, 2002, now U.S. Pat. No. 6,924,140 the entirety of the above application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates in general to a system for removal and treatment of pollutants in air, and more specifically to a source point closed loop remediation system. With respect to HAP (hazardous air pollutants) and VOC (volatile organic compounds) current methods of VOC removal include distillation; oxidation combustion ionization; biofiltration; and activated carbon adsorption. All of these methods are large whole-building fixed systems having high installation costs, and, with the exception of biofiltration, have high energy consumption and introduce new pollution considerations or generate hazardous waste.
The present invention includes the use of multiple small mini-reactor cartridges to reduce installation and repair or replacement and maintenance costs, permit incremental system expansion, and allow a variety of suitable mini-reactor based remediation technologies to be used together in series or parallel.
Present systems typically treat and exhaust an entire volume of building air without considering the actual pollution source and concentration, resulting in inefficient pollution removal. Furthermore, air heating or cooling of the makeup building air is required which adds to total energy consumed.
Biofiltration utilizes the natural process of biodegradation which in its most basic form occurs in a compost pile. Most typically, water-borne microbes consume the carbon in the organic matter of the pile, and release carbon dioxide and water. By passing an airstream containing an organic vapor (HAP/VOC) containing carbons through such a compost pile, the microbes will preferentially consume the more readily available carbon in the gas stream, thereby cleansing said airstream.
Notwithstanding initial installation costs, biofiltration is a proven and low energy cost, natural method of HAP/VOC remediation that has been in commercial use in large installations both in the United States and abroad for over 15 years. In biofiltration, no secondary carbon source (natural gas) is required to maintain combustion and make up for varying concentrations of VOC laden air as in the most widely employed oxidation process; and no hazardous waste is generated as with carbon absorption; and no by-products other than water and carbon dioxide are released. Distillation is usually not economically practical due to relatively low work place concentrations and value of the recovered chemical.
Because of their large size and method of construction and operation, current bioremediation systems have relatively high installation, secondary energy consumption and operational costs approaching the other methods.
Current biofiltration technology includes the use of naturally biodegradable media such as compost and vegetation as the supporting media and the source of both microbes and nutrients, and has proven to have inconsistent and relatively uncontrollable and repeatable long term field performance.
The present invention includes complete control of the microbial environment with the use of stable artificial media in conjunction with controlled water and nutrient addition for consistent operation. The present invention further includes the inoculation of said environment with specifically isolated and custom grown inoculate tailored to the VOC/HAP to be remediated to maintain high and consistent removal efficiency.
With respect to bioremediation, the following prior art is representative of the state of the art with respect to treating HAP's and VOC's.
U.S. Pat. No. 3,880,061 broadly relates to a contamination free work station by providing an air stream across the work station to remove any contaminants through filter means as shown in the figure.
U.S. Pat. No. 4,734,111 is directed to a process and apparatus for cleaning spent air or air polluted with styrene and filtering out the styrene in an apparatus and process which uses a specific biofilter utilizing a spruce bark and microorganisms thereon to degrade the styrene.
U.S. Pat. No. 5,409,834 relates to an invention and apparatus for removing pollutants from a source of polluted air such as a work paint station (see FIG. 1 ). Polluted air from the work station is introduced from a supply conduit into a wet plenum chamber which has a spray nozzle which sprays microbial laden liquid into the incoming polluted air.
U.S. Pat. No. 5,691,192 is related to a biological filter for removing volatile compounds from gas emissions such as styrene. The styrene is broken down with a fungus which is contained on a carrier or inert material such as perlite. Activated carbon may also be added to the mixture.
U.S. Pat. No. 5,869,323 is directed to a biofilter which uses a bioreactor treatment tank comprising at least one bioreactor bed and in which the air filtration is conducted such that the air flow through the tank is from the top downward, with the biofiltration being conducted under pressures of less than an ambient.
These inventions teach the conventional type of prior art systems which are used for aerobic bioremediation in commercial plants. All the above, and this patent pertain to aerobic biofiltration wherein the biodegradation occurs on the surface of a water film by a consortium of aerobic microbes.
U.S. Pat. No. 6,010,900 is directed to enhancing biodegradation using a bioreactor. The bioreactor contains an aqueous phase in which a microorganism capable of degrading a sparingly soluble volatile organic compound is contained. The patent further teaches contacting the solution with a gas/vapor stream comprising the sparingly soluble volatile organic compound such that the soluble volatile organic is solubilized in the aqueous phase to form an enriched solution, and then incubating the enriched solution so that the microorganism degrades the solubilized sparingly soluble volatile organic compound thereby enhancing biodegradation. (This is an anaerobic process and is not related to the present invention).
It can therefore be seen from the above cited commercial practices and prior art that there is a need for a bioremediation system which reduces natural gas and energy consumption and high fixed and operation costs of remediation; adds efficiency, control and repeatability to the bioremenation process; and does not produce hazardous waste by-products as is typical of the current prior art systems.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a shippable by common carrier, expandable, movable, modular components, cartridge based closed loop system for remediation of HAP/VOC's within a manufacturing plant at the source.
It is another object of the present invention to provide an efficient biological system which reduces HAP/VOC's to water and carbon dioxide.
It is another object of the present invention to remediate process HAP/VOC's concentration over 90%.
It is yet another object of the present invention to provide a system for collection and neutralizing HAP's (hazardous air pollutants) and VOC's (volatile organic compounds) at the source point.
Another object is to contain the biological eco-system in multiple small biofilter cartridges.
Another object is to use an artificial support media for the water film that supplies no naturally biodegradable matter and therefore will not degrade or compact.
Another object is the use of specifically isolated inoculate containing highly efficient microbe strain(s) tailored to maximally consume the VOC/HAP to be remediated.
Another object is to provide appropriate nutrient addition to enhance microbial growth.
Another object is to provide and maintain a suitable water film to the media to sustain the inoculate eco-system.
Another object is to replenish the media water film by periodically and discontinuously bio-recirculating inoculate and nutrient laden water through the media at a low flow rate.
Another object is to flush excess biomass and cleanse and reactivate the media by periodically and discontinuously filtering and recirculating inoculate and nutrient laden water through the media at a high flow rate.
Another object is to collect, filter, store, replenish and recirculate the nutrient and inoculate laden water within a remediation system at the work station.
Another object is to allow reversal of the airstream flow through the reactor cartridges.
Another object is to contain air and water functions in remediation modules.
Another object is to allow top-to-bottom physical reversal of the reactor cartridge in the system.
Another object is to allow system reversal of the airstream direction through the cartridge.
Another object is to allow for series and/or parallel airflow through multiple cartridges.
Another object is to allow various cartridges to contain differing media, inoculate, and/or remediation methods.
Another object is to allow individual replacement of a single cartridge in a remediation system.
Another object is to use the mini-reactor cartridge embodiment for other granular remediation techniques.
Another object is to include exhaust stream dehumidification.
Another object is to combine all remediation system functions in a single cartridge assembly.
The present invention is directed to providing a closed loop modular remediation system which includes air collection with air and water treatment and control and contains a predetermined size bay of multiple interchangeable mini-biofilter cartridges that function to consume the pollutant and recirculate remediated air back to the source point of the pollutant.
In one embodiment, a closed loop air stream is established at a work station area involving fiberglass laminating which generates and emits the styrene HAP, which is captured by the air stream flow which transports the emitted styrene directly into an adjacent biofilter module system as described above which contains selected microorganisms in multiple mini-biofilter cartridges which consume the styrene, and recirculates the remediated air back to the source point of the pollutant at the work station. The air flow is continuous and the system serves to maintain the styrene level at the work station at safe levels.
In a further embodiment, multiple sources of contaminants in a given room or area can be captured and treated at a single remediation station or multiple remediation stations can be used within a given room or area to treat higher concentrations.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of these and objects of the invention, reference will be made to the following detailed description of the invention which is to be read in connection with the accompanying drawing, wherein:
FIG. 1 is a front view with partial break away of a self-contained air collection, treatment and control module containing multiple biofilter cartridges used in the system of the present invention.
FIG. 2 is a schematic side view of a self-contained single cartridge remediating system for treating a small source.
FIGS. 3A and 3B are top and side views respectively of multiple and removable cartridges of varying heights.
FIG. 4 is a perspective view of a work table illustrating air flow at the perimeter of the table.
FIG. 5 is a perspective view which illustrates a work table having a partial or full hood with air flow at the front or back of the table.
FIG. 6 is a side view of the table illustrated in FIG. 5 .
FIG. 7 is a side view of a receptacle being remediated by a cartridge of the present invention.
FIG. 8 is a side view of a cabinet being remediated by a cartridge of the present invention.
FIG. 9 is a side view of an enclosure which contains VOC generating parts which are being remediated by a cartridge containing module of the present invention.
FIGS. 10A and 10B are top and side views respectively of walls or structural barriers made up of modules of the present invention.
FIG. 11 is a side view illustrating the use of a coax cable or hose used in conjunction with a cartridge of the present invention.
FIG. 12 is a side view illustrating a second embodiment using a coax cable or hose.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is more fully understood with reference to the drawings where FIG. 1 illustrates a closed loop system 10 for treating a work station area or module 12 which collects and remediates a source of pollutant such as styrene generated from laminating with fiberglass. The module contains end walls, 11 and 13 and connecting side walls (not shown), upper manifold 15 and lower manifold 17 and a centrally located control console 19 , also described as a control housing assembly, (not shown) which functions to control the timing and sequencing of the various pumps and blower which control the water and air flow of the system. This hardware and electronics control the operation of the system and are conventional in the art. The upper and lower manifolds provide a support means to hold a plurality of cartridges 14 in place and allow them to be easily removed for replacement or repair. The upper manifold is mounted to and supported by end walls 11 and 13 and control console 19 . As illustrated in FIG. 1 , compressible seal members 21 function to hold the cartridges in place, with the seal means functioning to seal the top and bottom of the cartridge which fits between the upper and lower manifold structure at 23 and 25 . It should be understood that any conventional support and sealing means available in the art may be used to seal and hold the interchangeable cartridges in place. For example, springs, hinges, a snap-fit geometry or any combination thereof may be used to hold the cartridges in place. Any conventional sealing means, such as O rings, cushioning foam, interlocking contact surfaces and the like, may also be used. The closed loop ducting system contains an array of interchangeable mini-biofilter cartridges 14 which contain a carrier medium 16 supporting a water film suitable for microorganisms or a mix of microorganisms on the carrier surface which have been selected to degrade the styrene or other VOC's of interest. The cartridge(s) is preferentially filled with a suitable inert carrier material such as perlite or an inert synthetic material such as plastic or a ceramic. A moisturized and nutrientized airflow through the biofilter promotes the growth of indigenous or synthesized microorganisms on the surface of the carrier material which through the action of the microorganisms acts to biodegrade the HAP and/or VOC's of interest. Suitable microorganisms which can be used to promote this degradation include bacteria, such as Pseudomonas and Mycobacterium . Other suitable natural occurring materials which contain indigenous microorganisms such as compost, peat, soil, wood chips, plant residues and tree bark may also be used or included. The reversible biofilters contain an outer housing or shell 15 suitability made of plastic and contain a perforated top and bottom, 18 and 20 respectively, which may include a screen to allow for air flow and water flow through the biofilter. Interconnecting ducting 22 passes a flow of contaminated air from the room through the bottom of the biofilters with remediated air passing back into the room through ducting 24 . Pump 25 functions to recirculate and replenish the inoculated nutrient laden water film on the carrier material in the biofilters which enhances the action of the microorganisms in degrading the styrene. Pump 25 preferentially draws water from lower collection trough 28 which has received excess water from the biofilters 14 . Pump 25 then recirculates the water to the top of the biofilter through water manifold 30 and nozzles 32 . In FIG. 1 , which is not drawn to scale, area or room 12 is depicted as grossly smaller in size than the closed loop system 10 . For example the cartridges 14 are typically about 30 inches in height and 15 inches×15 inches in cross-section. The discrepancy in relative sizes is to better show the detail of the closed loop system.
In a further embodiment of the present invention as shown in FIG. 2 , a single independent mini-reactor cartridge 40 is illustrated. The cartridge contains an outer housing 42 and is open at both ends 44 and 46 with supporting grilles (not shown) to contain the carrier media. The cartridge contains an upper clip-on blower housing 48 which contains an exhaust fan 50 and an exhaust port 52 . The blower housing is attached to the cartridge by latch (spring) 54 and ring seal 56 . A water reservoir 58 is attached to the bottom of cartridge 40 by latch (spring) 60 and ring seal 62 . The reservoir contains water 64 and optionally a wicking humidifier filter 66 . In operation, air to be treated is drawn in through inlet 68 and humidified in reservoir 58 . A suitable source of microorganisms contained on a carrier media 70 in the housing degrade the VOC of interest as previously described herein. The arrows in the drawing depict the flow path with the remediated air passing through media 70 and exiting through exhaust port 52 .
A water recirculation pump 72 and associated water transfer manifold 74 may optionally be added to recirculate the microbe and nutrient laden water from the reservoir 58 to the top of the reactor cartridge 40 . Optionally dehumidification may be required to lower exit air moisture buildup.
A single cartridge system of the type shown in FIG. 2 was used for evaluation and testing. The mini-reactor cartridge measured 15″ square and 30″ tall with 8½″ square inlet and outlet grilled openings at opposite ends. The nominal inside volume of the cartridge was approximately 3.6 cubic feet. The cartridge with a bottom grille installed, weighs approximately 16 pounds. The reactor was then loaded with 30 pounds of coarse perlite media, for a total cartridge plus media dry weight of about 46 pounds.
The blower housing as shown in FIG. 2 was attached to the top of the cartridge along with a water replenishment port and water recirculating hose, and a small water recirculating submergible pump was installed in the water reservoir. The system was assembled by placing the cartridge on top of the water reservoir and then adding the blower housing on top of the cartridge to make up a basic system as described in FIG. 2 .
The system parameters were then adjusted to achieve a 5 CFM airflow giving a nominal 45 second empty bed dwell time. The water flow was set at a nominal flow of 8 oz./hr. to supply sufficient bed moisture in the range of 4 oz./hr. to account for evaporation due to a 40% RH ambient air, plus an additional 100% excess to maintain some trickling flow through the bed.
The system was then loaded with 2 gallons of inoculate and nutrient mixed in water. The inoculate used was Pseudomonas Putida which is capable of growth on toluene and is grown on a dilute minimal medium using styrene as a sole carbon and energy source. The inoculate is used in a concentration of about 10 8 CFU/ml and introduced to the cartridge by trickling over the perlite. The nutrient used was a common slow release granular garden fertilizer sold by Agway under the trade name Osomocote.
A standard styrene source which releases 100 PPM styrene at 5 CFM was connected to the inlet port, and the system blower and pump were started up. Measurements were taken with a photo-ionization detector (PID) at the inlet and outlet of the system. Within 1 hour of startup, the average concentration in the outlet stream was 18 PPM, and after 24 hours had dropped under 9 PPM for a 90%+reduction in styrene concentration.
Earlier lab tests made on a similar size configuration set to the same airflow dwell time parameters, but using a horizontal lab reactor loaded with oak chips and natural compost, and with no water trickling or inoculate addition achieved a 75% removal rate after 7 days of operation, and maintained in that range for over 2 months until the test was terminated due to the bed drying out.
Another lab test using the same lab reactor and test setup and loaded with oak chips, and the inoculate, had faster startup results on the order of 4 days and better long term remediation on the order of 85%, until the natural bed settled and bed channeling occurred some time after 3 months. This was indicated by a decrease in remediation down to 80%. Disassembly of the reactor confirmed the channeling along with some bed dryup and compaction.
A further lab test using the same lab and test setup was loaded with plastic pellets and a water pump added to recirculate the water from the bottom of the reactor to the top. The Pseudomonas Putida inoculate described above was used with the addition of a slow release nutrient. Initial startup time was on the order of 2 days to reach a 80% removal rate, with 90% being reached after 4 days. The reactor efficiency continued to increase. Pump failure eventually occurred after another 10 days at which point the removal rate was up to 94%.
It should be understood that various component configurations and modifications my be used in the application of the system of the present invention. For example, modules in single and multiple widths and depths corresponding to the number of individual cartridges placed side-by-side and front-to-back may be employed. The modules as described herein are also called CAM's or “central air flow modules”.
Stacked modules in various heights corresponding with the cartridge heights can also be employed along with modules in various widths and depths with associated top and bottom manifold assemblies, control housings, and end walls in various heights.
Lower manifold assemblies with an integral reservoir, water and air passages and seals for removable cartridges can be used to facilitate easy cartridge insertion and removal. These assemblies can be used in conjunction with an upper manifold assembly having an integral water and air passages and seals for the removable cartridges. A control housing assembly connecting lower reservoir and upper manifold assemblies may also be employed, along with end walls connecting the lower reservoir and upper manifold assembly.
Multiple stacked and removable cartridges may be placed and contained within a module in various configurations such as 2-12″ high cartridges and/or 1-24″ high cartridge in the same height module. When stacked, removable inter-cartridge locating/sealing spacers may be employed along with reversible cartridges and end-to-end symmetry for inverting in module. FIGS. 3A and 3B illustrate this concept in 2-12″ high cartridges 14 A are used in a stacked configuration with 24″ high cartridges 14 in the same height module 12 .
From a process or system control standpoint, timed cartridge flushing with liquid from a reservoir may be used. Time recirculation of liquid within a reservoir may also be employed along with timed nutrient and buffer delivery into the reservoir liquid. Automatic filling of reservoir from a water source can be accomplished with a float valve or by other suitable means. Wicking humidification filters may optionally be used in the lower manifold assembly reservoir.
In use, multiple cartridge modules may be employed as production floor furniture, such as tables, walls, dividers, hooded tables, etc. Single and dual cartridge modules may also be used with production floor equipment such as scrap pails, drums, cabinets, drum enclosures, etc.
The collection or source capture equipment described above is employed to collect and/or contain the VOC released from a part operation, or cure cycle into a small or enclosed volume to limit the VOC from spreading throughout an entire area. VOC laden air from this volume is then passed through the CAM for remediation, and recirculated back to the source volume. The system any also be used to modify the ambient airflow and redirect it back towards a collection point on the equipment for re-introduction into the CAM for remediation, forming a closed loop between the VOC source and the VOC remediation equipment.
The following embodiments, along with their drawings which depict the respective embodiment, illustrate various applications of the system of the present invention.
Work Table Configurations. CAM 8 with top work surface—VOC air is drawn in around partial or perimeter of the table, and remediated in CAM underneath, and discharged at ends or bottom of the table 80 as illustrated by the arrows in FIG. 4 . Heavier-than-air VOC is collected as it spreads out and drops down from table top surface past the perimeter intake. FIGS. 5 and 6 illustrate a work table 90 with partial or full hood, 94 and 92 respectively. The partial hood has 3 shorter side walls and the full hood has three taller sidewalls plus a top over the table. VOC air is drawn in at the back of the table, remediated in CAM, and exhausted and recirculated at the front of the table forming a closed loop.
Cabinet Configurations. FIG. 7 illustrates VOC air drawn from the bottom of the receptacle, remediated in adjacent CAM 1 or 2 , and recirculated under and across the top lid next to the trash opening on top of the container 100 to make an air curtain across the trash opening. FIG. 8 illustrates heavier-than-air VOC drawn out from the bottom of a cabinet 120 , remediated in an adjacent CAM, and recirculated back into the top of the cabinet. The inlet and outlet can be reversed for VOC's lighter-than air.
Enclosure. FIG. 9 illustrates a temporary or permanent large, lightweight enclosure 100 for containing VOC generated from parts within the enclosure. VOC drawn out from bottom of enclosure is remediated in adjacent multiple CAMs, and recirculated back into top of the enclosure (see arrows). The enclosure can be clear flexible plastic material with a strip curtain, drape, etc. for entry/exit and placing/removing parts 27 and 27 A.
Wall Configurations. FIGS. 10A and 10B illustrate free-standing architectural air barriers placed in line(s) to contain VOC air within a defined floor area. Walls can be made up of multiple inline and/or stacked CAM units, and act as “windbreaks” for ambient airflow such as from heaters, etc. Intakes and exhausts can be on the same or opposite sides of the walls. FIG. 10A illustrates a top view and FIG. 10B a side view of single height and double height CAMs 12 placed inline end-to-end to form a wall plus a storage/work surface. Walls and demi-walls would typically employ two cartridges front to back, and multiples of four cartridges in line. Other configurations include one cartridge deep multiple CAM's, typically 4-6 cartridges, long lining building walls, and may be stacked two or more cartridges high. Intake is at the bottom and exhaust (not shown) is at the top of each CAM on the same face.
Coax Pickup/Discharge Hose. FIG. 11 illustrates a coaxial hose 130 which comprises flexible tubes 132 and 134 placed adjacent to a source point, with the outer tube 132 collecting the VOC from the source for delivery to the inlet 138 of the CAM with the inner tube 134 delivering the remediated exhaust from outlet 136 from a CAM to a source point. Pickup/discharge functions may be reversed as required by the source point.
FIG. 12 illustrates the coaxial concept 140 in which the inlet VOC source 142 is delivered downward through a central tube 146 and remediated upwardly through the cartridge media 16 through outlet tube 148 .
It should be understood that the present invention is not to be limited by the preferred embodiments of the mini-cartridge, which may be increased in size up to a maximum weight and volume that can be put on a pallet, moved by a factory pallet jack or fork lift, and shipped by common carrier. This is as opposed to current large permanent single reactor designs requiring a pit or rigging to install.
While the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawings, it will be understood by one skilled in the art that various changes in detail and configuration may be effected therein without departing from the spirit and scope of the invention as defined by the claims. | A system for capturing and neutralizing HAP's (hazardous air pollutants) and VOC's (volatile organic compounds) at the source point by providing a closed loop remediation system which utilizes an air collection, treatment and control module containing a predetermined size bay of multiple interchangeable mini-biofilter cartridges that function to consume the pollutant and recirculate remediated air back to the source point of the pollutant. The system includes establishing a closed loop air system at a work station which generates and emits VOC's, capturing the VOC's in the air stream flow and transporting them directly into an adjacent biofilter module which contains selected microorganisms in mini-cartridges which biodegrade said VOC's and recirculates remediated air back to the source point of the pollutant. The cartridges may be contained in modules in single and/or multiple widths and heights and in conjunction with various work stations, cabinets, receptacles, and tables. | 1 |
FIELD OF THE INVENTION
The present invention relates to an electronic musical instrument by using a plurality of slide-type faders preassigned with a series of tones based on a specified musical scale and to a method of playing the electronic musical instrument.
BACKGROUND OF THE INVENTION
A DJ play mixes different musics and reproduces the musics called non-stop remixes for a long period of time without interruption. The DJ play drastically develops by adopting the “scratch” technique which appeared in 1990s and uses the slide rheostat or resistor called the fader to create a rhythm by chopping up a music. The advent of this technique enables DJ devices such as a record player, CD, DJ mixer, etc. to be used like musical instruments. As a result, a new music genre was established and has become popular to the young generation.
When DJ devices are used like musical instruments in a way completely different from that for conventional stringed or keyboard instruments, phonographic records or CDs are only presently available sound sources. Accordingly, the power of expression is greatly restricted.
In order to enhance the power of expression, it may be possible to use a computer or a keyboard instrument. However, it is difficult to demand many practices and high proficiency from users in order to master the computer or the keyboard instrument anew in the field of DJ plays where many users create musics with acute sensitivity and based on their intuition. This makes it difficult for users to easily create music suitable for the DJ play.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the foregoing. It is therefore a first object of the present invention to provide an electronic musical instrument which can expand the power of expression by diversifying sound sources in order to enjoy a DJ play using DJ devices like musical instruments and can easily create and perform music appropriate for the DJ play without needing many practices and high proficiency. It is a second object of the present invention to provide a method of performing such electronic musical instrument.
According to the present invention, the first object is achieved by an electronic musical instrument comprising:
a plurality of slide-type faders for changing sound volume of tones included in a musical scale, the respective slide-type faders being provided with the respective tones;
a scale setup means for setting said musical interval to define the respective tones of the respective slide-type faders; and
a sound synthesis means for synthesizing sounds having the respective tones with predefined sound quality, the changing pattern of sound volume of the respective sounds being defined based on operation of the respective slide-type faders.
A slide rheostat or resistor is appropriate for the slide-type fader to be used here. It is preferable to use slide-type faders not fewer than the number of tones included in an octave. For example, a chromatic scale begins a new cycle of an octave at the 13th semitone, forming a whole-tone scale (diatonic scale) in which seven steps correspond to seven notes for moving up and down 12 semitones. In this case, it is preferable to use at least eight slide-type faders.
The scale setup means is preassigned with a plurality of scales such as the major scale (MAJOR), minor scale (MINOR), the other seven-note scales (natural minor scale, harmonic minor scale, melodic minor scale), and special scales used for folk or ethnic music. Selecting any scale can assign each slide-type fader with each pitch of the selected scale.
In this case, it is preferable to provide an assign key for assigning each slide-type fader with a tone included in the selected scale. For example, the assign key is used to set C-Major, D-Major, and so on, and C-Minor, D-Minor, and so on.
The slide-type fader enables performance using tones over an octave if there is provided an octave changeover switch that moves an interval up or down in units of octaves. The octave changeover switch may be provided to the respective slide-type faders as the number of tones or notes included in one octave. It may be preferable to provide a master octave changeover switch, i.e., a switch that changes all scales of all the slide-type faders in units of octaves at time.
The sound synthesis means synthesizes sounds through an electronic circuit and may comprise: an AD converter which converts an output in proportion to the slide-type fader operation amount (stroke amount) into a digital signal; a CPU which issues a command for making a sound having predetermined characteristics defined by the digital signal; a DSP which outputs specified timbre data based on the command; and a DA converter which converts the timbre data output from the DSP into an analog signal. The analog signal output from the DA converter is amplified in an amplifier to drive a speaker in a manner similar to that for the ordinary audio equipment.
The CPU issues a command to the DSP wherein the command not only specifies selection of the sound generation, envelope, sustain sound, and decay sound, but also indicates a sound volume. It may be preferable to add a key fader curve changeover switch to specify change characteristics of an output sound volume corresponding to a stroke amount of the slide-type fader. For example, this switch may be configured to select to gradually increase or decrease sound output with the lapse of time or to make the sound output constant, enabling more diversified performance.
The sound synthesis means can use various sound sources. An external storage medium can be used to store sound source data in advance and this data can be read for use. If the sound from a microphone, phonographic record, or CD is converted into a digital signal, the DSP can process and store this data in memory. The data can be read out for use.
According to the present invention, the second object is achieved by a method of performing an electronic musical instrument comprising the steps of: assigning tones included in a musical scale with different tones predefined by a sound synthesis means to a plurality of slide-type faders whose slide operation changes volume outputs; and varying operation strokes and operation speeds of the slide-type faders.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of an electronic musical instrument as an embodiment of the present invention;
FIG. 2 shows a configuration of a sound synthesis means used in the embodiment;
FIG. 3 shows output characteristics of a slide-type fader; and
FIGS. 4A-4D show examplanatory characteristics of sound source output corresponding to a fader stroke amount.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2 , the reference numeral 1 represents a series of the slide-type faders comprising a group of ten keys. The respective slide-type faders 1 uses, for example, a slide rheostat or resistor and changes its output or an output voltage in accordance with the slide amount (stroke amount) of a key. As shown in FIG. 3 , it is desirable that the output (voltage) changes in direct proportion to the stroke changes. The group of ten keys 1 is arranged so that a performer can simultaneously touch the keys 1 with fingertips of his or her both hands. Each key moves back and forth from the performer's viewpoint.
The reference numeral 2 represents an octave changeover switch that is provided for each slide-type fader 1 . The toggle switch 2 is rockable back and forth (to the lower and upper direction in FIG. 1 ) and can automatically return to a neutral position. The toggle switch 2 increases or decreases a tone or pitch for the corresponding slide-type fader or key 1 on an octave basis. Pressing up the toggle switch 2 once and then returning it to the neutral position raises the tone one octave higher. Pressing up the toggle switch 2 for a specified number of times raises the tone higher for the corresponding number of octaves. Likewise, pressing down the toggle switch 2 for a specified number of times drops the tone lower for the corresponding number of octaves.
The reference numeral 3 represents a master octave changeover switch which simultaneously increases or decreases tones of all the slide-type faders 1 on an octave basis. There is provided only one toggle switch 3 having the same structure as that of the octave changeover switch 2 .
The reference numeral 4 represents a key fader curve changeover switch. The selection switch 4 can be set to three positions, i.e., neutral (B), forward (A), and backward (C), for specifying change characteristics of an output sound volume in accordance with the stroke amount of the slide-type fader 1 . That is to say, the selection switch 4 changes fader curves to three types.
The reference numeral 5 represents a scale changeover switch. The switch 5 changes the musical scale of sound to be generated to the major scale (Major), minor scale (Minor), seven-tone scale (7th), folkloric scales (world 1 , world 2 ), etc.
The reference numeral 6 represents eight assign keys C (do), D (re), . . . , and C used for setting a tone or note of the scale selected by the scale changeover switch 5 . For example, it is assumed that the switch 5 is used to select the major scale (Major) and the assign key marked with “C” is pushed to be selected. In this case, tones or pitches included in a scale of C-Major is assigned to the ten slide-type faders 1 from the left to the right. The scale changeover switch 5 and the assign keys 6 constitute a scale setup means.
TABLE 1
SCALE set to MAJOR
Scale
Selected by
Tone Specified to the Fader Nos.
Assign Key
1
2
3
4
5
6
7
8
9
10
C
C
D
E
E#
G
A
B
B#
D
E
D
D
E
F
F#
A
B
C
C#
E
F
E
E
F
G
G#
B
C
D
D#
F
G
F
F
G
A
A#
C
D
E
E#
G
A
G
G
A
B
B#
D
E
F
F#
A
B
A
A
B
C
C#
E
F
G
G#
B
C
B
B
C
D
D#
F
G
A
A#
C
0
C
C
D
E
E#
G
A
B
B#
D
E
TABLE 2
SCALE set to MINOR
Scale
Selected by
Tone Specified to the Fader Nos.
Assign Key
1
2
3
4
5
6
7
8
9
10
C
C
D
D#
F
G
G#
B
C
D
D#
D
D
E
E#
G
A
A#
C
D
E
E#
E
E
F
F#
A
B
B#
D
E
F
F#
F
F
G
G#
B
C
C#
E
F
G
G#
G
G
A
A#
C
D
D#
F
G
A
A#
A
A
B
B#
D
E
E#
G
A
B
B#
B
B
C
C#
E
F
F#
A
B
C
C#
C
C
D
D#
F
G
G#
B
C
D
D#
Table 1 lists tones allotted to the slide-type faders 1 corresponding to the selected assign key 6 when the toggle switch (scale changeover switch) 5 is used to select “Major”. Likewise, Table 2 lists tones allotted to the slide-type faders 1 corresponding to the selected assign keys 6 when the toggle switch (scale changeover switch) 5 is used to select “Minor”.
The reference numeral 7 represents a control fader to select parameters for function keys 9 through 12 to be described. The reference numeral 8 denotes a display panel. The function key 9 is used to set a timbre. Pressing the function key 9 defines a timbre to be assigned to the slide-type faders 1 . When the function key 9 is pressed, for example, numbers on the display panel 8 start blinking. Moving up or down a control fader 7 selects one of 99 timbres 01 through 99 . Pressing an enter key 13 determines the timbre. Pressing the enter key 13 causes the numbers on the display panel 8 to light steadily, indicating that the specified timbre is assigned.
The reference numeral 10 represents a function key for tuning (TUNE). Pressing the key 10 once can change the tuning by a half tone (100 cents) sharp or flat. That is to say, pressing the key 10 once enables the tuning mode. Moving the control fader 7 up or down can provide tuning by a half tone (100 cents) sharp or flat.
The reference numeral 11 represents a function key for arpeggio setting. Pressing the key 11 enables automatic performance based on a predetermined sequence. The reference numeral 12 represents a function key used for setting various parameters when an external sound source is used with MIDI (Musical Instrument Digital Interface) system. The reference numeral 13 represents the enter key used to determine parameters for the function keys 9 through 13 .
The reference numeral 14 represents a bend wheel. Rotating the wheel 14 back and forth can change a tone or pitch of the generated sound by a whole tone up or down. The reference numeral 15 represents a master fader and controls a master volume (not shown) for the sound. Moving the fader 15 to the right end provides the maximum sound volume.
The reference numeral 16 represents a master fader curve changeover switch. The switch 16 can select one of fader curves A, B, and C for the master fader 15 . The reference numeral 17 represents a master equalizer, i.e., a 2-band master equalizer. The reference numeral 18 represents a level volume for headphone monitoring.
In FIG. 2 , the reference numeral 20 represents a sound synthesis means. The sound synthesis means 20 comprises an AD converter (A/D Matrix) 21 ; a CPU 22 ; a DSP (Digital Signal Processor) 23 ; memory 24 ( 24 A and 24 B) comprising ROM and RAM; and a CODEC (Coder-Decoder) 25 . The AD converter 21 converts an output (voltage) in proportion to the stroke amount of the slide-type fader 1 into a digital signal. The CPU 22 receives the digital signal from the AD converter 21 and issues a command for making a sound having predetermined characteristics based on the digital signal.
Specifically, the CPU 22 issues a specified command based on signals determined by the slide-type fader 1 , the octave changeover switches 2 and 3 , the scale selection switch 5 , the assign key 6 , the function keys 9 through 13 , the fader curve changeover switches 4 and 16 , and the like. The CPU 22 is supplied with signals from the switches 2 , 3 , 4 , 5 , and 16 , and keys 6 , 9 through 13 via a switch (SW/Matrix) 26 .
The DSP 23 is a so-called sound synthesis LSI and artificially produces sound through digital signal processing. The memory 24 (sound ROM 24 A and RAM 24 B) stores digitized sound signals or rules for generating sound and timbre data. The DSP 23 synthesizes or combines sounds based on the contents of the memory 24 .
The CPU 22 can be supplied with sound source data (timbre data) stored in a storage medium 27 such as an external memory card via an interface (CARD I/F) 28 . More diversified performance becomes available through the use of sounds in the external storage medium 27 . A user can unlimitedly increase timbre variations using his or her custom-made sampling sounds or computer-based data files.
The CODEC 25 is an integration of a digital coder and a digital decoder. The CODEC 25 is used to make it possible to use an external sound source 29 , other than the timbre data stored in the ROM 24 A; and data read from the external storage medium 27 , digitally processed and stored in the RAM 24 B.
More specifically, the CODEC 25 is supplied with an output (analog signal) from the external sound source 29 such as a microphone, a record turntable, an MD (Mini-Disc), or a CD (compact disk) via an input toggle switch (Input Select) 30 and an input buffer (Input BUF) 31 . The CODEC 25 converts the input signal (analog signal) into a digital signal and sends it to the DSP 23 . The DSP 23 digitally processes the signal and stores it in the RAM 24 B so as to be used as timbre data.
The DSP 23 reads timbre data corresponding to a specified sound source from the memory 24 based on a command issued from the CPU 22 and uses data read from the ROM 24 A to synthesize sounds.
When the sounds are synthesized into a digital signal, the CODEC 25 converts this signal into an analog signal. The signal is then split into right and left signals which are amplified in amplifiers 32 and are transmitted to right and left speakers 33 , respectively.
The following describes a method of controlling sound sources according to the apparatus. First, as mentioned above, the settings are configured for the function keys 9 through 13 , the scale changeover switch 5 , and the assign key 6 . The AD converter 21 is used to digitize (code) a full stroke (entire slide range) for any one of the ten slide-type faders 1 . Based on this data, the sound synthesis means 20 controls sound generation and envelopes.
When the 45 -mm stroke length is coded into 8-bit 256 gradations (A 0 to A 255 ), the sound source is controlled as shown in FIGS. 4A through 4D . It is assumed that the key of the slide-type fader 1 is moved from the bottom to the top in FIG. 4A . When the key reaches position A 10 , the sound generation starts. Thereafter, the volume of sustain sound proportionally increases until the key reaches position A 255 where the volume becomes maximum. Moving down the fader 1 decreases the volume. The sustain sound stops at position A 9 .
Likewise in FIG. 4B , the sound generation starts at position A 10 with the maximum volume. The sustain sound is continuously output up to position A 255 with this volume unchanged. Moving down the fader stops the sustain sound at position A 9 .
Likewise in FIG. 4C , the sound generation starts at position A 10 . The sustain sound volume increases in proportion to the stroke amount of the fader 1 between positions A 10 through A 64 . Between positions A 64 and A 128 , the sustain sound is output with a constant volume. At position A 129 , the sustain sound is released, and the attenuation control mechanism (sustain) starts operating. The sound attenuates in accordance with characteristics predetermined by the sound synthesis means 20 .
Likewise in FIG. 4D , the sound generation starts at position A 10 . Thereafter, the sustain sound amount gradually increases up to position A 254 based on exponential curve characteristics. The sustain sound volume becomes maximum at position A 255 .
In this manner, a performer presets volume change characteristics corresponding to the stroke amount of the fader 1 in accordance with his or her preferences. Then, the performer positions his or her fingers of both hands to the ten faders 1 . Moving up one or more of any faders can output the sound with an intended tone or pitch. Diversified performance is available by changing positions and speeds for moving the fader 1 .
The tone or pitch of the respective faders 1 can be changed in units of octaves using the octave changeover switches 2 and 3 . Therefore, it is possible to perform wide-range music.
The faders 1 can be used to control the sound generation and envelopes (patterns of volume change in time course) in two ways. The first method uses the fader curve toggle switch 4 for choosing from three general fader (envelope) curves (A, B, and C) to control envelopes. This method is mainly used for sampled timbres.
The second method uses the memory 24 (ROM 24 A and RAM 24 B) to store timbre data in advance. According to this method, the memory 24 stores programmed data in accordance with various envelope curves as shown in FIGS. 4A through 4D . It is possible to optimize the preset timbre data. That is to say, this method is appropriate for preset timbres.
As mentioned above, according to the present invention, tones or notes are assigned to a plurality of slide-type faders and the slide-type fader is operated to change an output sound volume of the sound synthesized by the sound synthesis means. Accordingly, it is possible to diversify sounds of the sound source and enhance the power of musical expression.
Since the slide-type faders can be manipulated by fingertips or the like for musical performance, everyone can easily enjoy the DJ play without many practices or high proficiency. | The electronic musical instrument comprises a plurality of slide-type faders ( 1 ), an interval setup device ( 5, 6 ), and a sound synthesis device ( 20 ). The slide-type faders are provided correspondingly to a plurality of tones included an interval and allow slide operations to change output sound volume. The interval setup device means sets the interval to define a tone for each slide-type fader. The sound synthesis device synthesizes sounds according to a volume changing pattern with predefined sound quality and based on operations of the slide-type fader. The slide-type faders can be manipulated by fingertips or the like for musical performance to enjoy the DJ play without many practices or high proficiency. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit of French patent application number 10/54304, filed on Jun. 2, 2010, entitled “METHOD FOR DESIGNING MASKS USED TO FORM ELECTRONIC COMPONENTS,” which is hereby incorporated by reference to the maximum extent allowable by law.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the designing of masks to be used to manufacture integrated circuits. More specifically, the present invention relates to a method for improving the design of such masks.
2. Discussion of the Related Art
To manufacture integrated electronic circuits, a set of several masks comprising openings defining work areas on the circuit is used. For example, different masks may be successively used to define locations of dopant implantation, of etching, etc.
The manufacturing of the different masks necessary to obtain an integrated circuit implies a relatively high cost. Further, modern integrated circuits may require, for their production, several tens of masks. It is thus essential to properly test the mask generation files before launching the production of the masks, or even the production of the integrated circuits. Especially, the compatibility of the masks, for example, for their superposition, should be optimal. Having to redesign a set of masks, at the last minute before the launching of the production of integrated circuits or after the launching of the production, may imply very large manufacturing delays and costs.
For each electronic component technology, integrated circuit designers should comply with a number of design rules put together in a “Design Rules Manual”, or DRM. Such a manual gathers, among other things, sets of rules relative to the superposition or to the juxtaposition of the layers necessary for the forming of the electronic components.
FIG. 1 illustrates a few examples of rules that may be imposed on designers for the forming of integrated circuits. This drawing shows, in hatchings, different areas at the surface of a substrate intended to receive electronic components. Among the rules to be respected for electronic components, the following can be mentioned:
respecting a minimum width W of some elements of the components, for example, the width of MOS transistor gates, the length of a transistor channel; respecting a minimum space S between different elements, to avoid interferences between these elements, for example, between two metal tracks, or again leakage currents; respecting a minimum surface area A for some elements.
FIG. 2 illustrates rules that may be imposed by DRMs when several layers are used to form electronic components, at close or superposed locations of a circuit. This drawing shows the design levels from which are formed masks which will subsequently be necessary to the manufacturing of electronic components, LAYER 1 for which the contour of the openings is shown in full lines, and LAYER 2 having its openings shown in hatched portions.
The examples of rules to be respected may be:
respecting a minimum enclosure E between the edge of the openings of the second mask LAYER 2 and the edge of the openings of the first mask LAYER 1 . This, for example, corresponds to the case of electronic components formed in a well of a specific conductivity type. In this case, for their proper operation, the components should not be formed too close to the edge of the well. This may also correspond to elements which should be formed in superposed fashion: for example, a transistor gate above a well of a specific conductivity type. respecting a minimum distance D between elements formed by means of second mask LAYER 2 with respect to elements formed by means of first mask LAYER 1 . This, for example, corresponds to the case where the first mask defines a well of a given conductivity type and where the components formed at the level of the openings of the second mask should not be formed too close to this well due to a risk of interactions.
It should be noted that the rules imposed by DRMs may also integrate an alignment error margin to take into account inaccuracies in the mask alignment on manufacturing of the circuits. The rules imposed by DRMs thus eliminate a number of situations with critical sizings, which could not operate properly and which are thus not accessible to designers.
Once the integrated circuits have been designed by the designers, the obtained CAD files should be turned into image files of the masks which will be necessary to form the integrated circuits. To achieve this, logical operations are defined by technologists to be applied to the integrated circuit files.
The logical operations also define all the elements missing for the proper operation of the circuit, which are not available to designers. Indeed, for an easy design of integrated circuits, designers only define some of the elements necessary to the forming of the integrated circuit. For example, in the case of a MOS transistor, designers may define the location of a well of a given conductivity type, and a second well necessary to the proper operation of the transistor may be automatically generated by the logical operations.
The logical operations finally define an optimized shape of the different masks. They may in particular provide to slightly widen the openings formed in the masks to compensate for a possible subsequent narrowing when the mask is being used.
FIG. 3 shows a conventional flowchart of the steps carried out to design integrated circuits, until the manufacturing of the masks used for manufacturing the integrated circuits.
As described hereabove, a first step 10 comprises forming a computer file which is an image of the desired integrated circuit (DESIGN FILE). This file is formed by designers 12 (DESIGNER), in compliance with the rules imposed by integrated circuit DRMs 14 associated with the technology used.
The integrated circuit file is then transformed, by a computer system, at a step 16 (LOP, Logical Operation Processing) and by means of a set of logical operations 18 (LO), to obtain an image file of the masks necessary to manufacture integrated circuits 20 (MASK FILES). The logical operations are especially provided to gather, within a same mask, the regions of the electronic components of the integrated circuits requiring a same processing.
As an example, low-voltage MOS transistors, high-voltage MOS transistors, dual-gate transistors, etc. may be provided on a same integrated circuit. Each of these transistors requires, to be formed, a specific processing, often obtained by a mask differentiation, for example, to form the wells of these different transistors. The logical operations of step 18 are used to generate the right masks according to the different steps to be carried out.
Step 16 of transformation of integrated circuit file 10 into a mask file may return errors, for example, in the case where the density of electronic components on the circuit would be too high, or in the case where there would be an incompatibility with the integrated circuit design rule manual. In this case, it is necessary to revise the transformation formulas 18 (LO) applied in transformation step 16 to validate or invalidate certain configurations provided by the designers.
Once step 18 has been carried out, all masks 20 are visually verified by a technologist (to spot evident errors, for example, of superposition of elements which should not be superposed), then is tested statistically again, at a step 22 (PLC) before the mask production. This last test, performed by a computer system, is a dimensional verification of the generated masks, for example, in comparison with dimensional criteria imposed by mask manufacturers (MRC, Manufacturing Rule Check), or with criteria imposed by integrated circuit manufacturers (PLC, Post Logical Check).
If test step 22 generates errors, a step 24 (ERROR) is provided, to modify logical operations 18 of transformation of step 20 so that the masks fulfill the conditions imposed by the mask manufacturers. This modification step is carried out manually by technologists and may be relatively long. Indeed, among all logical operations, the one having caused the incompatibility with the dimensional criteria imposed by the mask manufacturers should be targeted, and the required operation(s) should then be eliminated.
Once logical operations 18 have been modified, the operation of transformation of the integrated circuit file into a mask file is applied again to the integrated circuit file provided by the designers. If an error still occurs after test step 22 , logical operations 18 are modified again and the transformation operation of step 16 is repeated as many times as necessary.
When test step 22 is validated, the masks are sent to production at a step 26 (MASK FAB) and the integrated circuit production may start.
A problem may arise in specific cases where the designers desire to integrate new components in the integrated circuits. “New component” here means an entirely new component or a new adaptation of a known component, for example, the adding of a doped region at a new location of a transistor, the modification of the dimensions of an insulated gate, etc.
When a new component is designed, the integrated circuit in which this component is provided may be transformed according to the method described in relation with FIG. 3 to obtain the set of masks corresponding to this circuit, if this set of masks can be generated with no error. It is generally provided, before performing this transformation, to form a test file in which many configurations of the new component, in interaction with other components, are gathered. This test file is then tested to see if it complies with the rules imposed by the DRMs, after which it is transformed by means of the logical operations. This enables to verify that this new component poses no problem, related to the DRMs, of integration into the desired integrated circuit, but also into other future configurations that may be given thereto.
However, it is possible to have a test circuit comprising new components complying with the conditions imposed by the DRMs, where the transformations of the logical operations pose no problem, with a good post-transformation test regarding the criteria of mask manufacturers, but with finally produced masks which do not provide high-quality components.
This may be due to the fact that the logical operations transforming the integrated circuit file into a mask file may incorrectly process the design of the new component, or may introduce errors during the transformation.
If an erroneous set of masks is used to produce integrated circuits, this may have significant consequences in terms of time and cost, especially if an entire new set of masks has to be designed and manufactured.
It thus cannot be envisaged to detect errors at the end of the mask manufacturing process. A method for limiting as much as possible the need to redesign integrated circuit masks is thus needed.
SUMMARY OF THE INVENTION
An embodiment provides a method for designing integrated circuit manufacturing masks overcoming all or part of the disadvantages of usual methods.
More specifically, an embodiment is a method for designing integrated circuit manufacturing masks implementing particularly efficient test steps.
Thus, an embodiment provides a method for designing masks adapted to the forming of integrated circuits in a considered technology, comprising the steps of: (a) forming a first test file comprising a set of randomly-generated configurations of integrated circuit elements arranged according to layouts that may exceed the cases authorized by design rule manuals; (b) forming a second test file comprising all the elements of the first test file, less the elements corresponding to configurations forbidden by design rule manuals; (c) transforming the second test file by means of a set of logical operations implemented by computing means to obtain a mask file comprising the configuration of the set of masks necessary to obtain the integrated circuit associated with the second test file; (d) testing the mask file and, if the test is negative, modifying and adapting the design rule manuals according to the test result; and (e) reiterating steps (a) to (d) as many times as necessary until the test of step (d) is positive.
An embodiment provides a method for designing masks adapted to the forming of integrated circuits in a considered technology, comprising the steps of: (a) forming a first test file comprising a set of configurations of integrated circuit elements arranged according to layouts that may exceed the cases authorized by design rule manuals, generated by using mathematical models of interaction of segments or of polygons; (b) forming a second test file comprising all the elements of the first test file, less the elements corresponding to configurations forbidden by design rule manuals; (c) transforming the second test file by means of a set of logical operations implemented by computing means to obtain a mask file comprising the configuration of the set of masks necessary to obtain the integrated circuit associated with the second test file; (d) testing the mask file and, if the test is negative, modifying and adapting the design rule manuals according to the test result; and (e) reiterating steps (a) to (d) as many times as necessary until the test of step (d) is positive.
According to an embodiment, step (d) further comprises the step of modifying and adapting the logical operations of transformation of the second test file.
According to an embodiment, step (d) further comprises the step of modifying and adapting the test of the mask file.
According to an embodiment, step (e) is followed by the steps of: (f) forming an integrated circuit file respecting the rules imposed by the modified and adapted design rule manuals obtained by the last reiteration of step (d); and (g) transforming the integrated circuit file into a mask file by applying the logical transformation operations modified and adapted at step (d).
According to an embodiment, step (g) is followed by a step of manufacturing of a set of integrated circuit masks based on the mask file obtained at step (g).
According to an embodiment, the first test file comprises a set of randomly generated configurations of integrated circuit elements.
According to an embodiment, the first test file comprises a set of configurations of integrated circuit elements generated by using mathematical models of interaction of segments or of polygons.
The foregoing and other objects, features, and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates examples of rules that may be imposed to integrated circuit designers to form different elements of electronic components on a same level;
FIG. 2 illustrates examples of rules that may be imposed to integrated circuit designers for the forming of different elements of electronic components which require the use of several mask levels for their manufacturing;
FIG. 3 is a flowchart illustrating steps currently carried out between the design of integrated circuit files and the manufacturing of the masks for manufacturing the integrated circuits;
FIG. 4 is a flowchart illustrating steps according to an embodiment of the present invention; and
FIG. 5 is a flowchart illustrating steps of the manufacturing of integrated circuit masks according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 4 is a flowchart of a method provided to improve the design of integrated circuit masks, and especially when new components are provided by integrated circuit designers. More specifically, this drawing illustrates steps of a method for performing efficient and robust integrated circuit file tests, to avoid that erroneous masks are formed based on new components which comply with conventional tests.
The method described in relation with the flowchart of FIG. 4 will preferably be followed for each new electronic component technology. This method enables defining optimized integrated circuit design rules which may, later on, be adapted to any new component in the considered technology.
The method of FIG. 4 starts with a step 30 (ALL CONF) of forming of a complete test file. This complete test file comprises all the possible configurations of the various elements of a given technology (doped wells, metal tracks, etc.), be they known and existing configurations or configurations which do not appear as achievable.
It should be noted that “all the possible configurations of the various available elements” means that the complete test file for example comprises a set of random configurations of all the elements available to the designer, or also a set of configurations generated by using mathematical models of interactions of segments or of polygons. Any other method of formation of such a complete test file, comprising many configurations of the elements available to the designers, may also be used.
The complete test file is then tested (step 32 ) by means of the design rules imposed in the DRMs associated with this technology (step 34 ) to form an improved test file (step 36 , IMPROVED TEST CASE) comprising all the configurations of complete test file 30 less all the configurations which do not comply with the rules imposed by DRMs 34 . Thus, the improved test file comprises all the configurations authorized by the DRMs of the considered technology, be they conventional configurations (currently used by designers) or unusual configurations which are not filtered by the DRMs.
The obtained improved test file 36 is then transformed, at a step 38 (LOP), by a set of logical operations 40 (LO) implemented by computing means, for example, a computer, and defined by technologists, to form a mask set (MASK SET) at a step 42 .
The mask set obtained at step 42 is then submitted to a first visual test performed by a technologist, then to a mask post-generation test at a step 44 (PLC). The mask post-generation test 44 enables verifying that the obtained masks comply not only with the dimensional requirements of mask manufacturers, but also with the requirements of integrated circuit manufacturers.
If an error is detected during one of the tests of step 44 (FAIL), and this error corresponds to a case which should not be reproduced afterwards in the considered technology, it is provided to report the specific case having caused the error directly at the level of design rules 34 , at a step 46 (MOD DRM). Thus, such a situation can not be allowed afterwards by the test performed by means of the DRMs, for new integrated circuits.
If the detected error does not correspond to a case to be forbidden afterwards for new circuits, in the considered technology, or corresponds to a case to be refined and/or verified differently, it may be provided, at a step 48 (MOD LO), to modify the logical operations 40 performed at step 38 .
The set of steps 32 , 36 , 38 , 42 , and 44 is then repeated as often as necessary until a mask post-generation test step 44 providing no error is obtained (PASS). In this case, it is proceeded to a step 50 (ROBUST DRM/LO) where it can be said that the subsequent integrated circuit configurations authorized by the modified DRMs will provide high-quality and error-free mask files. The mask files thus obtained will be adapted to the manufacturing of high-quality and error-free integrated circuits.
It should be noted that the tests of mask post-generation test step 44 may also be modified and adapted when steps 32 to 42 are repeated. For example, some test steps may be modified and made less demanding if such a requirement appears not to be necessary.
Indeed, if a new integrated circuit is provided by the designers, this circuit will follow the conventional methods of transformation of the integrated circuit into a corresponding mask file for the integrated circuit manufacturing.
FIG. 5 illustrates the timing diagram of such a method. A new integrated circuit design file (NEW DESIGN FILE) is created at a step 60 by the integrated circuit designers. This integrated circuit design file complies with the integrated circuit design rules imposed by the improved design rule manuals formed by the method of FIG. 4 (IMPROVED DRM, step 62 ).
The integrated circuit file is then transformed, in a step 64 (IMPROVED LOP), by the improved logical operations formed by the method of FIG. 4 (step 66 , IMPROVED LO). The mask file thus obtained may be tested again with the mask post-generation steps, at a step 70 (PLC). If such a test is provided, the modified test will preferably be used on repeating of the method of FIG. 4 , if it has been modified. A mask set is thus obtained at a step 72 (MASK FAB), the masks being of good quality.
Thus, once the method described in relation with FIG. 4 has been carried out, any new integrated circuit file can be transformed into a mask file without fearing errors in the masks since the method described in relation with FIG. 4 has eliminated all forbidden design configurations.
Specific embodiments of the present invention have been described. Various alterations, modifications and improvements will occur to those skilled in the art. In particular, any other test step generally provided in addition to the steps disclosed herein for the manufacturing of integrated circuit masks may be carried out in combination with the method steps disclosed herein.
It should be noted that, conventionally, the complete test file, the improved test file, the mask files, and the integrated circuit design files may be formed in the GDSII file format, currently used for such files. It should however be noted that any other integrated circuit file format (for example, OASIS) may be used to form these files.
Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto. | A method for designing masks adapted to the forming of integrated circuits, including the steps of: (a) forming a first test file including a set of configurations of integrated circuit elements; (b) forming a second test file comprising the elements of the first test file, less the elements corresponding to configurations forbidden by design rule manuals; (c) trans-forming the second test file by means of a set of logical operations implemented by computing means to obtain a mask file; (d) testing the mask file and, if the test is negative, modifying the design rule manuals; and (e) repeating steps (a) to (d) until the test of step (d) is positive. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to a speech recognition method and apparatus using a Hidden Markov Model, a program for executing speech recognition by computer, and a storage medium from which the stored program can be read by a computer.
BACKGROUND OF THE INVENTION
[0002] Methods using the Hidden Markov Model (referred to as “HMM” below) are the focus of continuing research and application as effective methods of speech recognition, and many speech recognition systems are currently in use.
[0003] [0003]FIG. 6 is a flowchart illustrating an example of conventional speech recognition using an HMM.
[0004] Step S 1 , which is a voice input step, subjects a voice signal that has been input from a microphone or the like to an analog-to-digital conversion to obtain a digital signal. Step S 2 subjects the voice signal obtained by the conversion at step S 1 to acoustic analysis and extracts a time series of feature vectors. In acoustic analysis, an analytical window having a window width of 30 ms is provided for a voice signal, which is a continuous waveform that varies with time, and the voice signal is subjected to acoustic analysis while the analytical window is shifted by one-half to one-third the window width (i.e., 10 to 15 ms). The analytical results within each of the windows are output as feature vectors. The voice signal is converted to feature-vector sequences O(t) (1≦t≦/T), wherein t represents the frame number.
[0005] Next, processing proceeds to step S 3 . This step includes generating a search space, in which the two axes are HMM state sequences and feature-vector sequences of the input voice, by using an HMM database 5 , which stores HMMs comprising prescribed structural units, and a dictionary 6 that describes the corresponding relationship between words to be recogized and HMM state sequences, and finding an optimum path using Viterbi algorithm for which the maximum acoustic likelihood is obtained, in this search space.
[0006] The details of a procedure for the search will be described with reference to FIG. 7.
[0007] [0007]FIG. 7 illustrates search space and the manner in which the search is conducted in a case where two words “akil” and “aka” are subjected to continuous speech recognition using phoneme HMMs. In FIG. 7, horizontal axis shows an example of feature-vector sequences and the vertical axis shows an example of the HMM state sequences.
[0008] First, HMM state sequences corresponding to one or more words to undergo recognition are generated from the HMM database 5 and dictionary 6 , which describes the corresponding relationship between words to be recogized and the HMM state sequences. The HMM state sequences thus generated are as shown along the vertical axis in FIG. 7.
[0009] A two-dimensional, grid-like search space is formed from the HMM state sequences thus generated and feature-vector sequences.
[0010] Next, with regard to all paths that originate from “START” and arrive at “END” in the search space of FIG. 7, an optimum path for which the maximum cumulative acoustic likelihood will be obtained is found from the state output probability at each grid point and HMM state transition probability corresponding to a transition between grid points.
[0011] Then, with regard to each of the grid points (state hypotheses) in search space, the cumulative acoustic likelihoods (state-hypothesis likelihoods) up to arrival at the respective grid points are calculated in numerical order from t=1 to t=T. A state-hypothesis likelihood H(s,t) of state s of frame t is calculated by the following equation:
H ( s,t )=max H (s′,t−1)× a ( s′,s )× b[s,O ( t )] s′εS′ ( s ) . . . Eq. (1)
[0012] where S′ (s) represents a set of states connected to state s, a(s′,s) represents the transition probability from state s′ to state s, and b[s,O(t)] represents the state output probability of state s with respect to a feature vector 0 (t).
[0013] By using the state-hypothesis likelihood calculated above, the acoustic likelihood of the optimum path leading to “END” is calculated in accordance with the following equation:
max H ( s,T )× a ( s,s′ ) s εSf. . . Eq. (2)
[0014] where Sf represents a set of phoneme HMM states for which arrival at “END” is possible, i.e., a set of HMM final states representing each of the words to be recognized. Further, a(s,s′) denotes the probability of a transition from state s to other states.
[0015] When the state-hypothesis likelihood of each state hypothesis is calculated in the calculation process described above, the states of the origins of transitions [s′ in Equation (1)] for which the state-hypothesis likelihood is maximized are stored and the optimum path for which the maximum acoustic likelihood is calculated by tracing the stored values.
[0016] The HMM state sequences corresponding to the optimum path found through the above-described procedure are obtained and the recognized words corresponding to these state sequences are adopted as the results of recognition. In a case where the path indicated by the bold line in FIG. 7 is the optimum path for which the maximum cumulative acoustic likelihood is obtained, this path traverses the states of phoneme HMM/a/ /k/ /a/and therefore the result of speech recognition in this instance is “aka”.
[0017] Finally, processing proceeds to step S 4 in FIG. 6, where the result of recognition is displayed on a display unit or delivered to another process.
[0018] The search space shown in FIG. 7 increases in size in proportion to the number of words to be recognized and the duration of the input speech. This enlargement of the search space is accompanied by an enormous increase in the amount of processing needed to search for the optimum path. As a consequence, the response speed of speech recognition declines when implementing speech recognition applied to a large vocabulary and when implementing speech recognition using a computer that has an inferior processing capability.
SUMMARY OF THE INVENTION
[0019] Accordingly, an object of the present invention is to provide a speech recognition method, apparatus and storage medium wherein high-speed speech recognition is made possible by reducing the amount of processing needed for speech-recognition search processing.
[0020] According to the present invention, a speech recognition method for attaining the foregoing object comprises a speech recognition method comprising the steps of: extracting sequences of feature vectors from an input voice signal; and subjecting the voice signal to speech recognition using a search space in which an HMM-to-HMM transition is not allowed in specific feature-vector sequences.
[0021] Further, a speech recognition apparatus for attaining the foregoing object comprises a speech recognition apparatus comprising: extraction means for extracting sequences of feature vectors from an input voice signal; and recognition means for subjecting the voice signal to speech recognition using a search space in which an HMM-to-HMM transition is not allowed in specific feature-vector sequences.
[0022] Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principle of the invention.
[0024] [0024]FIG. 1 is a block diagram illustrating the hardware implementation of a speech recognition apparatus according to an embodiment of the present invention;
[0025] [0025]FIG. 2 is a flowchart illustrating speech recognition processing executed by the speech recognition apparatus according to an embodiment of the present invention;
[0026] [0026]FIG. 3 is a diagram useful in describing paths for executing search processing according to an embodiment of the present invention;
[0027] [0027]FIG. 4 is a diagram useful in describing a Hidden Markov Model;
[0028] [0028]FIG. 5 is a diagram illustrating the manner in which words to be recognized are constructed by a plurality of phoneme models;
[0029] [0029]FIG. 6 is a flowchart illustrating the procedure of speech recognition processing according to the prior art; and
[0030] [0030]FIG. 7 is a diagram useful in describing search processing paths in a speech recognition method according to the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings.
[0032] [0032]FIG. 1 is a block diagram illustrating the hardware implementation of a speech recognition apparatus according to an embodiment of the present invention.
[0033] As shown in FIG. 1, the apparatus includes an output unit 101 , which includes a display or printer, etc., for outputting the result of speech recognition or a response (document data) obtained from the result of speech recognition, and an input unit 102 , which is adapted to input voice from a microphone or the like and to input various data in response to operation by an operator using a keyboard and mouse, etc. The apparatus further includes a central processing unit (CPU) 103 for calculating numerical values and controlling the overall operation of the speech recognition, and a storage unit 104 , which includes an external memory device such as a disk drive and an internal memory such as a RAM or ROM, for storing a control program (illustrating in FIG. 2) for executing the procedure and processing of this embodiment. Also stored in the storage unit 104 are temporary data necessary for processing, a dictionary indicating the corresponding relationship between words to be recognized and HMMs, and the HMMs, etc. The apparatus further includes a speech recognition unit 105 .
[0034] The operation of the speech recognition unit 105 will now be described.
[0035] This embodiment will be described with regard to a case where input voice is subjected to continuous speech recognition using the state sequences of HMMs, in which the structural units of the HMMs are assumed to be phonemes and “aka”, “aki” are assumed to be the words undergoing recognition.
[0036] [0036]FIG. 5 is a diagram illustrating the words to be recognized in this embodiment. Each word is composed of phoneme HMMs, and each phoneme HMM is constructed as a linkage of a plurality of states, as shown in FIG. 4.
[0037] In FIG. 4, three states (S 1 , S 2 and S 3 ) are illustrated. Self-loop probability at state S 1 is indicated by a 11 , and the transition probability from state S 1 to state S 2 is indicated by a 12 . By using the Viterbi algorithm, the scores of paths within the search space are found based upon the transition probabilities between these states and then a search is conducted for the path that will afford the largest cumulative value (likelihood) of the score values.
[0038] [0038]FIG. 2 is a flowchart illustrating speech recognition processing executed by the speech recognition unit 105 according to this embodiment. It should be noted that steps similar to those of the speech recognition method using the HMM of FIG. 6 will not be described in detail again. The description will start from search processing, which follows the extraction of feature-vector sequences O(t) (1≦t≦T) from input voice by the voice input processing at step S 11 (with corresponds to step S 1 in FIG. 6) and the acoustic analysis processing of step S 12 (which corresponds to step S 2 ).
[0039] Processing proceeds from step S 12 to step S 13 , which is processing for generating search space. Specifically, state sequences of HMMs corresponding to one or more words to be recognized are generated using an HMM database 16 , which stores HMMs in which phonemes are the structural units, and a dictionary 17 that describes the corresponding relationship between words to be recogized and HMM state sequences, and generates a two-axis search space comprising feature-vector sequences O(t) and HMM state sequences (see FIGS. 3 and 7).
[0040] [0040]FIG. 3 is a diagram useful in describing paths for executing search processing in the speech recognition apparatus according to this embodiment.
[0041] The embodiment shown in FIG. 3 and the prior-art example of FIG. 7 differ in that when the search space is generated in FIG. 3, HMM-to-HMM transitions are allowed only in specific frames; an HMM-to-HMM transition is not allowed in frames other than these specific frames. As a result, it is possible to reduce the number of paths that are to be searched, and this in turn makes it possible to raise processing speed. By way of example, here the frames which allow the HMM-to-HMM transition are set in such a manner that the frame interval will be N (2≦N≦4).
[0042] In the example of FIG. 3, N=3 is assumed to hold and the search space is established so as to allow the HMM-to-HMM transition every three frames. In comparison between FIGS. 3 and 7, the number of paths transit between HMMs in FIG. 3 is much less than the number of the paths in FIG. 7.
[0043] According to the example of FIG. 3, the HMMs representing each of the phonemes (/a/, /k/, /i/) have three states and a transition from one HMM to another occurs in accordance with a predetermined transition rule. In this embodiment, a transition between these HMMs is allowed every N (=3) frames. More specifically, an HMM-to-HMM transition is allowed only in feature-vector sequences O(2), O(5), O(8), . . . , O(T−1).
[0044] Next, processing proceeds to step S 14 . Here, with regard to all paths that originate from “START” and arrive at “END” in the search space of FIG. 3, the cumulative likelihood of each state hypothesis is calculated from the state output probability and the state transition probability corresponding to the transition between each of the grid points. Then, the optimum path which has the maximum cumulative acoustic likelihood is found. The method of searching for optimum path is processing similar to that of step S 3 in FIG. 6 and need not be described here. At step S 14 , however, the frames at which the HMM-to-HMM transition is allowed are determined in advance. As a result, the amount of calculation needed to calculate likelihood in this search processing is reduced in comparison with step S 3 of FIG. 6.
[0045] The recognized words of the HMM sequences on the optimum path thus found are adopted as the results of recognition. These results are displayed on the display of output unit 101 or are delivered to other processing at the output processing of step S 15 .
[0046] Thus, in accordance with this embodiment as described above, an HMM-to-HMM transition is allowed every N frames when search space is generated using the sequences of feature vectors and the HMM state sequences, thereby making it possible to reduce the number of paths searched so that a higher speech recognition speed can be achieved.
[0047] This embodiment has been described with regard to a case where a transition between HMMs is allowed every N (N=3) frames at step S 13 in FIG. 2. However, this does not impose a limitation upon the invention. For example, taking into consideration the fact that the above-described search space grows in size with an increase in the number of words to be recognized or with an increase in duration of input speech, the frame interval at which the HMM-to-HMM transition is allowed can be enlarged in stages within the range 2≦N≦4 in accordance with the increase in number of words or increase in duration of input speech. Further, taking into consideration both an increase in the number of words to be recognized and an increase in duration of input speech, the frame interval can also be changed in stages within the range 2≦N≦4. By adopting this arrangement, a reduction in the number of search paths can be performed adaptively in dependence upon the scale of the search space, thereby making it possible to raise the speed of recognition processing.
[0048] Further, step S 13 in this embodiment has been described with regard to a case where a transition between HMMs is allowed every N (N=3) frames with respect to all HMMs that are present with the HMM state sequences. However, this does not impose a limitation upon the invention. For example, the frame interval at which the HMM-to-HMM transition is allowed can be changed within the range 2≦N≦4 between prescribed HMMs. Further, it is possible to vary the frame interval every prescribed number of feature-vector sequences. This will make it possible to change the frame interval, using one frame interval for HMMs for which the frequency of transition to another HMM is high and using another frame interval for HMMs for which the frequency of transition to another HMM is low. As a result, a smaller search space can be achieved.
[0049] Though the structural units of an HMM are described as being phonemes in the above embodiment, this does not impose a limitation upon the invention. For example, vocalized sounds such as syllables, demi-syllables, words and diphones may be adopted as the structural units.
[0050] Further, though an example in which words in the Japanese language are recognized has been described, this does not impose any limitation and the invention is applicable to other languages as well.
[0051] The present invention can be applied to a system constituted by a plurality of devices (e.g., a host computer, interface, reader, printer, etc.) or to an apparatus comprising a single device (e.g., a copier or facsimile machine, etc.).
[0052] The present invention is not limited solely to the above-described apparatus and method that implement the foregoing embodiment. The scope of the present invention covers also a case where the program codes of software for implementing the foregoing embodiments are supplied to a computer (CPU or MPU) in a system or apparatus and the computer of the system or apparatus is made to operate the various above-mentioned devices in accordance with the program code.
[0053] In this case, the program codes of the program per se implement the functions of the foregoing embodiment, and the program codes per se as well as the means for supplying these program codes to the computer, i.e., the storage medium on which these program codes have been stored, fall within the scope of the present invention.
[0054] Examples of storage media that can be used for supplying the program code are a floppy disk, hard disk, optical disk, magneto-optical disk, CD-ROM, magnetic tape, non-volatile type memory card or ROM, etc.
[0055] Furthermore, besides the case where the aforesaid functions according to the embodiment are implemented by controlling the various devices in accordance solely with the supplied program codes, the scope of the present invention covers a case where the program codes cooperate with an operating system running on the computer or with other application software or the like to implement the foregoing embodiments.
[0056] Furthermore, the scope of the present invention further covers also a case where, after the program codes read from the storage medium are written in a function expansion board of a computer or in a memory provided in a function expansion unit connected to the computer, a CPU or the like contained in the function expansion board or function expansion unit performs a part of or the entire process in accordance with the designation of program codes and implements the functions of the above embodiments.
[0057] Thus, in accordance with the embodiment as described above, an HMM-to-HMM transition is allowed only in specific frames when a search space for searching for maximum-likelihood state sequences is formed. As a result, paths to be searched can be reduced and it is possible to reduce the processing needed to search for the optimum path.
[0058] The present invention is not limited to the above embodiment and various changes and modifications can be made within the spirit and scope of the present invention. Therefore, to apprise the public of the scope of the present invention, the following claims are made. | Disclosed is a speech recognition method in a speech recognition apparatus to applying speech recognition to a voice signal applied thereto. The input voice signal is converted from an analog to a digital signal and sequences of feature vectors are extracted based upon the digital signal (S 12 ). A search space is defined by the sequences of feature vectors and an HMM ( 16 ) prepared beforehand for each unit of speech. The search space allows a transition between HMMs only in specific feature-vector sequences. A search is conducted in this space to find an optimum path for which the largest acoustic likelihood regarding the voice signal is obtained to find the result of recognition (S 14 ), and this result is output (S 15 ). | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an apparatus and method used to transport hydrocarbons from a wellbore to another location. More particularly, the invention relates to a multiphase pump for transporting hydrocarbons from the surface of a producing well. More particularly still, the invention relates to a pump having two vertically disposed plungers and circuitry providing more efficient operation of the pump.
2. Description of the Related Art
Oil and gas wells include a wellbore formed in the earth to access hydrocarbon bearing formations. Typically, a borehole is initially formed and thereafter the borehole is lined with steel pipe, or casing in order to prevent cave in and facilitate the isolation of portions of the wellbore. To complete the well, at least one area of the wellbore casing is perforated to form a fluid path for the hydrocarbons that either flow upwards to the surface of the well due to naturally occurring formation pressure or are urged upwards with some form of artificial lift. Regardless of the manner in which the hydrocarbons reach the surface of the well, this flow will arrive as a mixture of oil, gas, dirt and sand which is referred to as a “wellstream” or “fluidstream”. The fluidstream is then transported by a flowline to a predetermined location, such as a separator where it may be separated into gas, liquids, and solids. If the fluidstream cannot flow to the separator, it may be pumped by a multiphase pump. These pumps must be capable of moving volumes of the oil, gas, water or other substances making up the fluidstream. The pumps can be located offshore or onshore and can be connected to a single or multiple wellheads through the use of a manifold.
Over the past 20 years, two principle types of rotary pumps have been used as multiphase pumps: the twin screw pump and the helico-axial pump. The twin screw pump is a positive displacement pump constructed basically of two intermeshing screws. The fluidstream enters the pump from the wellhead and is trapped between the screws of the pump. The rotation of two screws forces the fluidstream into the downstream flowline. The helico-axial style pump combines positive displacement with dynamic compression and is basically constructed of turbine blades in combination with a screw drive. This combination imparts energy from turbine blades and the screw drive into the discharged fluids.
The rotary style multiphase pumps have been popular due to their long market exposure but have demonstrated deficiencies. Maintenance problems that usually require more than 24 hours to resolve is one deficiency that affects both the twin screw pump and the helico-axial pump. Many of these problems are associated with erosion or heat that damage the mechanical seals. Sand can also erode the screws and liners of the pumps. Excessive amounts of gas can cause a reduction in the dynamic performance occur in the helico-axial pumps and can lead to build up and gas locking in the twin screw pumps. Conversely, excessively long liquid slugs can affect the efficiency of the helico-axial pumps.
A horizontal, reciprocating pump has been successfully deployed for low to medium gas volume fraction applications. This pump contains horizontal rams that are moved in and out by a rotating crankshaft. The pump has reasonable tolerance for sand in the well stream. It uses replaceable liners to cover and protect the compression cylinders which can be changed in the field. Even though the horizontal reciprocating pump overcomes some of the deficiencies of a rotary style multiphase pump it may experience dynamic problems if the flow is mainly gas.
More recently, a vertical reciprocating pump (the RamPump™) has been used to transport well stream. This pump was introduced to overcome deficiencies of rotary pumps. It operates at a slower pace than the rotary pumps, using larger volume chambers and long strokes to attain the flow rates desired. Due to the slow fluid velocities and vertical plunger design, sand and other impurities from a wellbore have little adverse effect on its moving parts. Because it has no rotating mechanical seals; it can handle a full range of fluid mixtures without requiring liquid trapping or re-circulation to insure seal survival. Preferably driving cylinders are placed in line with their respective plungers. Power fluid supplied from a pressure compensated pump is used to drive one plunger fully down, triggering a sudden pressure increase at the end of the stroke. This pressure spike is used to shift a shuttle valve, causing the swash plate of the compensated pump to reverse angle and to redirect the power fluid to the opposite cylinder. Each power circuit is connected to the piston end of one cylinder and also to the rod end of the other cylinder, thus assuring that the opposite plunger will be driven upward when the first plunger is moving downward.
Even though the vertical RamPumps™ overcomes many of the deficiencies in the prior pumps, problems still exist with the use of vertical plungers in a hydraulically driven multiphase pump. For example, if a deficit of hydraulic fluid occurs, the pump will pause, and go to neutral, and may need intervention to restart. In another example, pressure spikes created during the operation of the hydraulically driven pump can cause premature failures in relief valves and hoses at the end fittings. These pressure spikes occur when one of the plungers reaches its preset retracted position and thereby causing the fluid to be further compressed in the hose without any way of escape. This increase pressure is utilized in the system to cause the swash plate in the pressure compensated pump to reverse angle thereby redirecting the flow of hydraulic fluid to the opposite cylinder. Since the swash plate does not change direction instantaneously, the pressure continues to increase in the hoses thereby causing a very high pressure spike resulting in failure of hydraulic components. In yet another example, when an inlet pressure is insufficient to raise the ascending plunger ahead of the descending plunger the pump begins to short stroke on subsequent cycles and ultimately stop pumping. The combination of these problems greatly reduced the functionality of hydraulically driven multiphase pump.
In view of the deficiencies of currently available hydraulically driven multiphase pump a need exists for a hydraulically driven pump that operates effectively and efficiently in pumping multiphase liquids and does not systematically pause during a pumping cycle. There is a further need for a hydraulically driven multiphase pump that is not subject to premature failure of hydraulic components and hoses. There is yet a further need for a hydraulically driven multiphase pump that does not short stroke while operating in various pressure conditions.
SUMMARY OF THE INVENTION
The present invention provides a hydraulically driven multiphase pump system with improved efficiency due to elimination of pressure spikes and priming problems of the plunger moving toward the extended position. The hydraulically driven multiphase pump system consists of two vertical disposed plungers. The plungers are hydraulically controlled and actuated to work in alternate directions during a stroking cycle using a closed loop hydraulic system. Each cycle is automatically re-indexed to assure volumetric balance in the circuits. An indexing circuit ensures that each plunger reaches its full extended position prior to the other plunger reaching its preset retracted position. The multiphase pump system is capable of operating in 100% gas and 100% liquids without requiring auxiliary liquid circuits.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, 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.
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 schematic view of a complete hydraulically driven multiphase pump system.
FIG. 2 is a schematic view showing a closed loop circuit in the hydraulically driven multiphase pump system.
FIG. 3 is a schematic view showing a indexing circuit in the hydraulically driven multiphase pump system.
FIG. 4 is a schematic view showing a charging circuit in the hydraulically driven multiphase pump system.
FIG. 5 illustrates a power saving circuit in the hydraulically driven multiphase pump system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic view of a complete hydraulically driven multiphase pump system 100 . For ease of explanation the invention will be first be described generally with respect to FIG. 1, thereafter more specifically with FIGS. 2-5. The system 100 contains a first 310 and second 315 plunger, each movable between an extended position and a retracted position. The first plunger 310 is moveable by a first and a second hydraulic cylinders 222 . The second plunger 315 is movable by a first and a second hydraulic cylinders 224 . When the first plunger 310 is moving toward the extended position, a suction is created by the plunger 310 , urging the fluidstream from the wellbore to enter the system 100 through an inlet 110 and fill a first plunger cavity 311 . Simultaneously, the second plunger 315 is moving in an opposite direction toward a preset retracted position, thereby expelling the fluidstream in a second plunger cavity 316 to a discharge 120 . As the first plunger 310 reaches its full extended position, the second plunger 315 then reaches its preset retracted position, thereby completing a cycle. The first plunger 310 then moves toward the preset retracted position expelling the fluidstream into the discharge 120 , as the second plunger 315 moves toward the extended position creating a suction and urging the fluidstream to enter the inlet 110 . In this manner, the plungers operate as a pair of substantially counter synchronous fluid pumps. While the described embodiment includes plungers acting in a counter-synchronous manner, it will be understood that so long as they move in a predetermined way relative to one another, a predetermined phase relationship, the plungers can assume any position as they operate.
The plungers 310 , 315 move in the opposite directions causing continuous flow of fluid from the inlet 110 to the discharge 120 . A first biasing member 325 is disposed at the lower end of the first plunger 310 , to facilitate the movement of the first plunger 310 toward the extended position. A second biasing member 327 is disposed at the lower end of the second plunger 315 to facilitate the movement of the second plunger 315 toward the extended position. The hydraulic cylinders 222 , 224 are shown on the side of the plungers 310 , 315 , which is a preferred embodiment. However, this invention is not limited to orientation of the hydraulic cylinders 222 , 224 as shown on FIG. 1 . For instance, depending on space requirement the plungers can be disposed in any orientation that is necessary and effective.
The system 100 includes a closed loop circuit 200 for supply of hydraulic fluid from a pressure compensated pump 230 to a rod end 221 of the first and the second hydraulic cylinders 222 of the first plunger 310 and to a rod end 223 of the first and the second hydraulic cylinders 224 of the second plunger 315 . The system 100 also includes an indexing circuit 300 providing hydraulic fluid to and from a blind end 227 of the first and the second hydraulic cylinders 222 of the first plunger 310 and to a blind end 229 of the first and the second hydraulic cylinders 224 of the second plunger 315 . The indexing circuit 300 ensures that one plunger reaches its full extended position prior to the other plunger reaching its preset retracted position. Additionally, the system 100 further includes a power saving circuit 500 to transfer energy between the first 310 and the second 315 plunger. The system 100 further includes a charge circuit 400 for providing hydraulic fluid to the closed loop circuit 200 , the indexing circuit 300 and the power saving circuit 500 .
FIG. 2 is a schematic view showing the closed loop circuit 200 in the hydraulically driven multiphase pump system 100 . In the circuit 200 , the rod end 221 of the first and the second hydraulic cylinders 222 of the first plunger 310 and to the rod end 223 of the first and the second hydraulic cylinders 224 of the second plunger 315 is connected to the pressure compensated hydraulic pump 230 . The pump 230 is energized by an external power source 265 such as an electric motor or an engine. The circuit 200 further includes a first 330 and a second 335 limit switch to commence the reversal of fluid flow by the pressure compensated hydraulic pump 230 . During a cycle, the pump 230 directs hydraulic fluid towards the first and the second hydraulic cylinders 222 of the first plunger 310 thereby causing the plunger 310 to move towards the retracted position. Once the plunger 310 reaches the preset retracted position, the limit switch 330 is triggered. The first 330 and the second 335 limit switches are arranged and constructed to trigger a signal to box 340 . The box 340 is connected to a control valve 270 which causes the pressure compensated pump 230 to redirect the flow of fluid in the closed loop circuit 200 . When redirected, the pump 230 draws the fluid from the rod end 221 the first and the second hydraulic cylinders 222 of the first plunger 310 in the retracted position and sends the fluid to the rod end 223 of the first and the second hydraulic cylinders 224 of the second plunger 315 in the extended position, thereby completing a cycle. The first 330 and the second 335 limit switches are movable to adjust the first 310 and the second 315 plunger preset retracted positions in order to optimize the pump cycle. The pump system is optimized when the volume of well stream pumped over time is increased.
In the event the circuit 200 experiences leakage through a loop flushing valve 245 or through normal leakage from the compensated pump 230 to a drain 260 , a replenishment flow of fluid can be introduced into the closed loop circuit 200 by means of the charge circuit 400 . The charge circuit 400 includes an accumulator 255 that stores fluid under pressure. A valve 250 between the accumulator 255 and the closed loop circuit 200 permits fluid introduction to the closed loop circuit 200 in the event that fluid pressure in the circuit 200 falls below a preset valve.
FIG. 3 is a schematic view showing the indexing circuit 300 in the hydraulically driven multiphase pump system 100 . The indexing circuit 300 ensures that each plunger reaches its full extended position prior to the other plunger reaching its preset retracted position. Circuit 300 connects the blind end 227 of the first and the second hydraulic cylinders 222 of the first plunger 310 to the blind end 229 of the first and the second hydraulic cylinders 224 of the second plunger 315 . In a low inlet pressure scenario, the extending plunger has less external force urging it toward the extended position. To compensate, the pressure increases in the indexing circuit 300 thereby preventing fluid introduction by the charge circuit 400 . One feature to address this problem is the use of an acceleration valve 350 for selective communication with the closed loop circuit 200 and the indexing circuit 300 . As the pump system 100 completes a cycle and one of the plungers moves from the extended position to the retracted position, the acceleration valve 350 briefly provides a small volume of fluid from the closed loop circuit 200 to the indexing circuit 300 . This fluid entering the indexing circuit 300 accelerates the movement of the plunger towards its extended position, thereby assuring that the plunger will reach its full extended position prior to the time the other plunger reaches its preset retracted position. A second feature in the preferred embodiment for low inlet pressures is the use of the first 325 and the second 327 biasing member for biasing at least one of the plungers as the plunger moves from the retracted position. The first biasing member 325 propels the first plunger 310 towards the extended position, thereby temporarily lowering pressure in the indexing circuit 300 below the pressure in the charge circuit 400 . A first pressure sensing member 415 in the charge circuit 400 opens and introduces fluid to the indexing circuit 300 . This fluid further ensures that the plunger moving toward the extended position will arrive prior to the time the other plunger reaches its preset retracted position. Likewise, upon reversal of pump 230 , the second biasing 327 member propels the second plunger 315 toward the extended position thereby following the same sequence of events as described.
The indexing circuit 300 further includes a first 320 and a second 322 check valve for selective communication from the indexing circuit 300 to the close loop circuit 200 . The first 320 and second 322 check valves are arranged to allow fluid to enter the suction line of pressure compensated pump 230 in the closed loop circuit 200 as one plunger reaches its full extended position while the other plunger proceeds to its preset retracted position thereby maintaining volumetric balance in the system 100 .
FIG. 4 is a schematic view showing the charging circuit 400 in the hydraulically driven multiphase pump system 100 . This circuit 400 picks up hydraulic fluid from a reservoir 450 and pumps it throughout the circuit 400 to re-supply the closed loop circuit 200 , the indexing circuit 300 and the power saving circuit 500 with hydraulic fluid. The charge circuit 400 has a predetermined pressure that is maintained by a charging pump 410 . The circuit also includes first 415 and a second 420 pressure sensing member. If the closed loop circuit pressure falls below the predetermined charge circuit pressure the first pressure sensing member 420 causes the introduction of hydraulic fluid into the close loop circuit 200 to replenish its supply of fluid. If the indexing circuit pressure falls below the predetermined charge circuit pressure the second pressure sensing member 415 causes the introduction of hydraulic fluid to flow into the indexing circuit 300 to replenish its supply of fluid. A hand operated valve 365 allows selective fluid communication from the charge circuit 400 to the indexing circuit 300 . Any fluid not needed by the system 100 is surplus, and is returned to the reservoir 450 .
FIG. 5 illustrates the power saving circuit 500 in the hydraulically driven multiphase pump system 100 . Circuit 500 will transfer energy between the plungers, 310 , 315 as they move in opposite directions. The power saving circuit 500 includes a first and second power saving hydraulic cylinders 510 disposed adjacent to the first plunger 310 connected to a first and second power saving hydraulic cylinders 515 disposed adjacent to the second plunger 315 . In high inlet pressure scenarios, the plunger moving toward the extended position is urged upwards by the inlet pressure of the fluidstream resulting in useful energy. This energy is transferred from the plunger moving toward its extended position to the plunger moving toward its preset retracted position by the power saving hydraulic cylinders 510 , 515 . Therefore, the amount of work needed from the pressure compensated pump 230 in the closed loop circuit 200 directed to the plunger moving toward the preset retracted position is substantially reduced. In low inlet pressure scenarios, the power saving circuit 500 in same manner as previously described may be economically applied where the plunger diameter is large thereby having a large surface area to act upon. Any excess fluid in the circuit 500 may be relieved to the reservoir 450 through valve 520 . While the described embodiment in FIG. 5 includes hydraulic cylinders 510 , 515 , it will be understood that any mechanism that facilitates the transfer of energy such as sheaves, chains, or hydraulic cylinders could be used. Additionally, this invention is not limited to the orientation of the hydraulic cylinders as shown on FIG. 5 but rather may be disposed in any orientation that is necessary and effective.
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. | The present invention provides a hydraulically driven multiphase pump system and methods for pumping a fluidstream from the surface of a well. The hydraulically driven multiphase pump system consists of two vertically disposed plungers. The plungers are hydraulically controlled and actuated to work in alternate directions during a cycle using a closed loop hydraulic system. Each cycle is automatically re-indexed to assure volumetric balance in the circuits. An indexing circuit ensures that each plunger reaches its full extended position prior to the other plunger reaching its preset retracted position. A bias member and an acceleration valve are used to prime the indexing circuit for use in low or variable inlet pressure situations. A power saving circuit is used to transfer energy from the extending plunger to the retracting plunger. | 5 |
FIELD OF THE INVENTION
This invention pertains to a process and apparatus for treating waste water and particularly waste water generated by the cleaning and repairing of automobile radiators.
BACKGROUND OF THE INVENTION
Hazardous and Solid Waste Regulations have greatly reduced the amount of wastes a small business can generate. The federal regulatory bodies governing the management of hazardous waste define hazardous waste as any solid waste which has the potential to harm human life or the environment. Under the passage of the Resource Conservation and Recovery Act of 1976, Small Quantity Generators, defined as those generating less than 1,000 kg per month of hazardous waste were provided an exemption from many of the requirements, but did have to go through the waste determination step and did have to dispose of their waste in an approved manner and/or at an approved site, including licensed municipal solid waste disposal facilities. The Hazardous and Solid Waste Amendments of 1984 have significantly changed this system by defining the SQG as one generating 100 kg (approximately 220 lbs or 27.5 gallons) per month. These changes have resulted in greatly increasing the number of regulated generators and the number of regulated wastes as well as increasing the pressure on local bodies to ensure that hazardous waste is not being introduced into the municipal waste stream.
Among the many Small Quantity Generators effected by these regulations are automobile service centers, such as gasoline service stations and radiator repair shops. Numerous contaminants are generated by these servicers in every day operations, such as the cleaning and repairing of engine parts. Included among these contaminants are solvents, road grime, used oil, organic compositions, such as antifreeze, and a wide variety of metals including significant quantities of copper, zinc and lead. In the past, such wastes have been disposed in municipal sewage systems, septic tanks and underground storage tanks. Each of these methods is costly in that special disposal is necessary and that such systems have high water requirements. The present invention is designed to treat all of these residues in a simple and efficient process.
It is expected that as concerns over the environment mount, and the diminishing quality of our water and the depletion of our landfills continues, further regulations will be enacted to lessen the amount of solids and hazardous wastes dispersed to the environment. Although there exists a number of methods for treating waste waters, none of these processes have been directed for the use of small generators of waste to treat waste waters produced in their stations and shops.
DESCRIPTION OF THE PRIOR ART
The prior art discloses various methods and apparatus for the treatment of sewage and the dewatering of aqueous solutions. None of the prior art shows a process and apparatus for treating water used for cleaning radiators and other industrial equipment which contain metals and other impurities. Representative of the prior art is the following list of patents. Copies are attached herewith for the record.
U.S. Pat. Nos. 4,724,085 and 4,882,069 to Pohoreski provide a method for the clarification of sewage waste water by adding thereto (1) an inorganic coagulant which comprises an aluminum or iron salt, (2) an anionic acrylamide polymer polyelectrolyte and (3) a cationic amine or acrylamide polymer polyelectrolyte. The sewage is turbulently mixed, the particulate matter is allowed to settle as sludge and pure water is separated. The sludge may be recycled to the sewage or other impure water to be treated.
U.S. Pat. No. 4,417,976 to Sander et al describes a process for dewatering petroleum-containing sludges by a two-stage method using finely divided additives, such as ash, coal, sand or mixtures thereof and organic flocculants, such as water-soluble, macromolecular compounds obtained by polymerizing or copolymerizing acrylamide, acrylic acid and/or its salts or esters. The predewatered sludge mixture is treated with an aqueous mixture of aluminum salts or trivalent iron salts and this mixture is substantially dewatered via pressure filtration.
U.S. Pat. No. 4,710,304 to Lang discloses a method for improving the utilization of polyelectrolytes in dewatering aqueous suspensions by aging a mixture of polyelectrolyte and water for a period of at least six hours to form an aged solution.
U.S. Pat. No. 4,173,532 to Keoteklian relates to a method for the removal of solid waste from a liquid effluent of an industrial plant utilizing coagulating and flocculating agents while simultaneously adjusting the pH of the treatment medium.
U.S. Pat. No. 3,506,570 to Wukasch describes a method for the clarification of and phosphate removal from sewage by the incorporation of a trivalent aluminum ion into the waste, followed by the application of a particular acrylamide-acrylic copolymer under flocculating conditions.
U.S. Pat. No. 3,171,804 to Rice relates to sewage and industrial waste purification by the use of a coagulating agent and a polyelectrolyte.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus for treating metal-containing waste waters.
It is another object of the present invention to provide a method and apparatus for the treatment of small amounts of metal-containing waste waters, such as those produced by a small quantity generator.
It is a still further object of the present invention to provide a method and apparatus for the treatment of waste waters produced by small quantity generators which is both safe and environmentally acceptable.
It is yet another object of the present invention to provide a method and apparatus for the treatment of waste waters produced by a small quantity generator which will be efficient and cost-effective.
It is a further object of the present invention to provide an apparatus for the treatment of waste water which is easily installed in any location.
It is another object of the present invention to provide a waste water treatment unit which is self-contained and which may be used by consumers in their homes or businesses.
It is also an object of the present invention to provide a method and apparatus for treating metal-containing waste waters wherein the resulting clean water may be recycled and the separated metals may be reclaimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus of the present invention.
FIG. 2 is schematic view of the apparatus wherein the process is carried out.
FIG. 3 is a perspective view of a stackable form of the apparatus.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method and apparatus for treating waste waters, particularly metal-containing waste waters. Such waste waters include industrial wastes, particularly waste waters produced from small quantity generators, such as automobile servicers, gasoline service stations and radiator service shops.
Radiator service shops generally clean and repair radiators, water pumps, thermostats and other engine parts. Although the following description is directed to waste waters resulting from the cleaning and repairing of a radiator, it will be obvious to those skilled in the art that the process and apparatus of the present invention applies to the treatment of any metal-containing waste water.
The repair of a radiator comprises a series of preliminary cleaning steps designed to remove build-up, dirt, grease, grime et al. Initially, the radiator must be drained, thereby generating anti-freeze and metals from oxidation. After the radiator is drained, it is cleaned in order to remove build-up, grease, dirt and other contaminants. Following the cleaning step, the radiator is repaired or recored by metal soldering or welding. Each of the foregoing procedures generates a metal-containing waste. As will be discussed more fully below, the present invention is designed to treat all of these residues and sludges in a simple and efficient process which is both safe and environmentally acceptable.
FIG. 1 shows a treatment tank 30, a storage and rinse tank 40 and a work station 100, sometimes referred to as a flush housing. The housing 100 has side walls 101, back wall, top wall 103, bottom wall 105, front wall 107 and swinging door 120. The tanks 30 and 40 may be of any size depending on the capacity requirements of a particular processing plant.
FIG. 2 is a schematic of the system of tanks and work station having numerous interconnections therebetween. It is seen that tank 30 has a cone-shaped bottom 32 with an opening 33 connected by line 35 having a valve 37 thereon, and an open end 39 for the discharge of material from the tank 30 to a container positioned below, said container being more fully described hereinafter.
The tank 30 is supported on a frame 49 of suitable strength to support a full tank with water containing metal particles and other impurities and contaminants. The frame 49 has a plurality of diagonal members 41 upon which rest the wall of the cone 32. This provides optimum support for the cone 32 when the tank 30 has been filled with waste water which is to be treated.
The cone wall 32 has a first opening 50 therein and a line 51 extending away therefrom to an air pump (or compressor) 52 having suitable valves, regulators and switches as is customary with such machinery.
The opening 50 for a pump inlet line 51 is in the upper section of the cone and between the bottom opening 33 and the top 39 of the cone. An agitator nozzle 53 on the opening 50 extends toward the bottom opening 33. Further along the cone wall 32, near the top 39 is another opening 43 from which extends a line 60 having a valve 61 therein. A down-turned nozzle 44 connects to line 61 from the inside of the cone 32. The line 60 attaches to a filter 62 which in turn is attached to the storage tank 40 near the top 45. It will be seen that tank 40 is a closed tank and can be of any size necessary to meet the requirements of a particular shop. A line 70 having a valve 71 connects the tank 40 to a sump line 80 as shown.
The sump line 80 is connected at one end 82 to a sump pump 84 which rests on a sump separator tray 212 to be more fully described below. The other end of line 80 passes through a valve 87 to the top 89 of tank 30. The sump line 80 may be connected within the work station 100 by any suitable means. The work station 100 is a housing having a back wall, side walls, a top wall and a front wall which may be of any size to accommodate the equipment to be cleaned. Access to the interior of the housing may be by way of a swinging door. A perforated or slotted platform 130 is suitably positioned in the work station 100 for optimum work rest position. A radiator 140 or other piece of equipment for cleaning is shown resting on the platform 130. A spray-head 170 is secured by either stationary or moveable means within the housing 100 and is attached by a line 180 to pump 83 through a valve 200 to the tank 40 near the bottom 47. The line 180 near the bottom 47 enters the inside of the tank 40 and has a down-turned nozzle 49 having an opening in its end, which opening is near the bottom wall 47. A line 203 extends from line 180 through a valve 201 through the wall of tank 40 to the inside thereof as shown. A down-turned nozzle 205 is on the inside of the tank and connects -to line 203.
The housing 100 has a sump area 210 having a separator tray 212 which receives water from the radiator cleaning step through the openings 131 of the platform 130. The waste water containing metals and other impurities collects in tray 212 which has a chamber 221 and a baffle 222 open at 224 for the passage of waste water. The waste water passes into chamber 225 and over baffle 226 into chamber 228. It will be seen that an equilibrium is reached once the water fills the chambers in tray 212. Once the equilibrium is reached, oils, metals and other debris may be skimmed off the top of the water in chamber 221 through outlet 230 by any known method. As cleaning of the equipment continues, the waste water continuously flows from the sump tray 212 by pump 84 to tank 30 through line 80. The waste water then passes by gravity pressure through opening 43 in cone 32 through line 60, valve 61 and filter 62 into tank 40 from where it is pumped by pump 83 through feed line 180 to the spray head 170. This recycling occurs when valves 87 and 61 are open and valves 71 and 200 are closed, and valve 201 is open to line 180. In operation, the tanks and work station are connected as shown. Tank 40 is filled with clean water from any source. Equipment, engine parts and the like, for instance, an automobile radiator, which requires cleaning, is placed on platform 130. Valves 61 and 87 are open. Valves 71 and 200 are closed and valve 201 is opened. Pump 83 is activated by, for example, a button near spray-head 170. Pump 84 is activated by an automatic switch which is opened when a predetermined amount of water is in tray 212. Water under pressure from pump 83 is sprayed from spray-head 170 onto the radiator 140 thereby resulting in the removal of metal particles and other impurities. The waste water flows into sump separator tray 212 and is recycled back to tank 30 by pump 84 through line 80 and open valves 87 and 61.
The water in the cone 32 and tank 40 is continuously recycled and used for shop work such as the cleaning of various equipment 140. After extended use, the water becomes too contaminated for either recycle or reuse. At this pont, valves 61 and 201 are closed and valve 200 is opened whereby pump 83 fills tank 30 from tank 40 through a separate line (not shown) from the pump to the tank 30. Pump 84 is then manually opened to drain the tray 212 into the tank 30 at which time valve 87 is closed. Once the tank 30 is full and pump 52 is started, the contaminated water in the cone 32 is vigorously agitated. As more fully described hereinbelow, this contaminated rinse water is treated by the process of the present invention.
The sludge remaining in the treatment tank settles into the cone 32 and is removed through line 35 and into container 280. The sludge may be dried, or otherwise treated, by processes well-known in the prior art, in apparatus 300 and 400.
As discussed above, the metal-containing waste water treatment process is initiated when the radiator rinse water, generated in the rinsing step outlined above, has been recycled to the point that it is no longer suitable for recycle or reuse, typically once every week or less in the average servicing shop. Once the waste water has been transferred to the treatment tank 30, it is rapidly agitated in order to thoroughly mix it. Small amounts of the sludge from various other cleaning operations (fully discussed herebelow) also may be transferred to the treatment tank. The pH of the contents of the treatment tank 30 is determined, and, if necessary, adjusted to an acceptable level. After the desired pH has been achieved, the chemical treating agents are added sequentially. The resulting waste water and sludge in the treatment tank is vigorously agitated for a short period of time. Following agitation, the metals and other contaminants undergo flocculation. Normally, flocculation occurs in a relatively short time, for instance two to three hours. Following a settling time of at least two hours, and preferably overnight, clean water is removed and recycled to the holding tank.
The sludge remaining in the conical bottom 32 of the treatment tank 30 is collected and placed in a container 280. Once the residue has dried, the metals therein may be reclaimed; for instance, the dry sludge may be sent/shipped to a metals reclaimer.
In addition to treating the rinse water from tank 40, other hazardous wastes resulting from comparable shop operations may be simultaneously treated. Once the radiator has been drained in the work station 100, it may be desirable to soak it in a boilout tank (not shown) in order to soften oxidation build-up, dirt, grease, road grime and paint thereby facilitating the cleaning of the radiator. The residue generated from the boilout tank normally contains a number of metal contaminants including significant quantities of lead, tin, copper and zinc; this metal-contaminated waste water may be returned to the tank 40 or it may be transferred to a separate storage tank.
The foregoing method is becoming replaced by new methods. One such method is ultrasonic cleaning which works more efficiently than the boilout tank and generates less residue; however, the residue has higher concentrations of metals. In most situations, the radiator is first soaked in the boiling tank and then undergoes ultrasonic cleaning. The resulting waste water contains the same metals as those generated in the boilout tank, although in higher concentrations. The contaminated waste water and sludge is treated as discussed above with respect to the boilout tank.
After the radiator has soaked in the boilout tank and/or has undergone ultrasonic cleaning, it is usually rinsed, for example, under a pressure washer such as that described above. The rinse water from the pressure washer drains into the sump area and is pumped to holding tank 30 and then to tank 40. This recycle continues until such a time that the water becomes so contaminated that it must be cleaned. Sludge settled at the bottom of the sump tank is subsequently removed for treatment.
A glass bead machine (not shown), which is essentially a cleaning gun, may also be used to further clean the radiator. Air and tiny glass beads are released from the gun, which operates somewhat like a small sand blaster. Some glass beads disintegrate and some are recycled. The disintegrated beads, together with the metal, dirt, and other contaminants removed from the radiator, are sucked into a dust collector (also not shown). The metal contaminants are the same as noted above.
Once the radiator has been cleaned, it is ready to be repaired. Repair methods include lead soldering, silver soldering and aluminum welding. Repair methods are conducted at the work station. After the radiator is repaired, it is put into a test tank to determine whether there are any leaks or other problems which require further repair work. The test tank generates a residue which is high in solder (i.e. lead and tin) and zinc.
If the radiator is not repairable, the radiator may be recored. In recoring the solder must be melted out of the radiator seam, which produces a significant amount of solder drippings. The radiator is then taken apart so that the individual parts (e.g. the tank, straps, and connections) may be reused. These parts are cleaned either with a glass bead machine or manually with a wire brush or flux acid, again generating contaminants. Solder then is used to reassemble the cleaned parts onto a new core, resulting in still more solder drippings which drain into the sump area 210 as described above.
More specifically, the process of treating the metal-containing waste water comprises the following steps:
(a) transferring the contaminated rinse water to a treatment tank and thoroughly agitating;
(b) optionally adding other hazardous wastes to the treatment tank and measuring the pH;
(c) adding an aluminum base, such as aluminum sulfate, to the treatment tank, followed by agitation;
(d) adding an organic polyelectrolyte to the treatment tank, followed by agitation;
(e) adding an acrylamide copolymer dispersed in mineral oil, such as a copolymer of sodium acrylate and acrylamide to the treatment tank;
(f) agitating the treatment tank in order to thoroughly mix resulting mixture;
(g) allowing precipitates to settle;
(h) recycling the treated water to the holding tank or releasing the treating water to the sewer;
(i) filtering the remaining sludge and transferring it to a smaller container;
(j) drying or otherwise treating the sludge; and
(k) collecting the dried product for transport to a metals reclaimer or for disposal.
The pH of the treatment tank containing the waste water and sludges most probably will be high, for example, between 10 and 12. However, if the servicing shop has no boilout tank or ultrasonic cleaner it may be necessary to raise the pH before adding the "AMISON" base. Raising the pH of the waste water in the treatment tank can be accomplished by any number of means well known in the art, said means including the addition of soda ash or other alkali salt.
The aluminum-containing base is preferably an aluminum sulfate (Al 2 (SO 4 ) 3 -14H 2 O), referred to hereinafter as an "AMUSON" base. The "AMUSON" base is characterized by its ability to attach itself to the metal ions in the waste water. The base is added to the treatment tank, preferably by dissolving in water. The amount of base to be added to the treatment tank will be dependent upon the size of the treatment tank, the pH of the tank, as well as the various types of waste which have been added to the contaminated rinse water. For example, if sludge has been generated from the boilout tank, ultrasonic cleaner, sump tank, et. al., the pH will be fairly high, for instance, in the range of 11 to 12. On the other hand, if the only sludge and waste water to be treated are generated from the sump and test tanks, the pH might be significantly lower.
Once the starting pH is determined, the "AMUSON" base is added to the treatment tank. Preferably, the "AMUSON" base first is dissolved in water thereby facilitating reaction with the metals contaminants in the treatment tank. Once the base has been added to the tank, the waste water is thoroughly agitated in order to allow the base to attach to the metal ions. After a period of from about five seconds to about thirty seconds, preferably from about fifteen seconds to about twenty five seconds, and most preferably about ten (10) seconds, the pH is again measured. For the process to proceed, the pH must be between from about 6 to about 9, preferably from about 7 to about 8 and most preferably, the ph should be about 7.5. If the pH is not within the desirable range, more "AMUSON" base may added in order to bring the pH to the desired level.
Organic polyelectrolytes are well known in the prior art and include acrylamides, acrylic acids, acrylic esters and derivatives thereof. The organic polyelectrolyte, hereinafter referred to as "AMUSON 03", must be of such a nature that it is capable of attaching to the base and also to other materials that are in the water, such as foreign debris, dirt and grime. The amount of "AMUSON 03" employed is determined by the amount of the "AMUSON" base previously added to the treatment tank. It is noted that as the "AMUSON 03" is measured in ounces, one ounce of "AMUSON 03" would equal one cup of "AMUSON" base. Preferably, the "AMUSON 03" is dissolved in water before being added to the treatment tank.
The acrylamide-based copolymer is preferably a copolymer of sodium acrylate and acrylamide dispersed in water, hereinafter referred to as "AMUSON 12". The ∓AMUSON 12 is capable of attaching to the "AMUSON " base and the "AMUSON 03" and the other above-noted contaminants in the treatment tank. The amount of "AMUSON 12" (also measured in ounces) which is to be added to the treatment tank should be from about 20% to about 45% of the amount of "AMUSON 03" added to the treatment tank, preferably from about 25% to about 40% of the amount of "AMUSON 03" added to the treatment tank, and most preferably, about 33% of the amount of "AMUSON 03" added to the treatment tank. The "AMUSON 12" is thoroughly premixed with water before being added to the treatment tank.
Once the three treating agents have been added to the treatment tank, the resulting treated waste water is thoroughly agitated for a period of from about 20 seconds to about one minute, preferably from about twenty seconds to about forty five seconds, and most preferably about thirty seconds. Following agitation, the flocculants or precipitates in the treatment tank are allowed to settle, preferably from about one hour to overnight. Following the settling step, the clean water is discharged. The clean water may be drained to the holding tank for reuse as rinse water, or it simply may be discharged into the municipal sewage system.
The residue and sludge remaining in the conical bottom of the treatment tank are collected, for instance by draining into a filter device, such as a filter-lined basket or similar container. The residue and sludge is dried, preferably by spreading the waste on a steel tray. Once a dried product has been obtained, it is collected and stored in any known manner, such as a bucket, barrel, or like container. At this point, the Small Quantity Generator has several alternatives; the Small Quantity Generator may store the dry product until he has accumulated a predetermined amount (for instance, about 100 lbs), the dry product may be disposed of immediately, for example in a landfill, or the dry product may be shipped for metal reclamation.
The following examples are illustrative of the present invention. Example 1 describes a preliminary test utilizing the "AMUSON" base without the use of the polyelectrolyte and the acrylamide-based copolymer.
EXAMPLE 1
Four hundred gallons of waste water, obtained from the cleaning of radiators, were transferred to a 450 gallon treatment tank. Analysis of the waste water determined that the waste water comprised approximately 200 ppm each of lead, zinc and copper and that the pH was 10.5. The treatment tank was agitated for five minutes. Five cups of "AMUSON" base, previously mixed in five gallons of water, were added to the treatment tank. The treated waste water was allowed to settle for four hours. Uncontaminated water (i.e. less than 1 ppm) was drained from the treatment tank. The remaining precipitates were filtered from the tank and dried. Analysis of this procedure determined that the resulting hazardous flock was very dust-like in texture and quite capable of reactivating in the clean water. The four hour waiting period was found to be too slow and costly.
EXAMPLE 2
Four hundred gallons of waste water having the same compositions and pH as above was transferred to the treatment tank. The waste water was agitated for five minutes. Five ounces of "AMUSON" base, previously mixed in five gallons of water, was added to the treatment tank. Five ounces of "AMUSON 03" previously mixed in water, was added to the treatment tank, followed by the addition of 1.67 ounces of "AMUSON 12" (also premixed in water).
The treated waste water was agitated approximately three minutes. Following agitation, the precipitates were allowed to settle for thirty minutes. Clean water (i.e. less than 1 ppm of each contaminant) was removed from the treatment tank, the remaining sludge was filtered and dried. Analysis of this procedure indicated that the addition of "AMUSON 03" and "AMUSON 12" resulted in the enlargement of the size of the flock, from that of a dust-like texture (in Example 1) to large dirt clogs having an average diameter of one-and-one-half (1.5) inches.
EXAMPLE 3
The radiator was placed in the boilout tank. The tank, containing water and an alkali mixture was heated to a temperature of about 200° C. The radiator was soaked for about one hour. A sludge was generated contaminated with lead, copper and zinc, as well as minor amounts of several other metals.
The radiator was transferred to an ultrasonic cleaner having transducers situated in the bottom of the tank. In operation, the transducers emit sound wave bubbles which implode upon contact with the radiator. The process cleaned the radiator down to the metal thereby generating a concentrated sludge.
Upon removal of the radiator from the ultrasonic cleaner, the radiator was rinsed in a pressure washer. Water was released from a 350 gallon holding tank. The flush and rinse water drained into a sump; the sludge accumulated in the sump area while a sump pump transported the water back to the holding tank for further use.
The cleaned radiator was then transferred to the work station for repairing. The radiator was sealed by lead soldering. Solder drippings accumulated in the sump area. The radiator was placed in the test tank to determine whether there were any leaks. Sludge resulting from the repair work was collected in the sump separator.
Contaminated rinse water from the holding tank was transferred to a 400 gallon treatment tank having a conical bottom mounted in a steel frame. To the waste water was added 1 gallon of boilout sludge, 1 gallon of ultrasonic cleaner sludge, 1 gallon of test tank sludge and 1 gallon of sump sludge, along with 1 gallon of spent coolant and 2 cups of glass bead dust. An analysis of the waste water determined that it was contaminated with the following metals: 52008.22 mg/1 lead, 2622.20 mg/1 copper, and 941.07 mg/1 zinc, as well as minor amounts of several other metals. The waste water was agitated for five minutes in the treatment tank.
The pH of the treatment tank was determined to be 14. Eight cups of "AMUSON" base were mixed with four gallons of water and added to the treatment tank. The tank was agitated for one minute and the pH was again measured. The pH was determined to be 7. Eight ounces of "AMUSON 03" were mixed with four gallons of water and added to the treatment tank. The tank was agitated for one minute. Three ounces of "AMUSON 12" were mixed with four gallons of water and added to the treatment tank, followed by two minutes of agitation. The precipitates were allowed to settle for approximately two hours.
The treated water was removed from the tank and analysis determined that the water contained 2.2 mg/1 copper, 8.22 mg/1 lead, and 1.07 mg/1 zinc. This clean water was recycled to the holding tank. The sludge remaining in the conical bottom of the tank was drained into a filter device. The sludge residue was then filtered and collected in a small, five-gallon bucket, spread onto a steel tray and dried. The sludge residue was left to dry overnight. Two and one-half gallons of dry product was collected.
In a variation of the present invention, the process and apparatus for treating waste water can be packaged in kit form. The kit package comprises chemical treating agents and storage means therefor; means for holding contaminated water, for example, a container or tank; means for combining said chemicals in the container, tank or other means of holding said contaminated water; and means for disposal of said contaminants, for instance, a small container. In a preferred embodiment of the variation of the present invention, the kit comprises (1) from about 100 to about 300 lbs of aluminum sulfate base, (2) from about 2 to about 10 quarts of an organic polyelectrolyte, and (3) from about one-half to about 4 quarts of a copolymer of sodium acrylate and acrylamide dispersed in mineral oil.
It is apparent that the sequential addition of the aluminum containing "AMUSON" base, the polyelectrolyte "AMUSON 03" and the acrylamide-based copolymer "AMUSON 12", coupled with vigorous agitation, results in the precipitation of large particles. These large particles, being heavier than the untreated contaminants, quickly settle to the conical bottom of the treatment tank, thereby affording the efficient separation of clean water from the treatment tank. The conical bottom of the treatment tank provides for the formation of a tight flock and also is very easy to clean.
While particular embodiments of the invention have been described, it will be understood, of course, that the invention is not limited thereto, and that many obvious modifications and variations thereof can be made, and that such modifications and variations are intended to fall within the scope of the appended claims. | The present invention relates to method and apparatus for treating waste water, particularly metal-containing waste water. The process includes separating and removing metals and other impurities from the waste water by the sequential addition of a base, a polyelectrolyte and an acrylamide-containing copolymer dispersion. The purified water is recycled for continuous reuse while the small quantities of metal-rich residue are available for reclamation. | 2 |
CROSS-REFERENCE TO PRIOR APPLICATIONS
[0001] This is a divisional of copending application Ser. No. 09/269,019, filed on Apr. 6, 1999, which was in turn a 35 USC 371 U.S. national stage application of international application number PCT/EP97/05079, filed on Sep. 17, 1997.
FIELD OF THE INVENTION
[0002] The present invention relates to the use of proteins extractable from animal organs, particularly from livers of mammals, for the preparation of medicaments active against autoimmune diseases, in particular activity against atherosclerosis, arthritis, multiple sclerosis, and diabetes.
BACKGROUND OF THE INVENTION
[0003] The administration of complete Freund's adjuvant has proved to be capable of inducing an experimental arthritis very similar to rheumatoid arthritis in rats. On the other hand, the administration of adjuvant to rabbits induces no arthritic pathology, but atherosclerosis. The studies carried out have evidenced that, in both lesions, immunoreactivity to an endogenous factor, which has been identified as the Heat Shock Protein 60 (HSP60), is present. Subsequent searches have confirmed these observations, proving that the administration of complete Freund's adjuvant can be replaced by the administration of HSP60, resulting in the same pathologies. Afterwards, pre-treatment of rat with adjuvant, HSP60 or fragments thereof has proved to prevent the onset of arthritis, with a still obscure mechanism, whereas the administration subsequent to the adjuvant worsens the progress of the disease.
[0004] More recently, pre-treatment with adjuvant has been found to also prevent other experimental pathologies which can be defined, generally speaking, as autoimmune disease, such as diabetes or experimental allergic encephalomyelitis (EAE). Finally, HSP60 has been found to have structural analogies to a high number of autoantigens, therefore it is assumed to be related to pathologies more widely than what up to now observed.
[0005] WO 92/10197 disclosed protein fractions extractable with perchloric acid from organs of mammals, and their use as anticancer agents. Within these fractions, three main components could be identified, having molecular weights 50, 14 and 10 KDa on gel electrophoresis. The purified extract containing these three components will be referred to as UK 101 in the following. The sequence of the 14 KDa protein component, which is the main, if not the only, responsible for the described activities, is reported in the Table hereinbelow and in WO 96/02567, and it has turned out to be related to that described by other authors (Levy-Pavatier, Eur. Biochem. 1903, 212 (3) 665-73) which have assumed that the novel identified sequences belong to the family of the proteins known as chaperoning, to which the HSPs themselves-belong.
SUMMARY OF THE INVENTION
[0006] The proteins described in WO 92/10197 and those of WO 96/02567 (in the following referred to as UK 114 ) show anyhow properties never observed for chaperonins or analogous proteins. More specifically, it has been found that said proteins can be used in the prevention and in the treatment of autoimmune diseases, in particular atherosclerotic conditions, such as the atherosclerosis induced by organ transplants, arthritis, multiple sclerosis, and diabetes.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The invention relates preferably to the use of the purified proteins UK 101 and UK 114 for the preparation of medicaments for the prevention and the treatment of autoimmune diseases such as atherosclerosis following organ transplants, arthritis, multiple sclerosis, diabetes.
[0008] Moreover the invention comprises the use of proteins showing a high homology degree to UK 114 , of at least 80%, preferably of at least 90%.
ANTIATHEROSCLEROTIC ACTIVITY
[0009] It has been ascertained that nowadays the more frequent cause of failure of organ transplants in time is no more the rejection, but the formation of atherosclerotic plaques at the contact point between the vases of the transplanted organ and those of the host. This pathology is worsened by the usual immunosuppressors such as cyclosporin, whereas the use of AZT, which is however very toxic, appears to be useful.
[0010] The activity of the proteins UK 101 and UK 114 has been evidenced using both a conventional atherosclerosis model, which is that of the rabbit pre-treated with complete Freund's adjuvant, and a transplant atherosclerosis model. In the first case, the subcutaneous treatment with adjuvant induces within 21 days the formation of atherosclerotic plaques at the iliac bifurcation and at the aortic arch. The pretreatment (7 days before) with UK 101 or UK 114 has significantly prevented the development of the pathology in a high percent of cases compared with the treatment with the only adjuvant, which has lead to the development of the disease in all of the animals.
[0011] On the other hand, the experimental model of transplant atherosclerosis consists in the venous by-passes at the level of arteries in the rat. After a short time, the formation of atherosclerotic plaques at the level of the host vase, as it happens in the human pathology, has been observed. The pre-treatment (7 days before) with UK 101 or UK 114 has significantly prevented the development of the pathology in a high percent of cases, compared with what observed in the animals non pre-treated before the transplant.
ANTIARTHRITIS ACTIVITY
[0012] This activity has been evidenced using a conventional arthritis model, which is the adjuvant-induced arthritis. In this model, Lewis rats are injected at the tail base with complete Freund's adjuvant: within 7 days, a pathology at the rear leg appears, characterized by swelling and joints alterations. The pathology reaches its peaks from the 14th to the 21st day, then decreasing until the leg returns to normal conditions. The pre-treatment (7 days before) with UK 101 or UK 114 has significantly prevented the development of the pathology in a high percent of cases compared with treatment with the only adjuvant, which has lead to the development of the pathology in 100% of the animals. The treatment with UK 101 or UK 114 after the administration of adjuvant has worsened the progress of the pathology.
[0013] Therefore, it is considered that UK 101 and UK 114 are capable of modifying the progress of or of preventing pathological conditions such as arthritis and rheumatoid arthritis.
ACTIVITY AGAINST MULTIPLE SCLEROSIS
[0014] This has been evidenced using a conventional multiple sclerosis model: the experimental allergic encephalomyelitis (EAE). The pathology is induced injecting subcutaneously Lewis rats with a Guinea-pig spinal cord homogenate together with complete Freund's adjuvant. The pathology appears as a progressive paralysis starting from the rear limbs, which begins at about the 12th day, reaches a maximum at about the 21st day and undergoes remission at about the 30th day from the administration of the immunogen. The pre-treatment (7 days before) with UK 101 or UK 114 has significantly prevented the development of the pathology in a high percent of cases and a less serious pathology has appeared, compared with treatment with the only marrow homogenate and adjuvant, which has lead to the development of the pathology in 100% of the animals.
[0015] Therefore UK 101 and UK 114 are believed to be able of changing the progress of or preventing pathological conditions such as multiple sclerosis.
ANTIDIABETIC ACTIVITY
[0016] This has been evidenced using a conventional diabetes model, represented by the BB rat which spontaneously develops diabetes around the 45th day of life. The animals have been treated at the 30th day of life with UK 101 or UK 114 and the development of the pathology has been observed, compared with untreated control animals. The pre-treatment has been found to decrease the incidence and the severity of the pathology in the experimental model. Some patients affected with tumors at different sites and also suffering from diabetes have been treated with UK 101 in the course of a compassionate treatment with the substance. All of the patients treated, independently of the effect on the tumor pathology, have shown a remission of the diabetic pathology going so far as to quit the insulin therapy.
[0017] Therefore UK 101 and UK 114 are believed to be capable of changing the course of diabetes or of preventing it.
[0018] The antidiabetic activity has in fact been confirmed, although up to now in a limited number of cases, also in vivo in patients suffering from diabetes.
Administration
[0019] The proteins of the invention can be administered using suitable formulations, mainly injectable.
[0020] The pattern of the administration (doses, frequency of administration, etc.) will be determined according to the circumstances, depending on factors such as conditions of the patient, phase of the disease, etc., but usually a daily dosage ranging from 1 to 100 mg will be suitable.
TABLE Met Ser Glu Asn Ser Glu Glu Pro Val Gly Glu Ala 1 5 10 Lys Ala Pro Ala Ala Ile Gly Pro Tyr Ser Gln Ala 15 20 Val Leu Val Asp Arg Thr Ile Tyr Tie Ser Gly Gln 25 30 35 Leu Gly Met Asp Pro Ala Ser Gly Gln Leu Val Pro 40 45 Gly Gly Val Val Glu Glu Ala Lys Gln Ala Leu Thr 50 55 60 Asn Ile Gly Glu Ile Leu Lys Ala Ala Gly Cys Asp 65 70 Phe Thr Asn Val Val Lys Ala Thr Val Leu Leu Ala 75 80 Asp Ile Asn Asp Phe Ser Ala Val Asn Asp Val Tyr 85 90 95 Lys Gln Tyr Phe Gln Ser Ser Phe Pro Ala Arg Ala 100 105 Ala Tyr Gln Val Ala Ala Leu Pro Lys Gly Gly Arg 110 115 120 Val Glu Ile Glu Ala Ile Ala Val Gln Gly Pro Leu 125 130 Thr Thr Ala Ser Val 135
[0021] [0021]
1
1
1
137
PRT
Unknown
Protein extracted with perchloric acid from
mammalian liver
1
Met Ser Glu Asn Ser Glu Glu Pro Val Gly Glu Ala Lys Ala Pro Ala
1 5 10 15
Ala Ile Gly Pro Tyr Ser Gln Ala Val Leu Val Asp Arg Thr Ile Tyr
20 25 30
Ile Ser Gly Gln Leu Gly Met Asp Pro Ala Ser Gly Gln Leu Val Pro
35 40 45
Gly Gly Val Val Glu Glu Ala Lys Gln Ala Leu Thr Asn Ile Gly Glu
50 55 60
Ile Leu Lys Ala Ala Gly Cys Asp Phe Thr Asn Val Val Lys Ala Thr
65 70 75 80
Val Leu Leu Ala Asp Ile Asn Asp Phe Ser Ala Val Asn Asp Val Tyr
85 90 95
Lys Gln Tyr Phe Gln Ser Ser Phe Pro Ala Arg Ala Ala Tyr Gln Val
100 105 110
Ala Ala Leu Pro Lys Gly Gly Arg Val Glu Ile Glu Ala Ile Ala Val
115 120 125
Gln Gly Pro Leu Thr Thr Ala Ser Val
130 135 | The use of proteins extracted with perchloric acid from animal organs, for the preparation of medicaments active against autoimmune diseases, in particular with activity against atheroscelerosis, arthritis, multiple sclerosis, and diabetes. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in receiving and control means for shuttles in looms, more particularly looms of the gripper shuttle type in which the shuttle is picked alternately from both sides of the loom. Each time that the shuttle is picked from one side of the loom it must be braked on the opposite side of the loom at a location within the shuttle receiving mechanism. The shuttle must then be precisely positioned at a predetermined location for a threading operation and for accurate picking out of the receiving mechanism. If the shuttle is not precisely positioned, the amount of force transmitted to the shuttle by the picking mechanism will vary and this will result in an inaccurate shuttle flight, which in some cases may be insufficient so that the shuttle will not make it all the way to the opposite side of the loom.
It has been known in the weaving art to positively position a shuttle which has been received into the shuttle box so that it is in a predetermined position for threading and picking. However, the mechanism for braking or checking the shuttle and for positioning the shuttle must be disengaged from the shuttle at the time of picking. Just prior to the time of picking, there exists a possibility of losing control of the shuttle whereby external forces may cause the shuttle to move out of the predetermined picking position. This problem is particularly acute in looms which operate with a shuttle box which is turned 180° after receiving the shuttle so that it can be picked out of the shuttle box to the opposite side of the loom. This type of loom is shown in the following U.S. patents to V. Svaty: No. 3,315,709 dated 25 Apr., 1967 and No. 3,330,305 dated 11 July, 1967 and No. 3,875,974 issued Apr. 8, 1975 to Rambousek. In the loom disclosed in these two U.S. patents, the gripper shuttle enters the shuttle box and is checked or braked. The filling which has been brought across the loom from the opposite side is disengaged and a new filling is inserted into the shuttle. The shuttle box is mounted on a turntable which is partially rotated after the new filling has been inserted into the shuttle box so that the shuttle is turned 180° so that the head of the shuttle points towards the end from which it came. At this point, the braking or checking mechanism is released from its checking function on the shuttle and the shuttle is propelled or picked out of the shuttle box. See, for example, the braking mechanism disclosed in the Svaty et al patent U.S. Pat. No. 3,487,860 dated 6 Jan., 1970. As is shown in this last patent, the braking pressure must be relieved before the shuttle is picked. It is at this point between the time the brake is released and before the shuttle is picked that there is a tendency for the shuttle to be moved out of position by the newly inserted filling which is under tension. Any slight movement of the shuttle at this point will pull it toward the shed away from the picking mechanism. This will result in a faulty pick.
The type of loom to which the present invention is applied further includes pneumatic means for picking the shuttle. The pneumatic means comprise a piston to which is attached a picking member which engages the end of the shuttle. If the shuttle is not properly positioned close to the end of the picking member, the end of the shuttle will be struck abruptly thereby producing a high initial acceleration which in turn causes the filling to break. In addition, there may be less than a full transfer of energy from the picking member to the shuttle so that the shuttle may not be picked entirely through the shed or boxed properly on the opposite side of the loom.
Further refinements to the loom disclosed in the above identified patents have included the addition of positioning mechanism which places the shuttle in the proper position after it has been checked. However, even this mechanism has to be disengaged from the shuttle before the shuttle is picked, thereby leaving the shuttle under the influence of the filling which has just been inserted into the shuttle.
SUMMARY OF THE INVENTION
It is the principle object of the present invention to overcome the disadvantages described above by providing control apparatus for looms operating with gripper shuttles in which the shuttle is braked or checked as it enters the shuttle box and positioned to the proper position for receiving a new filling and for picking. After the shuttle is positioned, the brake is released from its engagement with the shuttle to allow a shuttle box to be turned and the shuttle to be picked. The control means of the present invention comprises the addition of a restraining member within the shuttle box which exerts enough force to restrain the shuttle against sliding movement within the shuttle box in opposition to the tension of the newly inserted filling to maintain the shuttle in its proper position and yet which is sufficiently weak to allow the shuttle to be picked out of the shuttle box.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood from the detailed description when read together with the drawings in which:
FIG. 1 is fragmentary front elevation illustrating the shuttle control apparatus of the present invention as applied to a rotary shuttle box and showing the shuttle in the fully boxed position;
FIG. 2 is an end view looking in the direction of arrow 2 in FIG. 1, with portions broken away;
FIG. 3 is a plan view of the control apparatus shown in FIG. 1 prior to boxing of the shuttle;
FIG. 4 is a vertical section taken along line 4--4 of FIG. 3, looking in the direction of the arrows and showing the shuttle box and restraining means for the shuttle;
FIG. 5 is a fragmentary front elevation of the shuttle box with portions in section and illustrating the restraining means;
FIG. 6 is a front elevation of the gripper shuttle which is used with the present invention;
FIG. 7 is a horizontal section taken along line 7--7 of FIG. 1 of the shuttle braking member;
FIG. 8 is a vertical section of the shuttle taken along line 8--8 of FIG. 6 and looking in the direction of the arrows; and
FIG. 9 is a fragmentary view of the shuttle box after it has been rotated 180° with the shuttle in position for picking.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 6 and 8, the gripper shuttle which is used with the present invention is generally indicated by the reference numeral 10 and comprises a main body 12, a slanted first slide face 14 on the top, an oppositely slanted second slide face 16 on the bottom and a third slide face 18 at the back. The front portion of the shuttle 10 has a projection 20. The leading end 21 of the shuttle 10 is pointed and the trailing end 22 has a flat spring 23 which is urged against a clamping surface 24 for clamping a filling therebetween.
The means for receiving and controlling the shuttle 10 comprise a shuttle box generally indicated by the reference numeral 26, see particularly FIGS. 4 and 5. Shuttle box 26 comprises a generally flat front surface 28 which includes an elongated groove generally indicated at 30. Elongated groove 30 has a cross sectional configuration which is generally trapezoidal and comprises a back wall 32 forming the base of the trapezoid, upper and lower walls 34 and 36 which form the sides and which converge toward an opening 38 at the front surface 28. Groove 30 is designed for receiving the gripper shuttle 10 in a sliding fit whereby surfaces 14 and 16 of the shuttle slide on surfaces 34 and 36, respectively, of the groove and surface 18 slides on surface 32.
The shuttle receiving and control mechanism disclosed in the drawings is designed for application at the right hand side of the loom. It is to be understood that a similar mechanism will also be used at the left hand side of the loom but of opposite hand. Shuttle box 26 is rotatably mounted on a fixed structure 37. The loom to which the present invention is applied is shown in the above-identified U.S. patents. In the manner disclosed in these patents a shuttle 10 is picked to the left as viewed in FIG. 1, passes through the warp shed, enters the shuttle box on the opposite side of the loom, not shown, and is then picked in the opposite direction back into the shuttle box shown in FIG. 1. The leading end 21 of the shuttle enters the groove 30 of the shuttle box 26 with the trailing end 22 carrying the filling from the opposite side of the loom. This filling is then released and a new filling is inserted from the right side of the loom. The shuttle box 26 is rotated 180° so that the leading end 21 is now directed toward the left side of the loom. The shuttle 10 is then picked out of the shuttle box 26 towards the shuttle box located on the left side of the loom. The shuttle box 26 is thereafter rotated 180° in the opposite direction in readiness to receive the shuttle on its return flight from the left side of the loom.
Referring particularly to FIGS. 1, 2, 3 and 7, the mechanism for receiving and controlling the shuttle 10 comprises shuttle box 26 and a brake mechanism generally indicated by the reference numeral 39 and which includes a brake element 40 having a braking surface 41. Brake mechanism 39 is similar to and functions in the same manner as the brake mechanism disclosed in U.S. Pat. No. 3,875,974 to Rambousek, cited above. Brake element 40 is mounted on the upper end of a lever 42 which is mounted on a universal pivot 44 which permits movement of lever 42 toward and away from shuttle box 26 and also movement generally longitudinally of the groove 30. The lower end 46 of lever 42 has mounted thereon a follower 48 which rides in a groove 50 of a cam 52. Cam 52 is designed for moving brake mechanism 39 longitudinally of the groove 30. An intermediate lever 54 is also attached to the lower portion 46 of lever 42 and has attached thereto a follower 56. A cam 58 engages follower 56 and is effective to rock lever 42 so that brake element 40 moves toward and away from groove 30. A positioning element 60 is mounted on a lever 62 which also has controls similar to that of lever 42 for movement of positioning element 60 toward and away from the shuttle box 26 and also for movement generally longitudinally of the groove 30. This mechanism is not shown in complete detail, but it also has a lower cam follower indicated at 64 which rides in a groove 66 in cam 52. Lever 62 is also mounted in a universal pivot similar to pivot 44 so that it can also be moved toward and away from the shuttle box 26 by mechanism similar to lever 54, follower 56 and cam 58 which are used for controlling lever 42.
Referring particularly to FIGS. 3 and 7, brake element 40 is resiliently mounted in a housing 68 by means of springs 70. A lever 72 is pivotally mounted at 74 within housing 68. A spring 76 connects one end of lever 72 to one end of brake element 40. The opposite end of lever 72 contains a jaw 78 for a purpose to be described. A spring 80 maintains jaw 78 in an inactive position as shown in full lines in FIGS. 3 and 7. When the shuttle 10 approaches the shuttle box 26, brake element 40 is in its checking position adjacent the shuttle box as shown in FIG. 3. As the shuttle enters the box, projection 20 of the shuttle engages braking surface 41 of the brake which squeezes the shuttle against the back wall 32 of the shuttle box and thereby checks or brakes the shuttle. As the shuttle fully enters box 26 it strikes a portion 84 of braking surface 41 which tapers in toward groove 30 and causes the outer end of brake element 40 to be displaced within housing 68 to a greater extent than that of the opposite end of brake element 40 which is first engaged by the shuttle 10. The movement of the portion of brake element 40 which is adjacent surface portion 84 compresses spring 76 which in turn causes spring 80 to be compressed. This causes lever 72 to rock clockwise as viewed in FIG. 7 thereby causing jaw 78 to move toward the shuttle box to the dotted line position shown in FIGS. 3 and 7.
Shortly after the shuttle is braked, positioning element 60 is moved toward the left to the dotted line position as viewed in FIG. 3 and engages the end of projection 20 which is adjacent leading end 21 of the shuttle 10. Element 60 continues to move toward the left and pushes the shuttle 10 against surface 86 of jaw 78 thereby effectively clamping the shuttle between surface 86 and the inside surface 88 of positioning element 60. After the shuttle is so clamped, element 60 and jaw 78 are moved to the right as viewed in FIGS. 3 and 7 to position the shuttle to the proper threading and picking position. Details of the mechanism for positioning the shuttle have not been included in this application inasmuch as they are not novel to the present applicant. Details of the boxing of shuttles of the type shown in this application is illustrated and described in much more detail in U.S. Pat. No. 3,875,974. Therefore, further description of this mechanism and its operation is not necessary in this application and the text of said U.S. Patent is incorporated herein by reference. After the shuttle is so positioned, a lever 90, under the influence of a follower and cam, not shown, is moved toward the shuttle and engages spring 23 to release the filling which has just been carried through the shed from the opposite side of the loom. Subsequently, a new filling is inserted between clamping surface 24 and spring 23 by a threading member 97 in a manner fully disclosed in the patents identified above in the Background portion of this application. The shuttle box 26 is then rotated 180° to the position shown in FIG. 9 so that the leading end 21 of the shuttle is pointed toward the left hand side of the loom. During rotation of the shuttle, it is maintained in the proper position by stationary guideways 92 and 94. However, when it reaches the position shown in FIG. 9 the shuttle is free of guideways 92 and 94 to allow it to be picked by the picking member 95 out of the shuttle box to the other side of the loom. Prior to picking, brake element 40 is moved away from the shuttle box to allow the shuttle to be picked and since the shuttle is no longer guided in guideways 92 and 94 it is free to slide within groove 30. It is at this point that the newly threaded filling indicated at F which is under tension can shift the shuttle out of the proper picking position. The shuttle is maintained in the proper picking position by restraining means generally indicated by the reference numeral 96 located within shuttle box 26. The provision of restraining means 96 provides means for maintaining control over the position of the shuttle within the groove of the shuttle box when the checking and picking system releases the shuttle from its control. This provides a unique advantage over the mechanism of the patents referred to hereinabove in the Background section of this application. Restraining means 96 comprise an insert 98 located within a cavity 100 in upper surface 34. Insert 98 has a notch 102 formed by surfaces 104 and 106 which are, as shown in FIG. 4, contiguous with surfaces 32 and 34, respectively, of groove 30 when the shuttle 10 is located in the groove. A spring 108 located in cavity 100 urges insert 98 towards the lower surface 36 thereby exerting pressure on first slide face 14 of the shuttle when it is located within groove 30. This creates a slight drag on the shuttle 10 to restrain free-sliding motion of the shuttle within groove 30 and maintains the shuttle within the proper picking position just prior to picking. | In gripper shuttle looms for a shuttle box which contains a groove for receiving a gripper shuttle and which rotates 180° to turn the shuttle around and has a braking member which cooperates with the groove to check the shuttle in the groove, and wherein said braking member moves away from the groove to permit the shuttle box to be turned and the shuttle to be picked: restraining means located in the groove for restraining the shuttle against lateral movement along the longitudinal axis of the groove during the shuttle box turning motion and which maintains the shuttle in the proper position in the shuttle box and allows the shuttle to be picked out of the shuttle box. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to microprocessor-assisted musical instruments.
As microprocessors penetrate further into the marketplace, more products are appearing that enable people who have no formal training in music to actually produce music like a trained musician. Some instruments and devices that are appearing store the musical score in digital form and play it back in response to input signals generated by the user when the instrument is played. Since the music is stored in the instrument, the user need not have the ability to create the required notes of the melody but need only have the ability to recreate the rhythm of the particular song or music being played. These instruments and devices are making music mch more accessible to everybody.
Among the instruments that are available, there are a number of mechanical and electrical toy products that allow the player to step through the single tones of a melody. The simplest forms of this are little piano shaped toys that have one or a couple of keys which when depressed advance a melody by one note and sound the next tone in the melody which is encoded on a mechanical drum. The electrical version of this ability can be seen in some electronic keyboards that have a mode called "single key" play whereby a sequence of notes that the player has played and recorded on the keyboard can be "played" back by pushing the "single key play" button (on/off switch) sequentially with the rhythm of the single note melody. Each time the key is pressed, the next note in the melody is played.
There was an instrument called a "sequential drum" that behaved in a similar fashion. When the drum was struck a piezoelectric pickup created an on/off event which a computer registered and then used as a trigger to sound the next tone in a melodic note sequence.
There are also recordings that are made for a variety of music types where a single instrument or, more commonly, the vocal part of a song is omitted from the audio mix of an ensemble recording such as a rock band or orchestra. These recordings available on vinyl records, magnetic tape, and CDs have been the basis for the commercial products known as MusicMinusOne and for the very popular karoeke that originated in Japan.
SUMMARY OF THE INVENTION
In general, in one aspect, the invention features a virtual musical instrument including a multi-element actuator which generates a plurality of signals in response to being played by a user; an audio synthesizer which generates audio tones in response to control signals; a memory storing a musical score for the multi-element actuator; and a digital procesor receiving the plurality of signals from the multi-element actuator and generating a first set of control signals therefrom. The musical score includes a sequence of lead notes and an associated sequence of harmony note arrays, each harmony note array of the sequence corresponding to a different one of the lead notes and containing zero, one or more harmony notes. The digital processor is programmed to identify from among the sequence of lead notes in the stored musical score a lead note which corresponds to a first one of the plurality of signals. It is programmed to map a set of the remainder of the plurality of signals to whatever harmony notes are associated with the selected lead note, if any. And it is programmed to produce the first set of control signals from the identified lead note and the harmony notes to which the signals of the plurality of signals are mapped, the first set of control signals causing the synthesizer to generate sounds representing the identified lead note and the mapped harmony notes.
Preferred embodiments include the following features. The multi-element actuator is an electronic musical instrument, namely, a MIDI guitar, and the plurality of multi-element actuators includes strings on the guitar. The virtual musical instrument further includes a timer resource which generates a measure of elapsed time, wherein the stored musical score contains time information indicating when notes of the musical score can be played and wherein the digital processor identifies the lead note by using the timer resource to measure a time at which the first one of the plurality of signals occurred and then locating a lead note within the sequence of lead notes that corresponds to the measured time. The digital processor is further programmed to identify a member of the set of the remainder of the plurality of signals by using the timer resource to measure a time that has elapsed since a preceding signal of the plurality of signals occurred, by comparing the elapsed time to a preselected threshold, and if the elapsed time is less than the preselected threshold, by mapping the member of the set of the remainder of the plurality of signals to a note in the harmony array associated with the identified lead note. The digital processor is also programmed to map the member of the remainder of the plurality of signals to a next lead note if the elapsed time is greater than the preselected threshold.
In general, in another aspect, the invention featurs a virtual musical instrument including an actuator generating a signal in response to being activated by a user; an audio synthesizer; a memory storing a musical score for the actuator; a timer; and a digital processor receiving the signal from the actuator and generating a control signal therefrom. The stored musical score includes a sequence of notes partitioned into a sequence of frames, each frame of the sequence of frames containing a corresponding group of notes of the sequence of notes and wherein each frame of the sequence of frames has a time stamp identifying its time location within the musical score. The digital processor is programmed to use the timer to measure a time at which the signal is generated; it is programmed to identify a frame in the sequence of frames that corresponds to that measured time; it is programmed to select one member of the group of notes for the identified frame; and it is programmed to generate the control signal, wherein the control signal causes the synthesizer to generate a sound representing the selected member of the group of notes for the identified frame.
In preferred embodiments, the virtual musical instrument further includes an audio playback component for storing and playing back an audio track associated with the stored musical score. In addition, the digital processor is programmed to start both the timer and the audio playback component at the same time so that the identified frame is synchronized with the playback of the audio track. The audio track omits a music track, the omitted music track being the musical score for the actuator. The virtual musical instrument also includes a video playback component for storing and playing back a video track associated with the stored musical score. The digital processor starts both the timer and the video playback component at the same time so that the identified frame is synchronized with the playback of the video track.
In general, in yet another aspect, the invention features a control device including a medium containing stored digital information, the stored digital information including a musical score for the virtual instrument previously described and wherein the musical score is partitioned into a sequence of frames.
In general, in still another aspect, the invention features a method for producing a digital data file for a musical score. The method includes the steps of generating a digital data sequence corresponding to the notes in the musical score; partitioning the data sequence into a sequence of frames, some of which contain more than one note of the musical score; assigning a time stamp to each of the frames, the time stamp for any given frame representing a time at which that frame occurs in the musical score; and storing the sequence of frames along with the associated time stamps on a machine readable medium.
In preferred embodiments, the time stamp for each of the frames includes a start time for that frame and an end time for that frame. The musical score includes chords and the step of generating a digital data sequence includes producing a sequence of lead notes and a corresponding sequence of harmony note arrays, each of the harmony note arrays corresponding to a different one of the lead notes in the sequence of lead notes and each of the harmony note arrays containing the other notes of any chord to which that lead note belongs.
One advantage of the invention is that, since the melody notes are stored in a data file, the player of the virtual instrument need not know how to create the notes of the song. The player can produce the required sounds simply by generating activation signals with the instrument. The invention has the further advantage that it assures that the player of the virtual instrument will keep up with the song but yet gives the player substantial latitude in generating the music within predefined frames of the musical score. In addition, the invention enables user to produce one or more notes of a chord based on the number of strings (in the case of a guitar) that he strikes or strums. Thus, even though the actual musical core may call for a chord at a particular place in the song, the player of the musical instrument can decide to generate less than all of the notes of that chord.
Other advantages and features will become apparent from the following description of the preferred embodiment, and from the claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of the virtual music system;
FIG. 2 is a block diagram of the audio processing plug-in board shown in FIG. 1;
FIG. 3 illustrates the partitioning of a hypothetical musical score into frames;
FIG. 4 shows the sframes[], lnotearray[], and hnotesarray[] data structures and their relationship to one another;
FIG. 5 shows a pseudocode representation of the main program loop;
FIG. 6 shows a pseudocode representation of the playsong() routine that is called by the main program lop;
FIGS. 7A and 7B show a pseudocode representation of the virtualguitarcallback() interrupt routine that is installed during initialization of the system;
FIG. 8 shows the syncframe data structure;
FIG. 9 shows the lead note data structure; and
FIG. 10 shows the harmonynotes data structure;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a virtual music system constructed in accordance with the invention includes among its basic components a Personal Computer (PC) 2; a virtual instrument, which in the described embodiment is a MIDI guitar 4; and a CD-ROM player 6. Under control of PC 2, CD-ROM player 6 plays back an interleaved digital audio and video recording of a song that a user has selected as the music that he also wishes to play on guitar 4. Stored in PC 2 is a song data file (not shown in FIG. 1) that contains a musical score that is to be played by MIDI guitar 4. It is, of course, for the guitar track of the same song that is being played on CD-ROM player 6.
MIDI guitar 4 is a commercially available instrument that includes a multi-element actuator, referred to more commonly as a set of strings 9, and a tremelo bar 11. Musical Instrument digital Interface (MIDI) refers to a well known standard of operational codes for the real time interchange of music data. It is a serial protocol that is a superset of RS-232. When an element of the multi-element actuator (i.e., a string) is struck, guitar 4 generates a set of digital opcodes describing that event. Similarly, when tremelo bar 11 is used, guitar 4 generates an opcode describing that event. As the user plays guitar 4, it generates a serial data stream of such "events" (i.e., string activations and tremelo events) that are sent to PC 2 which uses them to access and thereby play back the relevant portions of the stored song in PC 2. PC 2 mixes the guitar music with the audio track from CD-ROM player and plays the resulting music through a set of stereo speakers 8 while at the same time displaying the accompanying video image on a video monitor 10 that is connected to PC 2.
PC 2, which includes a 80486 processor, 16 megabytes of RAM, and 1 gigabyte of hard disk storage 9, uses a Microsoft™ Windows 3.1 Operating System. It is equipped with several plug-in boards. There is an audio processing plug-in board 12 (also shown in FIG. 2) which has a built in programmable MIDI synthesizer 22 (e.g. a Proteus synthesis chip) and a digitally programmable analog 2 channel mixer 24. There is also a video decompression/accelerator board 14 running under Microsoft's VideoForWindows™ product for creating full-screen, full motion video from the video signal coming from CD-ROM player 6. And there is a MIDI interface card 16 to which MIDI guitar 4 is connected through a MIDI cable 18. PC 2 also includes a programmable timer chip 20 that updates a clock register every millisecond.
On audio processing plug-in board 12, Proteus synthesis chip 22 synthesizes tones of specified pitch and timbre in response to a serial data stream that is generated by MIDI guitar 4 when it is played. The synthesis chip includes a digital command interface that is programmable from an application program running under Windows 3.1. The digital command interface receives MIDI formatted data that indicate what notes to play at what velocity (i.e., volume). It interprets the data that it receives and causes the synthesizer to generate the appropriate notes having the appropriate volume. Analog mixer 24 mixes audio inputs from CD-ROM player 9 with the Proteus chip generated waveforms to create a mixed stereo output signal that is sent to speakers 8. Video decompression/accelerator board 14 handles the accessing and display of the video image that is stored on a CD-ROM disc along with a synchronized audio track. MIDI interface card 16 processes the signal from MIDI guitar 4.
When MIDI guitar 4 is played, it generates a serial stream of data that identifies what string was struck and with what force. This serial stream of data passes over cable 18 to MIDI interface card 16, which registers the data chunks and creates interrupts to the 80486. The MIDI Interface card's device driver code which is called as part of the 80486's interrupt service, reads the MIDI Interface card's registers and puts the MIDI data in an application program accessible buffer.
MIDI guitar 4 generates the following type of data. When a string is struck after being motionless for some time, a processor within MIDI guitar 4 generates a packet of MIDI formatted data containing the following opcodes:
MIDI STATUS=On
MIDI NOTE=<note number)
MIDI VELOCITY=<amplitude>
The <note number> identifies which string was activated and the <amplitude> is a measure of the force with which the string was struck. When the plucked string's vibration decays to a certain minimum, then MIDI guitar 4 sends another MIDI data packet:
MIDI STATUS=Off
MIDI NOTE=<note number)
MIDI VELOCITY=0
This indicates that the tone that is being generated for the string identified by <note number> should be turned off.
If the string is struck before its vibration has decayed to the certain minimum, MIDI guitar 4 generates two packets, the first turning off the previous note for that string and the second turning on a new note for the string.
The CD-ROM disc that is played on player 6 contains an interleaved and synchronized video and audio file of music which the guitar player wishes to play. The video track could, for example, show a band playing the music, and the audio track would then contain the audio mix for that band with the guitar track omitted. The VideoForWindows product that runs under Windows 3.1 has an API (Application Program Interface) that enables the user to initiate and control the running of these Video-audio files from a C program.
The pseudocode for the main loop of the control program is shown in FIG. 5. The main program begins execution by first performing system initialization (step 100) and then calling a registermidicallback() routine that installs a new interrupt service routine for the MIDI interface card (step 102). The installed interrupt service effectively "creates" the virtual guitar. The program then enters a while-loop (step 104) in which it first asks the user to identify the song which will be played (step 106). It does this by calling a getsongidfromuser() routine. After the user makes his selection using for example a keyboard 26 (see FIG. 1) to select among a set of choices that are displayed on video monitor 10, the user's selection is stored in a songid variable that will be used as the argument of the next three routines which the main loop calls. Prior to beginning the song, the program calls a setupdatastructures() routine that sets up the data structures to hold the contents of the song data file that was selected (step 108). The three data structures that will hod the song data are sframes[], lnotearray[], and hnotesarray[].
During this phase of operation, the program also sets up a timer resource on the PC that maintains a clock variable that is incremented every millisecond and it resets the millisecond clock variable to 0. As will become more apparent in the following description, the clock variable serves to determine the user's general location within the song and thereby identify which notes the user will be permitted to activate through his instrument. The program also sets both a current frame idx variable and a current lead note idx variable to 0. The current frame idx variable, which is used by the installed interrupt routine, identifies the frame of the song that is currently being played. The current lead note idx variable identifies the particular note within the leadnote array that is played in response to a next activation signal from the user.
Next, the program calls another routine, namely, initialize data structures(), that retrieves a stored file image of the Virtual Guitar data for the chosen song from the hard disk and loads that data into the three previously mentioned arrays (step 110). After the data structures have been initialized, the program calls a playsong() routine that causes PC 2 to play the selected song (step 112).
Referring to FIG. 6, when playsong() is called, it first instructs the user graphically that it is about to start the song (optional) (step 130). Next, it calls another routine, namely, wait for user start signal(), which forces a pause until the user supplies a command which starts the song (step 132). As soon as the user supplies the start command, the playsong routine starts the simultaneous playback of the stored accompaniment, i.e., the synchronized audio and video tracks on CD-ROM player 6 (step 134). In the described embodiment, this is an interleaved audio/video (.avi) file that is stored on a CD-ROM. It could, of course, be available in a number of different forms including, for example, a .WAV digitized audio file or a Red Book Audio track on the CD-ROM peripheral.
Since the routines are "synchronous" (i.e. do not return until playback is complete), the program waits for the return of the Windows Operating System call to initiate these playbacks. Once the playback has been started, every time a MIDI event occurs on the MIDI guitar (i.e., each time a string is struck), the installed MIDI interrupt service routine processes that event. In general, the interrupt service routine calculates what virtual guitar action the real MIDI guitar event maps to.
Before examining in greater detail the data structures that are set up during initialization, it is useful first to describe the 'song data file and how it is organized. The song data file contains all of the notes of the guitar track in the sequence in which they are to be played. As illustrated by FIG. 3, which shows a short segment of a hypothetical score, the song data is partitioned into a sequence of frames 200, each one typically containing more than one and frequently many notes or chords of the song. Each frame has a start time and an end time, which locate the frame within the music that will be played. The start time of any given frame is equal to the end time of the previous frame plus 1 millisecond. In FIG. 3, the first frame extends from time 0 to time 6210 (i.e., 0 to 6.21 seconds) and the next frame extends from 6211 to 13230 (i.e., 6.211 to 13.23 seconds). The remainder of the song data file is organized in a similar manner.
In accordance with the invention, the guitar player is able to "play" or generate only those notes that are within the "current" frame. The current frame is that frame whose start time and end time brackets the current time, i.e., the time that has elapsed since the song began. Within the current frame, the guitar player can play any number of the notes that are present but only in the order in which they appear in the frame. The pace at which they are played or generated within the time period associated with the current frame is completely determined by the user. In addition, the user by controlling the number of string activations also controls both the number of notes of a chord that are generated and the number of notes within the frame that actually get generated. Thus, for example, the player can play any desired number of notes of a chord in a frame by activating only that number of strings, i.e., by strumming the guitar. If the player does not play the guitar during a period associated with a given frame, then none of the music within that frame will be generated. The next time the user strikes or activates a string, then the notes of a later frame, i.e., the new current frame, will be generated.
Note that the pitch of the sound that is generated is determined solely by information that is stored the data structures containing the song data. The guitar player needs only activate the strings. The frequency at which the string vibrates has no effect on the sound generated by the virtual music system. That is, the player need not fret the strings while paying in order to produce the appropriate sounds.
It should be noted that the decision about where to place the frame boundaries within the song image is a somewhat subjective decision, which depends upon the desired sound effect and flexibility that is given to the user. There are undoubtedly many ways to make these decisions. Chord changes could, for example, be used as a guide for where to place frame boundaries. Much of the choice should be left to the discretion of the music arranger who builds the database. As a rule of thumb, however, the frames should probably not be so long that the music when played with the virtual instrument can get far out of alignment with the accompaniment and they should not be so short that the performer has no real flexibility to modify or experiment with the music within a frame.
For the described embodiment, an ASCI editor was used to create a text based file containing the song data. Generation of the song data file can, of course, be done in many other ways. For example, one could produce the song data file by first capturing the song information off of a MIDI instrument that is being played and later add frame delimiters in to that set of data.
With this overview in mind, we now turn to a description of the previously mentioned data structures, which are shown in FIG. 4. The sframes[] array 200, which represents the sequence of frames for the entire song, is an array of synchframe data structures, one of which is shown in FIG. 8. Each synchframe data structure contains a frame start time variable that identifies the start time for the frame, a frame end time variable that identifies the end time of the frame and a lnote idx variable that provides an index into both a lnotearray[] data structure 220 and an hnotesarray[] data structure 240.
The lnotearray[] 220 is an array of leadnote data structures, one of which is shown in FIG. 9. The lnotearray[] 220 represents a sequence of single notes (referred to as "lead notes") for the entire song in the order in which they are played. Each lead note data structure represents a singly lead note and contains two entries, namely, a lead note variable that identifies the pitch of the corresponding lead note, and a time variable, which precisely locates the time at which the note is supposed to be played in the song. If a single note is to be played at some given time, then that note is the lead note. If a chord is to be played at some given time, then the lead note is one of the notes of that chord and hnotearray[] data structure 240 identifies the other notes of the chord. Any convention can be used to select which note of the chord will be the lead note. In the described embodiment, the lead note is the chord note with the highest pitch.
The hnotearray[] data structure 240 is an array of harmonynote data structures, one of which is shown in FIG. 10. The lnote idx variable is an index into this array. Each harmonynote data structure contains an hnotecnt variable and an hnotes[] array of size 10. The hnotes[] array specifies the other notes that are to be played with the corresponding lead note, i.e., the other notes in the chord. If the lead note is not part of a chord, the hnotes[] array is empty (i.e., its entries are all set to NULL). The hnote cnt variable identifies the number of non-null entries in the associated hnotes[] array. Thus, for example, if a single note is to be played (i.e., it s not part of a chord), the hnotecnt variable in the harmonynote data structure for that lead note will be set equal to zero and all of the entries of the associated hnotes[] array will be set to NULL.
As the player hits strings on the virtual guitar, the Callback routine which will be described in greater detail in next section is called for each event. After computing the harmonic frame, chord index and sub-chord index, this callback routine instructs the Proteus Synthesis chip in PC , to create a tone of the pitch that corresponds to the given frame, chord, sub-chord index. The volume of that tone will be based on the MIDI velocity parameter received with the note data from the MIDI guitar.
Virtual Instrument Mapping
FIGS. 7A and 7B show pseudocode for the MIDI interrupt callback routine, i.e., virtualguitarcallback(). When invoked the routine invokes a getcurrenttime() routine which uses the timer resource to obtain the current time (step 200). It also calls another routine, i.e., getguitarstringevent(&stringid, &stringvelocity), to identify the event that was generated by the MIDI guitar (step 202). This returns the following information: (1) the type of event (i.e., ON, OFF, or TREMELO control); (2) on which string the event occurred (i.e. stringid); and (3) if an ON event, with what velocity the string was struck (i.e. stringvelocity).
The interrupt routine contains a switch instruction which runs the code that is appropriate for the event that was generated (step 204). In general, the interrupt handler maps the MIDI guitar events to the tone generation of the Proteus Synthesis chip. Generally, the logic can be summarized as follows:
If an ON STRING EVENT has occurred, the program checks whether the current time matches the current frame (210). This is done by checking the timer resource to determine how much time on the millisecond clock has elapsed since the start of the playback of the Video/Audio file. As noted above, each frame is defined as having a start time and an end time. If the elapsed time since the start of playback falls between these two times for a particular frame then that frame is the correct frame for the given time (i.e., it is the current frame). If the elapsed time falls outside of the time period of a selected frame, then it is not the current frame but some later frame is.
If the current time does not match the current frame, then the routine moves to the correct frame by setting a frame variable i.e., currentframeidx, to the number of the frame whose start and end times bracket the
current time (step 212). The current frame idx variable serves as an index into the sframearray. Since no notes of the new frame have yet been generated, the event which is being processed maps to the first lead note in the new frame. Thus, the routine gets the first lead note of that new frame and instructs the synthesizer chip to generate the corresponding sound (step 214). The routine which performs this function is starttonegen() in FIG. 7A and its arguments include the stringvelocity and stringid from the MIDI formatted data as well as the identity of the note from the lnotesarray. Before exiting the switch statement, the program sets the currentleadnoteidx to identify the current lead note (step 215) and it initializes an hnotesplayed variable to zero (step 216). The hnotesplayed variable determines which note of a chord is to be generated in response to a next event that occurs sufficiently close in time to the last event to qualify as being part of a chord.
In the case that the frame identified by the currentframeidx variable is not the current frame (step 218), then the interrupt routine checks whether a computed difference between the current time and the time of the last ON event, as recorded in a lasttime variable, is greater than a preselected threshold as specified by a SIMULTANTHRESHOLD variable (steps 220 and 222). In the described embodiment, the preselected time is set to be of sufficient length (e.g. on the order of about 20 milliseconds) so as to distinguish between events within a chord (i.e., approximately simultaneous events) and events that are part of different chords.
If the computed time difference is shorter than the preselected threshold, the string ON event is treated as part of a "strum" or "simultaneous" grouping that includes the last lead note that was used. In this case, the interrupt routine, using the lnoteidx index, finds the appropriate block in the harmonynotes array and, using the value of the hnotesplayed variable, finds the relevant entry in hnotes array of that block. It then passes the following information to the synthesizer (step 224):
stringvelocity
stringid
hnotesarray[currentleadnoteidx].hnotes[hnotesplayed++]
which causes the synthesizer to generate the appropriate sound for that harmony note. Note that the hnotesplayed variable is also incremented so that the next ON event, assuming it occurs within a preselected time of the last ON event, accesses the next note in the hnote[] array.
If the computed time difference is longer than the preselected threshold, the string event is not treated as part of a chord which contained the previous ON event; rather it is mapped to the next lead note in the lead note array. The interrupt routine sets the current lead note idx index to the next lead note in the leadnote array and starts the generation of that tone (step 226). It also resets the hnotesplayed variable to 0 in preparation for accessing the harmony notes associated with that lead note, if any (step 228).
If the MIDI guitar event is an OFF STRING EVENT, then the interrupt routine calls an unsoundnote() routine which turns off the sound generation for that string (step 230). It obtains the stringid from the MIDI event packet reporting the OFF event and passes this to the unsoundnote() routine. The unsound note routine then looks up what tone is being generated for the ON Event that must have preceded this OFF event on the identified string and turns off the tone generation for that string.
If the MIDI guitar event is a TREMELO event, the tremelo information from the MIDI guitar gets passed directly to synthesizer chip which produces the appropriate tremelo (step 232).
Having thus described illustrative embodiments of the invention, it will be apparent that various alterations, modifications and improvements will readily occur to those skilled in the art. Such obvious alterations, modifications and improvements, though not expressly described above, are nonetheless intended to be implied and are within the spirit and scope of the invention. Accordingly, the foregoing discussion is intended to be illustrative only, and not limiting; the invention is limited and defined only by the following claims and equivalents thereto. | A virtual musical instrument including a multielement actuator which generates a plurality of signals in response to being played by a user; an audio synthesizer which generates audio tones in response to control signals; a memory storing a musical score for the multi-element actuator, the stored musical score including a sequence of lead notes and an associated sequence of harmony note arrays, each harmony note array of the sequence corresponding to a different one of the lead notes and containing zero, one or more harmony notes. The instrument also includes a digital processor receiving the plurality of signals from the multi-element actuator and generating a first set of control signals therefrom, the digital processor programmed to identify from among the sequence of lead notes in the stored musical score a lead note which corresponds to a first one of the plurality of signals, the digital processor programmed to map a set of the remainder of the plurality of signals to whatever harmony notes are associated with the selected lead note, if any,; and the digital processor programmed to produce the first set of control signals from the identified lead note and the harmony notes to which the signals of the plurality of signals are mapped, the first set of control signals causing the synthesizer to generate sounds representing the identified lead note and the mapped harmony notes. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE
[0001] This application makes reference to, claims priority to, and claims the benefit of U.S. Provisional Application Ser. No. 60/542,945, entitled “Method for 3D Comb Synchronization and Alignment of Standard and Non-Standard Video Signals,” filed on Feb. 9, 2004.
[0002] This application makes reference to U.S. application Ser. No. (Attorney Docket No. 15500US02) filed on Jun. 24, 2004.
[0003] The above stated applications are hereby incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0004] Certain embodiments of the invention relate to processing of video signals. More specifically, certain embodiments of the invention relate to a method and system for 3D comb synchronization and alignment of standard and non-standard video signals.
BACKGROUND OF THE INVENTION
[0005] In video system applications, a picture is displayed on a television or computer screen by scanning an electrical signal horizontally across the screen one line at a time. The amplitude of the signal at any one point on the line represents the brightness level at that point on the screen. A video frame contains the necessary information from the lines that make up the picture and from the associated synchronization (sync) signals to allow a scanning circuit to trace the lines from left to right and from top to bottom in order to recreate the picture on the screen. This information includes the luma (Y), or brightness, and the chroma (C), or color, components of the picture. There may be two different types of picture scanning in a video system. The scanning may be interlaced or it may be non-interlaced or progressive. Interlaced scanning occurs when each frame is divided into two separate sub-pictures or fields. The interlaced picture may be produced by first scanning the horizontal lines that correspond to the first field and then retracing to the top of the screen and scanning the horizontal lines that correspond to the second field. The progressive or non-interlaced picture may be produced by scanning all of the horizontal lines of a frame in one pass from the top to the bottom of the screen.
[0006] The luma (Y) and chroma (C) signal components that represent a picture are modulated together in order to generate a composite video signal. Integrating the luma and chroma video elements into a composite video stream facilitates video signal processing since only a single composite video stream is transmitted. Once a composite signal is received, the luma and chroma signal components must be separated in order for the video signal to be processed and displayed as a picture on the screen. A comb filter may be utilized for separating the luma and chroma video signal components. For example, a television may be adapted to receive a composite video input but the chroma and luma video components have to be separated before the television can display the received video signal.
[0007] FIG. 1A is a diagram illustrating the generation of a conventional composite video signal. Referring to FIG. 1A , adding the chroma signal component 102 and the luma signal component 104 produces a composite video signal 106 . The luma signal component 104 may or may not increase in amplitude in a stair step fashion. The chroma signal component 102 may comprise a color difference component U that is modulated by, for example, a sine signal with a 3.58 MHz frequency, and a color difference component V that is modulated by, for example, a cosine signal with a 3.58 MHz frequency. The modulation scheme may be selected so that it provides quadrature modulation between the U and V color difference components. An exemplary composite video signal 106 may be a composite video signal with burst and syncs (CVBS).
[0008] FIG. 1B is a diagram illustrating the position of color burst and active video in a conventional composite video signal. Referring to FIG. 1B , a portion of the composite video signal 108 may be a color burst 110 and a different portion may be the active video signal 112 . The color burst 110 may comprise a brief sample of, for example, eight to ten cycles of unmodulated color subcarrier which have been inserted by an NTSC or PAL encoder onto the back porch of the composite video signal to enable a decoder to regenerate the color subcarrier from it. The active video portion 112 of the composite video signal 108 contains the luma and chroma signal components of the picture or image.
[0009] FIG. 1C is a graphical diagram illustrating the phase relationship of modulated chroma signals in contiguous composite video signal frames. The chroma signal component in the active video portion of an NTSC composite video signal may modulated at such a frequency that every line of video in a video frame is phase-shifted by 180 degrees from the previous line. Referring to FIG. 1C , the bottom frame, the current frame, and the top frame are contiguous composite video frames and the (M−1) video line, the M video line, and the (M+1) video lines are contiguous video lines within the video frame, where M corresponds to any current line which may have a previous line and a next line adjacent to it. The “bottom frame” may correspond to the frame that is currently being received while the “current frame” and the “top frame” may correspond to frames that have been delayed by one and two frames respectively. The M video line in the “current frame” is phase-shifted by 180 degrees from the (M−1) video line in the “current frame” as well as from the (M+1) video line in the “current frame.” Similarly, the M video line in the “bottom frame” is phase-shifted by 180 degrees from the (M−1) video line in the “bottom frame” as well as from the (M+1) video line in the “bottom frame.” In addition, since the fields are at a frequency rate of 59.94 Hz, there is a 180-degree phase shift between two adjacent frames, for example, the “current frame” and the “top frame.” Correspondingly, the M video line in the “current frame” is 180 degrees phase-shifted from the M video line in the “top frame.” In a PAL composite video signal, adjacent video lines and adjacent frames may have a 90-degree phase shift, requiring a two line or two frame delay in order to obtain video lines or frames with a 180-degree phase shift.
[0010] In conventional video processing, there are three ways to separate the luma and chroma video components received in a composite video signal—by utilizing a notch filter, by combing vertically or by combing temporally. During separation of the luma and chroma signal components, there are three bandwidth directions that may incur losses in the separation process and in the separated signal. Depending on the combing method that is utilized, the separated signal may have reduced vertical bandwidth, horizontal bandwidth, and/or temporal bandwidth.
[0011] The first way to separate the luma and chroma video components is by utilizing a notch filter. Since the components in a chroma signal are modulated at 3.58 MHz, a notch filter that is set at 3.58 MHz may be utilized. The notch filter, however, reduces the horizontal bandwidth in the output video signal and as a result the luma video component is increased. A comb filter delays a prior horizontally scanned line in order it compare it with a currently scanned horizontal line. Combing vertically may also be utilized to separate the luma and chroma video components. Combing vertically may be achieved in three different ways—the current line may be combed with the previous and the next line, the current line may be combed with the line just before it, or the current line may be combed with the line just after it. The vertical combing is performed spatially, i.e., only within two fields at a time and without any temporal combing. During combing in the “current frame,” for example, if the current line is added to the previous line, the chroma content cancels out and two times the luma content is obtained. On the other hand, if the previous line is subtracted from the current line, the luma content cancels out and two times the chroma content is obtained. In this way, luma and chroma content may be separated from the composite video signal for further processing. In addition, the vertical combing results in a reduced vertical bandwidth.
[0012] A third way to comb a composite signal is to comb temporally. Combing temporally comprises combing between two adjacent or contiguous frames, for example, the “current frame” and the “bottom frame” or the “current frame” and the “top frame.” Further, temporal combing is characterized by a reduced temporal bandwidth. The luma and chroma components may be separated by utilizing the same addition and subtraction methodology between a current line and a previous line, which is employed by vertical combing.
[0013] While 2-D comb filters may be adapted to process successive scan lines for a single field of a video frame, 3-D comb filters may be adapted to process scan lines that are taken from successive video frames. In general, for 3-D comb filtering, if there is motion between the successive video frames, a 3-D comb filter must revert to 2-D comb filtering. Motion includes color changes and image movement between frames. Accordingly, the 3-D comb filter may be required to buffer at least one frame in order to determine whether there is motion between the buffered frames. In an instance where there are color changes or image movements between the buffered frames, the corresponding Y/C components for the buffered frames will be different and the results of combing would be incorrect.
[0014] Since the 3-D comb filter may be required to buffer at least one frame of video data, several complete frames of video data must be stored in buffers as opposed to just 2 or 3 lines which are required by 2-D comb filters. Accordingly, 3-D comb filters require a large or significant amount of video memory and excessive memory processing bandwidth requirements. This large memory and excessive memory processing bandwidth requirements, along with the necessary motion detection processing, increases the cost associated with 3-D comb filter solutions.
[0015] Three-dimensional (3D) combing algorithms typically operate on video samples that are temporally separated by a video frame, for example, the bottom frame, the current frame, and the top frame in FIG. 1C . These temporally separated video samples or video frames must be exactly aligned in order to prevent the formation of artifacts in the displayed picture due to misalignment. Alignment of the temporally separated video frames is generally achieved by delaying the frames. The amount of the delay required to align these frames generally varies depending on the video processing standard and/or processing scheme employed. For example, the amount of delay system required for NTSC and PAL standards and for progressive scan input video may vary between the standards. Furthermore, although some signals may conform in some respects to a particular standard, these signals may vary outside the specified ranges permitted by the particular standard. These signals that vary outside the specified ranges permitted by the standard may be referred to as non-standard signals. For example, a non-standard signal, which may be part of a data stream, may have frame lengths that vary outside the ranges permitted by a specific standard or these signals in the data stream may violate the relationship between a specified line length and the subcarrier frequency.
[0016] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with some aspects of the present invention as set forth in the remainder of the present application with reference to the drawings.
BRIEF SUMMARY OF THE INVENTION
[0017] Certain embodiments of the invention may be found in a method and system for 3D comb synchronization and alignment of standard and non-standard video signals. Aspects of the method comprise coarsely synchronizing and finely aligning a bottom frame, a current frame, and a top frame for video combing. A plurality of bottom frames may be stored prior to coarse synchronization. The stored bottom frames may be standard video frames, non-standard video frames, or compressed video frames. Each field in the bottom frames may be labeled with a bottom frame field count value when a bottom frame vertical sync signal is asserted and with an indication of the location of the bottom frame vertical sync signal. The bottom frame field count may be a modulo N count that is incremented with each assertion of the bottom frame vertical sync signal. The modulo number N may be larger than the total number of fields that may be assigned to the current frame and to the top frame.
[0018] The current frame may be assigned a first frame transferred immediately prior to a bottom frame or a first field and a second field transferred immediately prior to the bottom frame. The current frame and the bottom frame may be locked, or coarsely synchronized, when the bottom frame vertical sync signal occurs within a current frame window signal. The top frame may be assigned a frame transferred two frames prior to the bottom frame or a third field and a fourth field transferred prior to the bottom frame. The top frame and the bottom frame may be locked, or coarsely synchronized, when the bottom frame vertical sync signal occurs within a top frame window signal. Coarse synchronization may result in at least two frames being synchronized to within one subcarrier period. The bottom frame starting field may be utilized as a reference to determine the video fields that may be assigned to the current frame, the top frame, and the bottom frame.
[0019] Fine alignment between the current frame and the bottom frame may comprise correlating a phase difference between a subcarrier signal in the coarsely synchronized current frame and a subcarrier signal in the bottom frame and modifying the phase difference between the frames until the correlation results in a specified phase lock value range. Similarly, fine alignment between the current frame and the top frame may comprise correlating a phase difference between a subcarrier signal in the coarsely synchronized current frame and a subcarrier signal in the coarsely synchronized top frame and modifying the phase difference between the frames until the correlation results in a specified phase lock value range. The specified phase lock value range may correspond to the level of alignment accuracy that may be achieved. The fine frame alignment may result in the addition or removal of an integer sample delay when an integer sample delay slip occurs.
[0020] Aspects of system for synchronization and alignment of standard and non-standard video signals comprise a coarse frame synchronizer that coarsely synchronizes and a fine frame aligner that finely aligns a bottom frame, a current frame, and a top frame for video combing. A plurality of bottom frames may be stored into a memory prior to coarse synchronization. The bottom frames stored may be standard video frames, non-standard video frames, or compressed video frames. A processor may label each field in the bottom frames with a bottom frame field count value when a bottom frame vertical sync signal is asserted and with an indication of the location of the bottom frame vertical sync signal. The bottom frame field count may be a modulo N count that is incremented with each assertion of the bottom frame vertical sync signal. The modulo N number may be larger than the total number of fields that may be assigned to the current frame and to the top frame.
[0021] The processor may assign to the current frame a frame transferred immediately prior to a bottom frame or a first field and a second field transferred immediately prior to the bottom frame. The coarse frame synchronizer may generate a current frame window signal and a top frame window signal. The current frame and the bottom frame may be locked by the coarse frame synchronizer when the bottom frame vertical sync signal occurs within the current frame window signal. The processor may assign to the top frame, a frame transferred two frames prior to the bottom frame or a third field and a fourth field transferred prior to the bottom frame. The top frame and the bottom frame may be locked by the coarse frame synchronizer when the bottom frame vertical sync signal occurs within the top frame window signal. The coarse frame synchronizer may synchronize at least two frames being synchronized to within two integer sample delays. The bottom frame starting field may be utilized as a reference to determine the video fields that may be assigned to the current frame, the top frame, and the bottom frame.
[0022] A fine frame aligner may correlate a phase difference between a subcarrier signal in the coarsely synchronized current frame and a subcarrier signal in the bottom frame and may modify the phase difference between the frames until the correlation results in a specified phase lock value range. Similarly, the fine frame aligner may correlate a phase difference between a subcarrier signal in the coarsely synchronized current frame and a subcarrier signal in the coarsely synchronized top frame and may modify the phase difference between the frames until the correlation results in a specified phase lock value range. The specified phase lock value range may correspond the level of alignment accuracy that may be achieved and may be specified by the processor. The fine frame aligner may add or remove an integer sample delay when an integer sample delay slip occurs.
[0023] These and other advantages, aspects and novel features of the present invention, as well as details of an illustrated embodiment thereof, will be more fully understood from the following description and drawings.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0024] FIG. 1A is a diagram illustrating the generation of a conventional composite video signal.
[0025] FIG. 1B is a diagram illustrating the position of color burst and active video in a conventional composite video signal.
[0026] FIG. 1C is a graphical diagram illustrating the phase relationship of modulated chroma signals in contiguous composite video signal frames.
[0027] FIG. 2 is a block diagram illustrating an exemplary system which may be utilized for 3D comb synchronization and alignment of standard and non-standard video signals, in accordance with an embodiment of the invention.
[0028] FIG. 3 is an exemplary timing diagram illustrating coarse synchronization between the bottom frame, the current frame, and the top frame for interlaced video signals, in accordance with an embodiment of the invention.
[0029] FIG. 4 is a flow diagram illustrating exemplary steps which may be utilized for coarse synchronization between the bottom frame, the current frame, and the top frame, in accordance with an embodiment of the invention.
[0030] FIG. 5 is a block diagram of an exemplary fine frame synchronizer which may be utilized for fine synchronization between the bottom frame, the current frame, and the top frame, in accordance with an embodiment of the invention.
[0031] FIG. 6 is a flow diagram illustrating exemplary steps which may be utilized for fine synchronization between the current frame, the bottom frame, and the top frame, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Certain aspects of the invention may be found in a method and system for 3D comb synchronization and alignment of standard and non-standard video signals. Aspects of the invention may facilitate the handling of video stream switching and non-standard data streams. Video stream switching may occur, for example, when a television channel is changed, thereby causing the video stream to also change. The handling of video stream switching and the handling of the non-standard data streams may be accomplished in an organized manner by, for example, appropriately labeling and storing the video stream, followed by a coarse synchronization and then by a fine alignment of the stored video fields and/or video frames.
[0033] FIG. 2 is a block diagram illustrating an exemplary system which may be utilized for 3D comb synchronization and alignment of standard and non-standard video signals, in accordance with an embodiment of the invention. Referring to FIG. 2 , the synchronization and alignment system 200 may comprise a coarse frame synchronizer 202 , a fine frame aligner 204 , a processor 206 , and a memory 208 . The coarse frame synchronizer may comprise suitable logic, code, and/or circuitry and may be adapted to coarsely synchronize a current frame with a bottom frame and/or a top frame with the bottom frame to within one subcarrier period. The fine frame aligner 204 may comprise suitable logic, code, and/or circuitry and may be adapted to finely align the top frame with the current frame and/or the bottom frame with the current frame to within a specified phase lock value range. The processor 206 may comprise suitable logic, code, and/or circuitry and may be adapted to control the operation of the coarse frame synchronizer 202 and the fine frame aligner 204 , and to transfer control information and/or data between the memory 208 and the coarse frame synchronizer 202 and the fine frame aligner 204 . The memory 208 may comprise suitable logic, code, and/or circuitry and may be adapted to store control information and/or data for use by the synchronization and alignment system 200 .
[0034] FIG. 3 is an exemplary timing diagram illustrating an exemplary coarse synchronization between the bottom frame, the current frame, and the top frame for interlaced video signals, in accordance with an embodiment of the invention. Referring to FIG. 3 , timing signals that may be utilized by the coarse frame synchronizer 202 for coarse synchronization in interlaced video signals may comprise a bottom frame vertical sync (VW) signal 302 , a bottom frame field count (FC) signal 304 , a current frame state (CFS) signal 306 , a current frame window (CFW) signal 308 , a top frame state (TFS) signal 310 , and a top frame window (TFW) signal 312 . The VW signal 302 may correspond to the clock assertion of a vertical sync signal which indicates the presence of a video field in a bottom frame video stream from the memory 208 . The FC signal 304 may correspond to the count value in a modulo N counter indicating the order of arrival of a new video field in the bottom frame video stream. The CFS signal 406 may correspond to the status of the current frame relative to a bottom frame starting field. The CFW signal 308 may correspond to a time interval during which confirmation of coarse synchronization between the current frame and the bottom frame may be determined. The TFS signal 310 may correspond to the status of the top frame relative to the bottom frame starting field. The TFW signal 312 may correspond to a time interval during which confirmation of coarse synchronization between the top frame and the bottom frame may be determined.
[0035] At time t 0 in the timing diagram, the bottom frame, the current frame, and the top frame are not locked or coarsely synchronized. The time in FIG. 3 increases from left to right. When the VW signal 302 , also known as V-Write signal, is asserted, the FC signal 304 is incremented to indicate the presence of a new bottom frame video field. The FC signal 304 is incremented after every new video field in the bottom frame video stream until it reaches its maximum value, as determined by the modulo N count, at which point the next FC signal 304 value is 0. The number N may be based on the ability to track the number of video field delays that exist between the top frame and the bottom frame. The bottom frame starting field may be, for example, the video field in the bottom frame video stream in FIG. 3 that corresponds to an FC signal 304 of value 0. The bottom frame starting field may be used as a reference to determine the video fields that may correspond to the top frame, the current frame, and the bottom frame. For example, when the bottom frame starting field in FIG. 3 corresponds to the FC signal 304 value of 0, then it may be delayed by two fields from the bottom frame video field that corresponds to an FC signal 304 value of 2 and by four fields from the bottom frame video field that corresponds to an FC signal 304 value of 4. When the bottom frame comprises the bottom frame video fields that corresponds to FC signal 304 values 5 and 4, then the current field may comprise the bottom frame video fields that correspond to FC signal 304 values 3 and 2 and the top frame may comprise the bottom frame video fields that correspond to FC signal 304 values 1 and 0. Similarly, when the bottom frame comprises the bottom frame video fields that corresponds to FC signal 304 values 6 and 5, then the current field may comprise the bottom frame video fields that correspond to FC signal 304 values 4 and 3 and the top frame may comprise the bottom frame video fields that correspond to FC signal 304 values 2 and 1. The bottom frame may comprise the most recent video fields received from the bottom frame video stream by the coarse frame synchronizer 202 .
[0036] The CFS signal 306 may be utilized to indicate whether the coarse frame synchronizer 202 has read the bottom frame starting field from the memory 208 . The CFS signal 306 may also be utilized to indicate that, after the bottom frame starting field has been read at time t 1 , the coarse frame synchronizer 202 is reading additional video fields from the memory 208 . The CFS signal 306 may be utilized to confirm, at time t 3 , that the video fields necessary to assemble the current frame have been read from the memory 208 and that they are now locked, at time t 4 , to the VW signal 302 . The CFW signal 308 may be generated by the coarse frame synchronizer 202 during confirmation of the current frame in the CFS signal 306 and may be used by the CFS signal 306 to determine whether the current frame is coarsely synchronized.
[0037] The TFS signal 310 may be used to indicate whether the coarse frame synchronizer 202 has read the bottom frame starting field from the memory 208 . The TFS signal 310 may also indicate that, after the bottom frame starting field has been read at time t 1 , the coarse frame synchronizer 202 is reading additional video fields from the memory 208 and that those additional video fields may be delayed by the appropriate amount, for example, at time t 5 . The TFS signal 310 may confirm, at time t 6 , that the video fields necessary to assemble the top frame have been read from the memory 208 and that they are now locked, at time t 7 , to the VW signal 302 . The TFW signal 312 may be generated by the coarse frame synchronizer 202 during confirmation of the top frame in the TFS signal 310 and may be used by the TFS signal 310 to determine whether the top frame is coarsely synchronized.
[0038] The timing signals that may be utilized by the coarse frame synchronizer 202 for coarse synchronization in interlaced video signals may also be used for progressive video signals when the progressive video signals have an odd number of lines.
[0039] FIG. 4 is a flow diagram illustrating exemplary steps which may be utilized for coarse synchronization between the bottom frame, the current frame, and the top frame, in accordance with an embodiment of the invention. Referring to FIG. 4 , after start step 402 , in step 404 the synchronization and alignment system 200 stores and labels the bottom frames in the bottom frame video stream continuously into the memory 208 . The labeling may indicate the field count value and/or the location of the vertical sync signal. In an interlaced system the field count corresponds to a bottom frame field count while in a progressive system the field count corresponds to a bottom frame count. In step 406 , after the assertion of the VW signal, the current frame and top frame read pointers may be adjusted to correspond to the bottom frame starting field or the bottom frame starting frame. In step 408 , the coarse frame synchronizer 202 may read from the memory 208 the labeled bottom frame fields or bottom frames depending on whether the system is interlaced or progressive. In step 410 , the coarse frame synchronizer 202 determines whether the fields or frames read correspond to the bottom frame starting field or a bottom frame starting frame for progressive systems. If the field or frame which has been read does not correspond to the bottom frame starting field or to the bottom frame starting frame, then the coarse frame synchronizer returns to step 406 and adjusts the current frame and top frame pointers. If the field or frame which has been read does correspond to the bottom frame starting field or to the bottom frame starting frame, then the coarse frame synchronizer may proceed to step 412 to coarsely synchronize the current frame with the bottom frame and/or to step 420 to coarsely synchronize the top frame with the bottom frame.
[0040] In step 412 , after having read the bottom frame starting field or the bottom frame starting frame, the coarse frame synchronizer 202 waits for the appropriate number of fields or frames to be read. Once the appropriate fields or frame are delayed that may correspond to the current frame, the coarse frame synchronizer 202 may assign the fields or frame to the current frame. In step 414 , after the current frame has been completed, the coarse frame synchronizer 202 may generate the current frame window (CFW) signal to confirm synchronization between the current frame and the bottom frame.
[0041] In step 416 , the coarse frame synchronizer 202 may determine whether the current frame and the bottom frame are coarsely synchronized by comparing the VW signal and the CFW signal. If the VW signal occurs within the duration of the CFW signal, the current frame and the bottom frame are coarsely synchronized and the coarse frame synchronizer may proceed to step 418 . If the VW signal does not occur within the duration of the CFW, then the current frame and the bottom frame are not coarsely synchronized and the coarse frame synchronizer 202 may return to step 406 and start the process again. In step 418 , the coarse frame synchronizer 202 may indicate in the current frame state (CFS) signal that the current frame and the bottom frame are locked. Coarse synchronization may bring the current frame and bottom frame to within one subcarrier period. Once the frames are locked, the synchronization and alignment system 200 may proceed to step 428 where the bottom frame, the current frame, and the top frame may be finely aligned.
[0042] Returning to step 420 , after having read the bottom frame starting field or the bottom frame starting frame, the coarse frame synchronizer 202 waits for the appropriate number of fields or frames to be read. Once the appropriate fields or frame are delayed that may correspond to the top frame, the coarse frame synchronizer 202 may assign the fields or frames to the top frame. In step 422 , after the top frame has been completed, the coarse frame synchronizer 202 may generate the top frame window (TFW) signal to confirm synchronization between the top frame and the bottom frame.
[0043] In step 424 , the coarse frame synchronizer 202 may determine whether the top frame and the bottom frame are coarsely synchronized by comparing the VW signal and the TFW signal. If the VW signal occurs within the duration of the TFW signal, the top frame and the bottom frame are coarsely synchronized and the coarse frame synchronizer may proceed to step 426 . If the VW signal does not occur within the duration of the TFW, then the top frame and the bottom frame are not coarsely synchronized and the coarse frame synchronizer 202 may return to step 406 and start the process again. In step 426 , the coarse frame synchronizer 202 may indicate in the top frame state (TFS) signal that the top frame and the bottom frame are locked. Coarse synchronization may bring the top frame and bottom frame to within one subcarrier period. Once the frames are locked, the synchronization and alignment system 200 may proceed to step 428 where the bottom frame, the current frame, and the top frame may be finely aligned.
[0044] FIG. 5 is a block diagram of an exemplary fine frame synchronizer which may be utilized for fine synchronization between the bottom frame, the current frame, and the top frame, in accordance with an embodiment of the invention. Referring to FIG. 5 , the fine frame aligner 204 may comprise a fixed integer delay 502 , 504 , a matching delay 506 , an integer slip 508 , 510 , a FSA filter 512 , 514 , a bottom frame subcarrier lock loop 516 , and a top frame subcarrier lock loop 518 . The bottom frame subcarrier lock loop may comprise a filter 520 , for example, a Hilbert filter, a correlator 522 , a low pass filter 524 , and a loop filter 526 . The top frame subcarrier lock loop may comprise a filter 528 , for example, a Hilbert filter, a correlator 530 , a low pass filter 532 , and a loop filter 534 .
[0045] The fixed integer delay 502 , 504 may comprise suitable logic, code, and/or circuitry and may be adapted to provide integer sample delays for the current frame and for the top frame in fixed clock architectures. For example, the sample delays may be based on an integer sample from a 27 MHz clock. The matching delay 506 may comprise suitable logic, code, and/or circuitry and may be adapted to adjust the delay for the current frame in fixed clock architectures. The integer slip 508 , 510 may comprise suitable logic, code, and/or circuitry and may be adapted to add or remove an integer sample delay when the fractional delay crosses an integer boundary. The FSA filter 512 , 514 may comprise suitable logic, code, and/or circuitry and may be adapted to determine the amount of fractional delay to apply to the bottom frame and for the top frame. The bottom frame subcarrier lock loop 516 may comprise suitable logic, code, and/or circuitry and may be adapted to lock the subcarrier signals in the current frame and the bottom frame. The top frame subcarrier lock loop 518 may comprise suitable logic, code, and/or circuitry and may be adapted to lock the subcarrier signals in the current frame and the top frame.
[0046] The Hilbert filter 520 in the bottom frame subcarrier lock loop 516 may comprise suitable logic, code, and/or circuitry and may be adapted to shift the subcarrier phase in the color burst of the signal coming from the FSA filter 512 by 90°. The correlator 522 may comprise suitable logic, code, and/or circuitry and may be adapted to correlate the color burst subcarrier of the signal coming from the Hilbert filter 520 and the color burst subcarrier of the current frame. The low pass filter 524 may comprise suitable logic, code, and/or circuitry and may be adapted to remove higher level harmonics that may result from the operation of the correlator 522 . The loop filter 526 may comprise suitable logic, code, and/or circuitry and may be adapted to control the feedback rate in the bottom frame subcarrier lock loop 516 .
[0047] The Hilbert filter 528 in the top frame subcarrier lock loop 518 may comprise suitable logic, code, and/or circuitry and may be adapted to shift the subcarrier phase in the color burst of the signal coming from the FSA filter 514 by 90°. The correlator 530 may comprise suitable logic, code, and/or circuitry and may be adapted to correlate the color burst subcarrier of the signal coming from the Hilbert filter 528 and the color burst subcarrier of the current frame. The low pass filter 532 may comprise suitable logic, code, and/or circuitry and may be adapted to remove higher level harmonics that may result from the operation of the correlator 530 . The loop filter 534 may comprise suitable logic, code, and/or circuitry and may be adapted to control the feedback rate in the top frame subcarrier lock loop 518 .
[0048] FIG. 6 is a flow diagram illustrating exemplary steps which may be utilized for fine synchronization between the current frame, the bottom frame, and the top frame, in accordance with an embodiment of the invention. Referring to FIG. 6 , after start step 602 , the integer slip 508 , 510 may determine, in step 604 , whether the coarsely synchronized bottom frame and/or the coarsely synchronized top frame may require the addition or removal of an integer sample delay. If an integer sample delay may not need to be added or removed, the bottom frame and/or the top frame in the fine frame aligner 204 may proceed to step 608 . In step 608 , the FSA filter 512 , 514 may adjust a fractional delay to the bottom frame and/or the top frame respectively if the feedback from the bottom frame subcarrier lock loop 516 and the top frame subcarrier lock loop 518 provides for the adjustment.
[0049] In step 610 , the Hilbert filter 520 , 528 may apply a 90 phase shift to the color burst subcarrier in the bottom frame and/or the top frame. In step 612 , the correlator 522 , 530 may correlate the color burst subcarrier of the bottom frame and top frame respectively with the color burst subcarrier of the current frame. The correlation in step 612 may correspond to an error signal between the color burst subcarrier phase of the current frame and the color burst subcarrier phase of the bottom frame and/or the top frame. In step 614 , the subcarrier phase error produced by the correlator 522 , 530 may be low pass filtered to remove any higher order harmonics. In step 616 , the low pass filtered subcarrier phase error from step 614 may be applied to the loop filter 526 , 534 to determine feedback rate at which the subcarrier phase error may be applied to the integer slip 508 , 510 and/or the FSA filter 512 , 514 . In step 618 , the loop filter 526 , 534 may determine whether the subcarrier phase error is within a specified phase lock value range. The specified phase lock value range may be programmed by the processor 206 and may be determined based on systems requirements. If the subcarrier phase error is not within the specified phase lock value range, then the fine frame aligner 204 may return to step 604 and provide the subcarrier phase error to the integer slip 508 , 510 and/or it may return to step 608 and provide the subcarrier phase error to the FSA filter 512 , 514 at the feedback rate determined in step 616 . Whether the fine frame aligner 204 returns to step 604 or to step 608 may depend on the need for an integer slip in the feedback loop.
[0050] Returning to step 604 , when the feedback provided by the bottom frame subcarrier lock loop 516 and/or the top frame subcarrier lock loop 518 produces a fractional delay that crosses an integer boundary, that is, a delay that may be longer than an integer sample delay and that may require an integer slip, the fine frame aligner 204 may add or remove an integer sample delay in step 606 before proceeding to step 608 . In this case, the fractional delay applied in step 608 may be adjusted to reflect the integer slip that may have taken place in step 606 .
[0051] Returning to step 618 , if the subcarrier phase error is within the specified phase lock value range, then the fine frame aligner may proceed to step 620 where the bottom frame and/or the top frame may be considered to be finely aligned with the current frame.
[0052] Accordingly, the present invention may be realized in hardware, software, or a combination of hardware and software. The present invention may be realized in a centralized fashion in at least one computer system, or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system or other apparatus adapted for carrying out the methods described herein is suited. A typical combination of hardware and software may be a general-purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein.
[0053] The present invention may also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which when loaded in a computer system is able to carry out these methods. Computer program in the present context means any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following: a) conversion to another language, code or notation; b) reproduction in a different material form.
[0054] While the present invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from its scope. Therefore, it is intended that the present invention not be limited to the particular embodiment disclosed, but that the present invention will include all embodiments falling within the scope of the appended claims. | In a method and system for 3D comb synchronization and alignment of standard and non-standard video signals, a coarse synchronization is performed on a bottom frame, a current frame, and a top frame based on a bottom frame field count. The current frame is assigned the frame transferred immediately prior to a bottom frame whereas the top frame is assigned the frame transferred two frames. A current frame window signal and a top frame window signal may be used to lock the current frame and the top frame to a bottom frame vertical sync signal. After coarse synchronization, the video frames are finely aligned by correlating a phase difference between the subcarrier signals in each frame and modifying the phase difference until the correlation results in a specified phase locked value range. This method and system may facilitate the handling of video stream switching and non-standard data streams. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to improvements in suspended ceiling panels and, more specifically, to fabric covered panels for suspended ceilings.
PRIOR ART
Suspended grid ceiling systems are in widespread use because of their functionality in allowing access to the plenum for service, alternation and/or addition to wiring, air conditioning, heating, plumbing and other hardware typically found in a building. Ceiling panels that lay in the suspended grid come in a variety of materials and finishes. Most commonly, the panels are rigid boards made of various materials that often have their visible faces perforated or otherwise textured to obtain a level of sound absorption. U.S. Pat. No. 4,026,081 shows an example of a fabric covered acoustical panel with a rigid perimeter frame for use with a suspension ceiling grid. The product disclosed in this patent requires a vinyl rope to retain the fabric and the attendant complications of handling and installing the rope. Additionally, this patented product may be difficult to install and especially to remove. This is of particular consequence where the person attempting to install or remove the panel is unfamiliar with the motions which apparently must be performed to place or remove the patented panel.
SUMMARY OF THE INVENTION
The invention provides an improved fabric covered acoustical panel assembly for suspended ceiling structures that uses inexpensive parts, is readily assembled and is easy to install and remove. The disclosed panel assembly has a rigid polygonal perimeter frame that serves to hold the fabric, a sound absorbing material and a sound transmission attenuating material in assembled relation and precisely engages supporting flanges of the tees of a suspension grid. The frame is preferably an extrusion of suitable thermoplastic such as polyvinylchloride.
As disclosed, the frame has integral gripping elements that frictionally engage the margin of the fabric facing. The gripping elements allow the fabric to be simply and quickly installed on the frame by tucking its margins into the reach of the gripping elements. The frame includes a cavity for receiving any excess marginal material and thereby neatly controlling its location regardless of limited extra material or imperfect positioning of the fabric. Thus, the edge of the fabric does not “read through” the visible part of the fabric. The gripping elements of the frame are situated so that the fabric margins can be tucked into their control from operations conducted on the front or visible face of the panel so that the fabric condition and position can be continuously observed and corrected for proper positioning by the person installing the fabric on the frame. Additionally, the frame includes retaining rib elements for holding the sound absorbing material in place. Still further, the frame includes a support area for receiving and locating the sound transmission attenuating material.
The disclosed panel construction is suitable for factory mass production, limited production in a small shop or custom manufacture at the site where the panels are to be installed. The frame is assembled by connecting its sides together at corners with an angle bracket that is simply pushed longitudinally into the sides and is retained in place by a strong friction fit. The panel assembly can be readily recovered with fabric when damaged, outdated, or other conditions require a change.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a suspended ceiling incorporating ceiling panels constructed in accordance with the invention;
FIG. 2 is a fragmentary cross-sectional view of a pair of adjacent panels constructed in accordance with a first embodiment of the invention and a supporting grid tee;
FIG. 3 is a fragmentary plan view of the corner of a perimeter frame of the panel according to the first embodiment; and
FIG. 4 is a fragmentary cross-sectional view of a pair of adjacent panels constructed in accordance with a second embodiment of the invention and a supporting grid tee.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIG. 1, there is illustrated a suspended ceiling structure 10 comprising a rectangular grid 11 , and a plurality of panels 12 supported on the grid. The grid 11 , according to conventional practice, is made of runners 13 having the configuration of an inverted tee. The runners 13 are typically suspended from an overhead structure with wires that are looped through holes in a stem or vertical part 14 of the grid runner 13 . The runners 13 are made of steel but can be of other suitable material. The runners 13 have oppositely extending horizontal flanges 16 that serve to support the panels 12 in a manner to be described. Commonly, the tees or runners 13 are provided with connections at their ends to enable them to be joined with intersecting tees and/or with ends of other tees. Typically, the tees are arranged in a rectangular array that has openings for the panels 12 that nominally measure 2′×2′ or 2′×4′.
The panels 12 are assemblies of a rigid perimeter frame 17 , fabric or fabric sheet 18 , sound absorbing material 19 and sound transmission attenuating material 20 . The fabric sheet 18 forms the visible face or face side of the panel when it is installed in the ceiling grid. The illustrated frame 17 is an assembly of four side members 22 and four corner connectors 56 . The four side members have identical or substantially similar cross-sections shown as typical in FIG. 2 . The side members 22 are preferably formed as extrusions of a suitable thermoplastic material such as polyvinylchloride with flame resistant properties satisfying suitable standards such as ASTM-E84 and are Class A-rated for flame spread. The cross-section of a side member 22 , which is uniform along its length, is somewhat complex to enable it to serve multiple functions. The cross-section includes a lower generally horizontally extending flange 26 which has an extension or flange 35 having an upwardly curved or angled lower surface 24 which prevents the plastic frame member “reading through” the stretched fabric 18 . Extending generally vertically upwardly from the flange 26 is a web 27 having a plurality of barbs 28 projecting towards the center of the panel 12 . The barbs 28 are optional and have angled surfaces 29 on their upper faces and less inclined almost horizontal surfaces 30 on their lower sides. A main bridge or flange 31 at the top of the web 27 extends primarily outwardly away from the center of the panel 12 . Towards the center of the panel 12 , the bridge 31 provides a projection 32 that has a steeply inclined camming surface 33 and a generally horizontal retaining face 34 .
A pair of spaced parallel flanges 36 extend vertically from the main bridge 31 . Oppositely facing ribs 37 existing on each flange 36 have lower surfaces 38 that cooperate with surfaces 39 of the flanges 36 to form the sides of a longitudinally extending rectangular channel 41 of a C section. Depending from the main bridge or flange 31 and lying in the same plane as the upstanding flange 36 is a generally vertical web 42 . A generally horizontal flange 43 projects from a lower end of the web 42 in a direction away from the center of the panel 12 . As shown, a lower surface 44 of the flange 43 is inclined upwardly in a direction away from the center of the panel 12 to bias the vertical web 42 towards the center of the panel 12 when the weight of the panel is borne by this surface on the flange 16 . Alternatively the lower surface 44 may be horizontal. Adjacent its lower end, the web 42 has a series of longitudinally extending small gripping ribs 45 on a surface 46 facing the center of the panel 12 . A generally vertical leg 47 extends upwardly from an outer edge of the flange 26 . The flange 26 and leg 47 intersect to form a rounded corner 48 . The leg 47 has an inwardly bent area 49 that provides a longitudinally extending recess 51 that is roughly centered, in a vertical sense, on a plane tangent to the inner end of the flange surface 44 . Adjacent its upper edge, the leg 47 has a series of small gripping ribs 52 that oppose the ribs 45 on the depending web 42 . Ideally, in a free state and before assembly of the fabric 18 as described below, the leg 47 is configured so that its ribs 52 resiliently contact the ribs 45 of the depending web 42 . The depending web 42 , main flange 31 , barbed web 27 , lower flange 26 and leg 47 cooperate to form a closed chamber 54 .
The side members 22 are mitered at the corners of the frame 17 as shown in FIG. 3 . The members 22 are joined at the corners by a corner connector or right angle piece or angle bracket 56 . The bracket 56 can be made of suitable plastic material such as polyvinylchloride. The bracket 56 is economically made by cutting short sections of a long piece of angle stock. A leg 57 of each angle bracket 56 is assembled in the channel 41 of the two frame side members 22 forming a corner. The cross-section of the bracket legs 57 is preferably proportioned to provide a tight force fit into the channel 41 to frictionally lock the members 22 together and thereby assure that the frame can be freely handled without the risk of it inadvertently coming apart.
The distance between an upper face 58 of the lower flange 26 and an underside 34 of the projection 32 is made to receive the thickness of the sound absorbing material 19 . Preferably the sound absorbing material is commercially available rigid fiberglass board of 1″ thickness and a density of preferably 6 lbs. per cubic foot and less preferably as low as 3 lbs. and as high as 20 lbs. density. The planar dimensions of the sound absorbing material or board are made to closely fit within the perimeter frame 17 so as to have its edges gripped and held in position by the barbs 28 . The camming surface 33 facilitates inserting the sound absorbing material into the frame 17 .
A top face 61 of the main flange 31 and an inner face 62 of the inner flange 36 form a perimeter pocket area for reception of the sound transmission attenuating material 20 . This material is preferably gypsum board or drywall but can be other suitable fire resistant materials such as sheet rock, plywood, flake board, particle board or the like, rated to meet fire code requirements for combustibility and smoke and flame spread. The material 20 is cut to a planar size to loosely fit within and be contained by the boundary formed by the flange surface 62 . The board can have a thickness of, for example, ⅜″.
With the frame 17 assembled and the sound absorbing board material 19 in the frame, the frame can be inverted onto a suitable support such as a work table for installation of the face material or fabric 18 . The fabric is a suitable material such as a quality weight upholstery fabric that, ideally, is hydrophobic or with as little hydrophilicity as possible so as to avoid moisture absorption and potential sagging. Preferred fabric materials are panel fabrics, such as panel fabrics from Guilford of Maine. Suitable fabric materials include polyester as a preferred material and, less preferably, polyolefin materials, vinyl-coated fabric, or acrylic fabric. The fabric 18 , like the other materials of the panel, are flame retardant and preferably satisfy ASTM standard E84. The fabric 18 is cut oversize of the finished fabric covered area. Marginal areas of the fabric are tucked in the crevice between the web 42 and leg 47 with a flat tool like a putty knife. This can be done most efficiently by working the fabric material into the crevice at one side member 22 first and then into the crevice at the opposite side. This procedure is then performed at the remaining two sides. The cavity or chamber 54 is relatively large so it readily accommodates excess marginal material of the fabric 18 . Proper positioning and tensioning of the fabric 18 is relatively easy because its alignment and local stretch can be viewed as it is being tucked into the frame crevices. The fabric 18 is stretched over the frame to the desired degree by appropriate manipulation of the flat installation tool. The fabric 18 is reliably held in place by the gripping ribs 45 , 52 to a degree sufficient to maintain the fabric tensioned during normal surface life of the fabric 18 . Other gripping elements known in the art may be used, such as opposing teeth or projections or interlocking surfaces or other surfaces which lockingly or frictionally hold the fabric. Any loosening of the fabric after a panel 12 has been installed can be accomplished in the same manner as the fabric was originally tensioned. It is also noteworthy that the ribs 45 , 52 will release the fabric when a strong pulling force is applied such as in the case where it is desired to replace the fabric.
After the fabric has been installed, the subassembly of the frame 17 , fabric 18 and sound absorbing material 19 can be turned so that the fabric is facing downward and the sound transmission attenuating material 20 can be positioned on the frame.
With placement of the sound transmission attenuating board material 20 in the pocket bounded by the flanges 36 , the assembly of the panel 12 is complete. The panel is installed on the grid 11 in a generally conventional lay-in manner. The hollow area of the recess 51 can receive a portion of the grid tee flange 16 to permit the panels 12 to be installed on a grid even where the grid is slightly out of proper position or where the panel is slightly oversize for the opening left by the grid. It will be understood that the panel assembly 12 can be manufactured in a factory, small shop, or on site where it is to be used. The frame members 22 are saw cut from long stock lengths. The disclosed panel assembly 12 does not require any fasteners or adhesives apart from the right angle bracket 56 . If desired, the area adjacent the corner 48 can be covered with double-sided tape or otherwise provided with pressure-sensitive adhesive to facilitate placement and stretching of the fabric 18 on the frame 17 .
Various modifications of the panel assembly are contemplated. While the preferred arrangement is of the tegular type where the face of the panel assembly represented by the fabric 18 lies in a plane below the plane of the grid flanges 16 , as shown in FIG. 2, a panel can be configured to have its face lie at or above the plane of the grid tee flanges. The edge detail, defined by the corner 48 can be greater or less in radius than that shown, can be beveled, and can even be square. Where desired, the gypsum board 20 or its equivalent can be omitted or can be cut out to mount an audio speaker. Similarly, the sound absorbing material 19 can be omitted to allow the speaker to be hidden behind the fabric and to operate without interference of such material. As suggested, the panel can be constructed to fit either 2′×2′ or 2′×4′ standard ceiling grid modules or can be made into other suitable polygonal shapes such as triangles, hexagons and octagons. The frame can be dyed, painted, stained or otherwise colored to match the color of the fabric. If desired, the sound absorbing board 19 can be replaced by drywall, foil-backed fiberglass, non-rigid fiberglass batts or like material.
FIG. 4 illustrates a second embodiment of a ceiling panel assembly 70 . The panel assembly 70 includes a frame constructed of side members 71 , sound absorbing material 19 , sound transmission attenuating material 20 and a fabric face 18 . In this embodiment, like numerals are used to identify like materials common with the embodiment of FIGS. 2 and 3. The frame side members 71 have identical cross-sections as shown in FIG. 4 . The frame side member cross-section includes a generally vertical wall 72 that at its lower end is curved to transition from a vertical surface 73 to a horizontal surface 74 . An inner face 76 of the wall includes a horizontally projecting barb 77 . The outer vertical surface or face 73 has a series of gripping ribs 78 at its mid-section. A generally C-shaped panel 79 formed by flanges 81 , 82 and a web 83 is joined to the vertical wall 72 by a web 84 . An inverted J-shaped channel 86 extends upwardly from the web 84 horizontally, and then downwardly alongside an upper portion of the wall 72 . An inside surface of a lower part 88 of the J-channel has ribs 89 . At its lower end, the J-channel 86 has a horizontally extending flange 91 that engages the flange 16 of a supporting tee 13 . An interior of the J-channel 86 forms a chamber 92 .
Opposing areas of the J-channel 86 and the web 83 include ribs 93 to form the boundary of a rectangular open sided channel 94 . Like the embodiment of FIGS. 2 and 3, a rectangular frame is constructed with appropriate lengths of the side members 71 having the cross-section illustrated in FIG. 4 . The lengths are suitably mitered similar to the showing in FIG. 3 . The frame is assembled around the rigid rectangular board of sound absorbing material 19 and a rectangular piece of drywall or other suitable sound transmission attenuating material 20 . The projection or barb 77 digs into the sound absorbing material 19 to retain it in position. An angle bracket like the bracket 56 shown in FIG. 3 can be used in the open-faced channel 94 under the ribs 93 to lock the frame members 71 together.
With the frame members 71 assembled together around the sound absorbing material 19 and sound transmission attenuating material 20 , the fabric 18 can be installed. This is accomplished in a manner like that described in connection with the embodiment of FIGS. 2 and 3. The margins of the fabric 18 are tucked between the wall 72 and leg or lower part 88 of the J-channel 86 . The J-channel leg 88 resiliently grips the fabric material 18 with its ribs 89 holding it against the mutually gripping ribs 78 on the wall 72 .
While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention. | An acoustical panel assembly for a suspended ceiling comprising a rigid frame, sound absorbing material, sound transmission attenuation material and a face fabric. The frame is an assembly of extruded members secured together in a polygonal pattern such as a square or a rectangle. The fabric is secured to the frame by gripping elements integral with the frame. Marginal portions of the fabric are captured and hidden in receiving chambers formed by the frame members. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of U.S. patent application Ser. No. 09/832,739 filed Apr. 11, 2001, now U.S. Pat. No. 6,860,218, entitled “Flexible Fluid Containment Vessel” and which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a flexible fluid containment vessel (sometimes hereinafter referred to as “FFCV”) for transporting and containing a large volume of fluid, particularly fluid having a density less than that of salt water, more particularly, fresh water, and the method of making the same.
BACKGROUND OF THE INVENTION
The use of flexible containers for the containment and transportation of cargo, particularly fluid or liquid cargo, is well known. It is well known to use containers to transport fluids in water, particularly, salt water.
If the cargo is fluid or a fluidized solid that has a density less than salt water, there is no need to use rigid bulk barges, tankers or containment vessels. Rather, flexible containment vessels may be used and towed or pushed from one location to another. Such flexible vessels have obvious advantages over rigid vessels. Moreover, flexible vessels, if constructed appropriately, allow themselves to be rolled up or folded after the cargo has been removed and stored for a return trip.
Throughout the world there are many areas which are in critical need of fresh water. Fresh water is such a commodity that harvesting of the ice cap and icebergs is rapidly emerging as a large business. However, wherever the fresh water is obtained, economical transportation thereof to the intended destination is a concern.
For example, currently an icecap harvester intends to use tankers having 150,000 ton capacity to transport fresh water. Obviously, this involves, not only the cost involved in using such a transport vehicle, but the added expense of its return trip, unloaded, to pick up fresh cargo. Flexible container vessels, when emptied can be collapsed and stored on, for example, the tugboat that pulled it to the unloading point, reducing the expense in this regard.
Even with such an advantage, economy dictates that the volume being transported in the flexible container vessel be sufficient to overcome the expense of transportation. Accordingly, larger and larger flexible containers are being developed. However, technical problems with regard to such containers persist even though developments over the years have occurred. In this regard, improvements in flexible containment vessels or barges have been taught in U.S. Pat. Nos. 2,997,973; 2,998,973; 3,001,501; 3,056,373; and 3,167,103. The intended uses for flexible containment vessels is usually for transporting or storing liquids or fluidisable solids which have a specific gravity less than that of salt water.
The density of salt water as compared to the density of the liquid or fluidisable solids reflects the fact that the cargo provides buoyancy for the flexible transport bag when a partially or completely filled bag is placed and towed in salt water. This buoyancy of the cargo provides flotation for the container and facilitates the shipment of the cargo from one seaport to another.
In U.S. Pat. No. 2,997,973, there is disclosed a vessel comprising a closed tube of flexible material, such as a natural or synthetic rubber impregnated fabric, which has a streamlined nose adapted to be connected to towing means, and one or more pipes communicating with the interior of the vessel such as to permit filling and emptying of the vessel. The buoyancy is supplied by the liquid contents of the vessel and its shape depends on the degree to which it is filled. This patent goes on to suggest that the flexible transport bag can be made from a single fabric woven as a tube. It does not teach, however, how this would be accomplished with a tube of such magnitude. Apparently, such a structure would deal with the problem of seams. Seams are commonly found in commercial flexible transport bags, since the bags are typically made in a patch work manner with stitching or other means of connecting the patches of water proof material together. See e.g. U.S. Pat. No. 3,779,196. Seams are known to be a source of bag failure when the bag is repeatedly subjected to high loads. Seam failure can obviously be avoided in a seamless structure.
Other problems face the use of large transport containers. In this regard, when partially or completely filled flexible barges or transport containers are towed through salt water, problems as to instability are known to occur. This instability is described as a flexural oscillation of the container and is directly related to the flexibility of the partially or completely filled transport container. This flexural oscillation is also known as snaking. Long flexible containers having tapered ends and a relatively constant circumference over most of their length are known for problems with snaking. Snaking is described in U.S. Pat. No. 3,056,373, observing that flexible barges having tapered ends, build up to damaging oscillations capable of seriously rupturing or, in extreme cases, destroying the barge, when towed at a speed above a certain critical speed. Oscillations of this nature were thought to be set up by forces acting laterally on the barge towards its stern. A solution suggested was to provide a device for creating breakaway in the flow lines of the water passing along the surface of the barge and causing turbulence in the water around the stern. It is said that such turbulence would remove or decrease the forces causing snaking, because snaking depends on a smooth flow of water to cause sideways movement of the barge.
Other solutions have been proposed for snaking by, for example, U.S. Pat. Nos. 2,998,973; 3,001,501; and 3,056,373. These solutions include drogues, keels and deflector rings, among others.
Another solution for snaking is to construct the container with a shape that provides for stability when towing. A company known as Nordic Water Supply located in Norway has utilized this solution. Flexible transport containers utilized by this company have a shape that can be described as an elongated hexagon. This elongated hexagon shape has been shown to provide for satisfactory stable towing when transporting fresh water on the open sea. However, such containers have size limitations due to the magnitude of the forces placed thereon. In this regard, the relationship of towing force, towing speed and fuel consumption for a container of given shape and size comes into play. The operator of a tugboat pulling a flexible transport container desires to tow the container at a speed that minimizes the cost to transport the cargo. While high towing speeds are attractive in terms of minimizing the towing time, high towing speeds result in high towing forces and high fuel consumption. High towing forces require that the material used in the construction of the container be increased in strength to handle the high loads. Increasing the strength typically is addressed by using thicker container material. This, however, results in an increase in the container weight and a decrease in the flexibility of the material. This, in turn, results in an increase in the difficulty in handling the flexible transport container, as the container is less flexible for winding and heavier to carry.
Moreover, fuel consumption rises rapidly with increased towing speed. For a particular container, there is a combination of towing speed and fuel consumption that leads to a minimum cost for transportation of the cargo. Moreover, high towing speeds can also exacerbate problems with snaking.
In the situation of the elongated hexagon shaped flexible transport containers used in the transport of fresh water in the open sea, it has been found, for a container having a capacity of 20,000 cubic meters, to have an acceptable combination of towing force (about 8 to 9 metric tons), towing speed (about 4.5 knots) and fuel consumption. Elongated hexagon shaped containers having a capacity of 30,000 cubic meters are operated at a lower towing speed, higher towing force and higher fuel consumption than a 20,000 cubic meter cylindrical container. This is primarily due to the fact that the width and depth of the larger elongated hexagon must displace more salt water when pulled through open sea. Further increases in container capacity are desirable in order to achieve an economy of scale for the transport operation. However, further increases in the capacity of elongated hexagon shaped containers will result in lower towing speeds and increased fuel consumption.
The aforenoted concerning snaking, container capacity, towing force, towing speed and fuel consumption defines a need for an improved flexible transport container design. There exists a need for an improved design that achieves a combination of stable towing (no snaking), high FFCV capacity, high towing speed, low towing force and low fuel consumption relative to existing designs.
In addition, to increase the volume of cargo being towed, it has been suggested to tow a number of flexible containers together. Such arrangements can be found in U.S. Pat. Nos. 5,657,714; 5,355,819; and 3,018,748 where a plurality of containers are towed in line one after another. So as to increase stability of the containers, EPO 832 032 B1 discloses towing multiple containers in a pattern side by side.
However, in towing flexible containers side by side, lateral forces caused by ocean wave motion creates instability which results in one container pushing into the other and rolling end over end. Such movements have a damaging effect on the containers and also effect the speed of travel.
Another problem with such flexible containers is the large towing forces thereon, in addition to the forces created by extreme sea and wind conditions. Accordingly, it is imperative that ruptures in the container be avoided, otherwise the entire cargo could become compromised. Reinforcing the container against such failures is desirable and various means for reinforcing the container have been proposed. These typically include the attachment of ropes to the outer surface of the container, as can be seen in, for example, U.S. Pat. Nos. 2,979,008 and 3,067,712. Reinforcement strips and ribs cemented to the outer surface of the container have also been envisioned, as disclosed in U.S. Pat. No. 2,391,926. Such reinforcements, however, suffer the disadvantages of requiring their attachment to the container while also being cumbersome, especially if the container is intended to be wound up when emptied. Moreover, external reinforcements on the container's surface provide for increased drag during towing. While reinforcements are very desirable, especially if a somewhat light weight fabric is envisioned, the manner of reinforcement needs to be improved upon.
Furthermore, while as aforenoted, a seamless flexible container is desirable and has been mentioned in the prior art, the means for manufacturing such a structure has its difficulties. Heretofore, as noted, large flexible containers were typically made in smaller sections which were sewn or bonded together. These sections had to be water impermeable. Typically such sections, if not made of an impermeable material, could readily be provided with such a coating prior to being installed. The coating could be applied by conventional means such as spraying or dip coating.
For larger coated fabrics (i.e. 40′×200′), it is possible to coat them using a large two roll liquid coating system. Although large, these fabrics are not as large as required for FFCVs. It is economically impractical to build a roll system to coat a fabric of the large size envisioned.
As distinct from the roll system, impermeable fabrics have also traditionally been made by applying a liquid coating to a woven or non-woven base structure and then curing or setting the coating via heat or a chemical reaction. The process involves equipment to tension and support the fabric as the coating is being applied and ultimately cured. For fabrics in the size range of 100″ in width, conventional coating lines are capable of handling many hundreds or thousands of feet. They involve the use of support rolls, coating stations and curing ovens that will handle woven substrates that fall within the 100″ width.
However, with an extremely large flexible woven seamless container, in order of 40′ diameter and 1000′ in length or larger, conventional coating methods would be difficult. While relatively small flat fabrics are readily coated, a tubular unitary structure, extremely long and wide, is much more difficult.
Accordingly, there exist a need for a FFCV for transporting large volumes of fluid which overcomes the aforenoted problems attendant to such a structure and the environment in which it is to operate.
SUMMARY OF THE INVENTION
It is therefore a principal object of the invention to provide for a relatively large seamless woven FFCV for the transportation of cargo, including, particularly, fresh water, having a density less than that of salt water.
It is a further object of the invention to provide for such an FFCV which has means of inhibiting the undesired snaking thereof during towing.
It is a further object of the invention to provide means for allowing the transportation of a plurality of such FFCVS.
A further object of the invention is to provide for a means for reinforcing of such an FFCV so as to effectively distribute the load thereon and inhibit rupture.
A yet further object is to provide for a method of coating the woven tube used in the FFCV or otherwise rendering it impermeable.
These and other objects and advantages will be realized by the present invention. In this regard the present invention envisions the use of a seamless woven tube to create the FFCV, having a length of 300′ or more and a diameter of 40′ or more. Such a large structure can be woven on existing machines that weave papermaker's clothing such as those owned and operated by the assignee hereof. The ends of the tube, sometimes referred to as the nose and tail, or bow and stern, are sealed by any number of means, including being folded over and bonded and/or stitched with an appropriate tow bar attached at the nose. Examples of end portions in the prior art can be found in U.S. Pat. Nos. 2,997,973; 3,018,748; 3,056,373; 3,067,712; and 3,150,627. An opening or openings are provided for filling and emptying the cargo such as those disclosed in U.S. Pat. Nos. 3,067,712 and 3,224,403.
In order to reduce the snaking effect on such a long structure, a plurality of longitudinal stiffening beams are provided along its length. These stiffening beams are intended to be pressurized with air or other medium. The beams are preferably woven as part of the tube but also may be woven separately and maintained in sleeves woven as part of the FFCV. They may also be braided in a manner as set forth in U.S. Pat. Nos. 5,421,128 and 5,735,083 or in an article entitled “3-D Braided Composites-Design and Applications” by D. Brookstein, 6 th European Conference on Composite Materials, September 1995. They can also be knit or laid up as an integral part of the textile structure used to make the tube. The entire structure is preferably made as one piece (unitized construction). Attaching or fixing such beams by sewing is also possible, however, unitized construction is preferred due to the ease of manufacturing and its greater strength.
Stiffening or reinforcement beams of similar construction as noted above may also be provided at spaced distances about the circumference of the tube.
The beams also provide buoyancy to the FFCV as the cargo is unloaded to keep it afloat, since the empty FFCV would normally be heavier than salt water. Valves may be provided which allow pressurization and depressurization as the FFCV is wound up for storage.
In the situation where more than one FFCV is being towed, it is envisioned that one way is that they be towed side by side. To increase stability and avoid “roll over”, a plurality of beam separators, preferably containing pressurized air or other medium, would be used to couple adjacent FFCVs together along their length. The beam separators can be affixed to the side walls of the FFCV by way of pin seam connectors or any other means suitable for purpose.
Another way would be by weaving an endless or seamless series of FFCVs interconnected by a flat woven portion.
In addition, the present invention includes fiber reinforcements woven into the tube used to construct the FFCV. These reinforcement fibers can be spaced in the longitudinal direction about the circumference of the tube and in the vertical direction along the length of the tube. In addition to providing reinforcement, such an arrangement may allow for the use of a lighter weight fabric in the construction of the tube. Since they are woven into the fabric, external means for affixing them are not necessary nor do they create additional drag during towing.
Reinforcement may also take the form of woven pockets in the tube to receive lengthwise and circumferential reinforcing ropes or wires which will address the load requirements on the FFCV while preserving its shape.
The present invention also discloses methods rendering the tube impervious. In this regard various methods are proposed so as to allow for conventional coating to be used, i.e. spray, dip coating, etc. The tube can be coated on the inside, outside, or both with an impervious material. The tube, if the weave is tight enough, may be inflated with the outside spray coated. A non-stick bladder may be inserted, if necessary, to allow the coating of the outside. The bladder is then removed and the tube can be inflated and the inside coated. Alternatively, a flat non-stick liner can be inserted into the tube to prevent the sticking of the interior surface during coating and thereafter it is removed. Also, mechanical means may be inserted within the tube during coating to keep the interior surfaces apart during coating.
Alternatively, the tube may be woven with a fiber having a thermoplastic coating or with thermoplastic fibers interdispersed within the weave. The tube would then be subject to heat and pressure so as to cause the thermoplastic material to fill the voids in the weave and create an impermeable tube. An apparatus that provides for accomplishing this is also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
Thus by the present invention its objects and advantages will be realized, the description of which should be taken in conjunction with the drawings, wherein:
FIG. 1 is a somewhat general perspective view of a prior art FFCV which is cylindrical having a pointed bow or nose;
FIG. 2 is a somewhat general perspective view of a FFCV which is cylindrical having a flattened bow or nose incorporating the teachings of the present invention;
FIG. 2A is a somewhat general perspective view of a tongue arrangement sealing the bow or nose of the FFCV incorporating the teachings of the present invention;
FIG. 2B is a side section view of the bow of the FFCV shown in FIG. 2A incorporating the teachings of the present invention;
FIGS. 2C and 2D show an alternative tongue arrangement to that shown in FIGS. 2A and 2B incorporating the teachings of the present invention;
FIG. 2E is a somewhat general perspective view of a collapsed and folded end portion of the FFCV prior to sealing incorporating the teachings of the present invention;
FIG. 2F is a somewhat general perspective view of a FFCV having blunt end caps on its bow and stern incorporating the teachings of the present invention;
FIGS. 2G and 2H show an alternative end cap arrangement to that shown in FIG. 2F incorporating the teachings of the present invention;
FIG. 2I is a somewhat general perspective view of a FFCV having a flattened bow which is orthogonal to the stern incorporating the teachings of the present invention;
FIG. 3 is a sectional view of a FFCV having longitudinal stiffening beams incorporating the teachings of the present invention;
FIG. 3A is a somewhat general perspective view of a FFCV having longitudinal stiffening beams (shown detached) which are inserted in sleeves along the FFCV incorporating the teachings of the present invention;
FIG. 4 is a partially sectional view of a FFCV having circumferential stiffening beams incorporating the teachings of the present invention;
FIG. 5 is a somewhat general view of a pod shaped FFCV having a longitudinal stiffening beam and a vertical stiffening beam at its bow incorporating the teachings of the present invention;
FIGS. 5A and 5B show somewhat general views of a series of pod shaped FFCVs connected by a flat woven structure, incorporating the teachings of the present invention;
FIG. 6 is a somewhat general view of two FFCVs being towed side by side with a plurality of beam separators connected therebetween incorporating the teachings of the present invention;
FIG. 7 is a somewhat schematic view of the force distribution on side by side FFCVs connected by beam separators incorporating the teachings of the present invention;
FIG. 8 is a perspective view of a device for applying heat and pressure to a tube which is to be used in an FFCV incorporating the teachings of the present invention;
FIG. 9 is a perspective view of the device shown in FIG. 8 in conjunction with the tube incorporating the teachings of the present invention; and
FIGS. 10 , 10 A and 10 B are perspective views of an alternative form of the tube portion of the FFCV having woven pockets for receiving reinforcing members incorporating the teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The proposed FFCV 10 is intended to be constructed of a seamless woven impermeable textile tube. The tube's configuration may vary. For example, as shown in FIG. 2 , it would comprise a tube 12 having a substantially uniform diameter (perimeter) and sealed on each end 14 and 16 . It can also have a non-uniform diameter or non-uniform shape. See FIG. 5 . The respective ends 14 and 16 may be closed, pinched, and sealed in any number of ways, as will be discussed. The resulting coated structure will also be flexible enough to be folded or wound up for transportation and storage.
Before discussing more particularly the FFCV design of the present invention, it is important to take into consideration certain design factors. The even distribution of the towing load is crucial to the life and performance of the FFCV. During the towing process there are two types of drag forces operating on the FFCV, viscous drag and form drag forces. The total force, the towing load, is the sum of the viscous and form drag forces. When a stationary filled FFCV is initially moved, there is an inertial force experienced during the acceleration of the FFCV to constant speed. The inertial force can be quite large in contrast with the total drag force due to the large amount of mass being set in motion. It has been shown that the drag force is primarily determined by the largest cross-section of the FFCV profile, or the point of largest diameter. Once at constant speed the inertial tow force is zero and the total towing load is the total drag force.
As part of this, and in addition thereto, it has been determined that to increase the volume of the FFCV, it is more efficient to increase its length than it is to increase both its length and width. For example, a towing force as a function of towing speed, has been developed for a cylindrically shaped transport bag having a spherically shaped bow and stern. It assumes that the FFCV is fully submersed in water. While this assumption may not be correct for a cargo that has a density less than salt water, it provides a means to estimate relative effects of the FFCV design on towing requirements. This model estimates the total towing force by calculating and adding together two components of drag for a given speed. The two components of drag are viscous drag and form drag. The formulae for the drag components are shown below.
Viscous Drag (tons)=(0.25*( A 4+ D 4)*( B 4+(3.142 *C 4))* E 4^1.63/8896
Form Drag (tons)=((( B 4−(3.14 *C 4/2))* C 4/2)^1.87)* E 4^1.33*1.133/8896
Total towing force (tons)=Viscous drag (tons)+Form drag (tons)
where A 4 is the overall length in meters, D 4 is the total length of the bow and stern sections in meters, B 4 is the perimeter of the bag in meters, C 4 is the draught in meters and E 4 is the speed in knots.
The towing force for a series of FFCV designs can now be determined. For example, assume that the FFCV has an overall length of 160 meters, a total length of 10 meters for the bow and stern sections, a perimeter of 35 meters, a speed of 4 knots and the bag being filled 50%. The draught in meters is calculated assuming that the cross sectional shape of the partially filled FFCV has a racetrack shape. This shape assumes that the cross section looks like two half circles joined to a rectangular center section. The draught for this FFCV is calculated to be 3.26 meters. The formula for the draught is shown below.
Draught (meters)= B 4/3.14*(1−((1− J 4)^0.5))
where J 4 is the fraction full for the FFCV (50% in this case).
For this FFCV the total drag is 3.23 tons. The form drag is 1.15 tons and the viscous drag is 2.07 tons. If the cargo was fresh water, this FFCV would carry 7481 tons at 50% full.
If one desires a FFCV that can carry about 60,000 tons of water at 50% full, the FFCV capacity can be increased in at least two ways. One way is to scale up the overall length, total length of the bow and stern sections and perimeter by an equal factor. If these FFCV dimensions are increased by a factor of 2, the FFCV capacity at 50% full is 59,846 tons. The total towing force increases from 3.23 tons for the prior FFCV to 23.72 tons for this FFCV. This is an increase of 634%. The form drag is 15.43 tons (an increase of 1241%) and the viscous drag is 8.29 tons (an increase of 300%). Most of the increase in towing force comes from an increase in the form drag which reflects the fact that this design requires more salt water to be displaced in order for the FFCV to move through the salt water.
An alternative means to increase the capacity to 60,000 tons is to lengthen the FFCV while keeping the perimeter, bow and stern dimensions the same. When the overall length is increased to 1233.6 meters the capacity at 50% fill is 59,836 tons. At a speed of 4 knots the total drag force is 16.31 tons or 69% of the second FFCV described above. The form drag is 1.15 tons (same as the first FFCV) and the viscous drag is 15.15 tons (an increase of 631% over the first FFCV).
This alternative design (an elongated FFCV of 1233.6 meters) clearly has an advantage in terms of increasing capacity while minimizing any increase in towing force. The elongated design will also realize much greater fuel economy for the towing vessel relative to the first scaled up design of the same capacity.
With the preferred manner of increasing the volume of the FFCV having been determined, we turn now to the general construction of the tube 12 which will make up the FFCV. The present invention envisions weaving the tube 12 in a seamless fashion on a large textile loom of the type typically used for weaving seamless papermaker's cloth or fabric. The tube 12 is woven on a loom having a width of about 96 feet. With a loom having such a width, the tube 12 would have a diameter of approximately 92 feet. The tube 12 could be woven to a length of 300 feet or more. The tube as will be discussed will have to be impervious to salt water or diffusion of salt ions. Once this is done, the ends of the tubes are sealed. Sealing is required not only to enable the structure to contain water or some other cargo, but also to provide a means for towing the FFCV.
Sealing can be accomplished in many ways. The sealed end can be formed by collapsing the end 14 of the tube 12 and folded over one or more times as shown in FIG. 2 . One end 14 of the tube 12 can be sealed such that the plane of the sealed surface is, either in the same plane as the seal surface at the other end 16 of the tube. Alternatively, end 14 can be orthogonal to the plane formed by the seal surface at the other end 16 of the tube, creating a bow which is perpendicular to the surface of the water, similar to that of a ship. (See FIG. 2I ). For sealing the ends 14 and 16 of the tube are collapsed such that a sealing length of a few feet results. Sealing is facilitated by gluing or sealing the inner surfaces of the flattened tube end with a reactive material or adhesive. In addition, the flattened ends 14 and 16 of the tube can be clamped and reinforced with metal or composite bars 18 that are bolted or secured through the composite structure. These metal or composite bars 18 can provide a means to attach a towing mechanism 20 from the tugboat that tows the FFCV.
In addition, as shown in FIGS. 2A and 2B , a metal or composite article, which will be called a tongue 22 , can be inserted into and at the end of the tube 12 prior to sealing. The tongue 22 would be contoured to match the shape of the tube end when the tube end is either fully open, partially collapsed, or fully collapsed. The end 14 of the tube 12 would be sealed around the tongue with an adhesive or glue. The tongue would be secured in place with bolts 24 or some other suitable means. The tongue would be bolted not only to the end of the coated tube, but also to any exterior metal plate or composite support device. The tongue could also be fitted with fixtures for towing the FFCV. The tongue could also be fitted with one or more ports or pipes 28 that can be used to either vent the FFCV, fill the FFCV with water, or empty the FFCV of water. These pipes can be made such that pumps connected to a discharge pipe and external power supply can be inserted into the FFCV and be used to empty the FFCV of water.
Other configurations for the construction of the tongue are possible such as the five prong tongue 22 ′ shown in FIGS. 2C and 2D . The tongue 22 ′ would be similarly attached to the tube 12 as discussed with each of the prongs having ports 28 ′ for filling, emptying, or venting. As with each tongue arrangement, it is sized to have an outer surface perimeter to match that of the end of the tube 12 .
An alternative to a tongue arrangement is a pin seam structure that can be created in the sealed end. A way to do this is to make use of the lead and trailing edges of the FFCV to form seams such as a pin seam. A pin seam could be made by starting off the weaving of the tube by first weaving a flat fabric for a length of about 10 feet. The loom configuration would then be changed to transition into a tubular fabric and then at the opposite end changed back to a flat fabric for about 10 feet. After coating the flat end of the tube, it is folded back onto itself to form a closed loop. This loop would be fixed in place by fastening together the two pieces of coated fabric that come in contact to form the loop. These pieces could be fastened with bolts and reinforced with a composite or metal sheet. The closed loop would be machined or cut such that it formed a series of equally sized, looped fingers with spaces between the fingers. These spaces would have a width slightly larger than the width of a looped finger. The looped fingers form one end of a pin seam that can be meshed with another set of looped fingers from another FFCV. Once the looped fingers are meshed from the two ends of two FFCVs, a rope or pintle would be inserted in the loops and fixed in place. This pin seam can be used for attaching a towing mechanism. Alternatively, it can provide a means for joining together two FFCVs. The two FFCVs can be joined together quickly and disconnected quickly by this means of joining.
An alternative to forming a simple collapsed and sealed end involves both collapsing and folding the end 14 of the tube 12 such that the width W of the sealed end matches either the diameter of the tube or the width of the tube when the tube is filled with water and floated in sea water. The general configuration of the collapsed and folded end is shown in FIG. 2E . This feature of matching the width of the sealed end with either the width of the tube or diameter of the tube as filled will minimize stress concentration when the FFCV is being towed.
The end 14 (collapsed and folded) will be sealed with a reactive polymer sealant or adhesive. The sealed end can also be reinforced as previously discussed with metal or composite bars to secure the sealed end and can be provided with a means for attaching a towing device. In addition, a metal or composite tongue, as discussed earlier, can be inserted into and at the end of the tube prior to sealing. The tongue would be contoured to match the shape of the tube end when the tube end is collapsed and folded.
Another means for sealing the ends involves attaching metal or composite end caps 30 as shown in FIG. 2F . In this embodiment, the size of the caps will be determined by the perimeter of the tube. The perimeter of the end cap 30 will be designed to match the perimeter of the inside of the tube 12 and will be sealed therewith by gluing, bolting or any other means suitable for purpose. The end cap 30 will serve as the sealing, filling/emptying via ports 31 , and towing attachment means. The FFCV is not tapered, rather it has a more “blunt” end with the substantially uniform perimeter which distributes the force over the largest perimeter, which is the same all along the length, instead of concentrating the forces on the smaller diameter, neck area of prior art FFCV (see FIG. 1 ). By attaching a tow cap that matches the perimeter it ensures a more equal distribution of forces, particularly start up towing forces, over the entire FFCV structure.
An alternative design of an end cap is shown in FIGS. 2G and 2H . The end cap 30 ′ shown is also made of metal or composite material and is glued, bolted or otherwise sealed to tube 12 . As can be seen, while being tapered, the rear portion of cap 30 ′ has a perimeter that matches the inside perimeter of the tube 12 which provides for even distribution of force thereon.
The collapsed approach, the collapsed and folded configuration for sealing, the tongue approach, or the end cap approach can be designed to distribute, rather than concentrate, the towing forces over the entire FFCV and will enable improved operation thereof.
Having already considered towing forces to determine the shape which is more efficient i.e. longer is better than wider, and the means for sealing the ends of the tube, we turn now to a discussion of the forces on the FFCV itself in material selection and construction.
The forces that may occur in a FFCV can be understood from two perspectives. In one perspective, the drag forces for a FFCV traveling through water over a range of speeds can be estimated. These forces can be distributed evenly throughout the FFCV and it is desirable that the forces be distributed as evenly as possible. Another perspective is that the FFCV is made from a specific material having a given thickness. For a specific material, the ultimate load and elongation properties are known and one can assume that this material will not be allowed to exceed a specific percentage of the ultimate load. For example, assume that the FFCV material has a basis weight of 1000 grams per square meter and that half the basis weight is attributed to the textile material (uncoated) and half to the matrix or coating material with 70% of the fiber oriented in the lengthwise direction of the FFCV. If the fiber is, for example, nylon 6 or nylon 6.6 having a density of 1.14 grams per cubic centimeter, one can calculate that the lengthwise oriented nylon comprises about 300 square millimeters of the FFCV material over a width of 1 meter. Three hundred (300) square millimeters is equal to about 0.47 square inches. If one assumes that the nylon reinforcement has an ultimate breaking strength of 80,000 pounds per square inch, a one meter wide piece of this FFCV material will break when the load reaches 37,600 lbs. This is equivalent to 11,500 pounds per lineal foot. For a FFCV having a diameter of 42 ft. the circumference is 132 ft. The theoretical breaking load for this FFCV would be 1,518,000 lbs. Assuming that one will not exceed 33% of the ultimate breaking strength of the nylon reinforcement, then the maximum allowable load for the FFCV would be about 500,000 lbs or about 4,000 pounds per lineal foot (333 pounds per lineal inch). Accordingly, load requirement can be determined and should be factored into material selection and construction techniques.
Also, the FFCV will experience cycling between no load and high load. Accordingly, the material's recovery properties in a cyclical load environment should also be considered in any selection of material. The materials must also withstand exposure to sunlight, salt water, salt water temperatures, marine life and the cargo that is being shipped. The materials of construction must also prevent contamination of the cargo by the salt water. Contamination would occur, if salt water were forced into the cargo or if the salt ions were to diffuse into the cargo.
With the foregoing in mind, the present invention envisions FFCVs being constructed from coated textiles. Coated textiles have two primary components. These components are the fiber reinforcement and the polymeric coating. A variety of fiber reinforcements and polymeric coating materials are suitable for FFCVs. Such materials must be capable of handling the mechanical loads and various types of extensions which will be experienced by the FFCV.
The present invention envisions a breaking tensile load that the FFCV material should be designed to handle in the range from about 1100 pounds per inch of fabric width to 2300 pounds per inch of fabric width. In addition, the coating must be capable of being folded or flexed repeatedly as the FFCV material is frequently wound up on a reel.
Suitable polymeric coating materials include polyvinyl chloride, polyurethanes, synthetic and natural rubbers, polyureas, polyolefins, silicone polymers and acrylic polymers. These polymers can be thermoplastic or thermoset in nature. Thermoset polymeric coatings may be cured via heat, room temperature curable or UV curable. The polymeric coatings may include plasticizers and stabilizers that either add flexibility or durability to the coating. The preferred coating materials are plasticized polyvinyl chloride, polyurethanes and polyureas. These materials have good barrier properties and are both flexible and durable.
Suitable fiber reinforcement materials are nylons (as a general class), polyesters (as a general class), polyaramids (such as Kevlar®, Twaron or Technora), polyolefins (such as Dyneema and Spectra) and polybenzoxazole (PBO).
Within a class of material, high strength fibers minimize the weight of the fabric required to meet the design requirement for the FFCV. The preferred fiber reinforcement materials are high strength nylons, high strength polyaramids and high strength polyolefins. PBO is desirable for it's high strength, but undesirable due to its relative high cost. High strength polyolefins are desirable for their high strength, but difficult to bond effectively with coating materials.
The fiber reinforcement can be formed into a variety of weave constructions. These weave constructions vary from a plain weave (1×1) to basket weaves and twill weaves. Basket weaves such as a 2×2, 3×3, 4×4, 5×5, 6×6, 2×1, 3×1, 4×1, 5×1 and 6×1 are suitable. Twill weaves such as 2×2, 3×3, 4×4, 5×5, 6×6, 2×1, 3×1, 4×1, 5×1 and 6×1 are suitable. Additionally, satin weaves such as 2×1, 3×1, 4×1, 5×1 and 6×1 can be employed. While a single layer weave has been discussed, as will be apparent to one skilled in the art, multi-layer weaves might also be desirable, depending upon the circumstances.
The yarn size or denier in yarn count will vary depending on the strength of the material selected. The larger the yarn diameter the fewer threads per inch will be required to achieve the strength requirement. Conversely, the smaller the yarn diameter the more threads per inch will be required to maintain the same strength. Various levels of twist in the yarn can be used depending on the surface desired. Yarn twist can vary from as little as zero twist to as high as 20 turns per inch and higher. In addition, yarn shapes may vary. Depending upon the circumstances involved, round, elliptical, flattened or other shapes suitable for the purpose may be utilized.
Accordingly, with all of the foregoing in mind, the appropriate fiber and weave may be selected along with the coating to be used.
Returning now, however, to the structure of the FFCV 10 itself, while it has been determined that a long structure is more efficiently towed at higher speeds (greater than the present 4.5 knots), snaking in such structures is, however, a problem. To reduce the occurrence of snaking, the present invention provides for an FFCV 10 constructed with one or more lengthwise or longitudinal beams 32 that provide stiffening along the length of the tube 12 as shown in FIG. 3 . In this way a form of structural lengthwise rigidity is added to a FFCV 10 . The beams 32 may be airtight tubular structures made from coated fabric. When the beam 32 is inflated with pressurized gas or air, the beam 32 becomes rigid and is capable of supporting an applied load. The beam 32 can also be inflated and pressurized with a liquid such as water or other medium to achieve the desired rigidity. The beams 32 can be made to be straight or curved depending upon the shape desired for the application and the load that will be supported.
The beams 32 can be attached to the FFCV 10 or, they can be constructed as an integral part of the FFCV. In FIG. 3 , two beams 32 , oppositely positioned, are shown. The beams 32 can extend for the entire length of the FFCV 10 or they can extend for just a short portion of the FFCV 10 . The length and location of the beam 32 is dictated by the need to stabilize the FFCV 10 against snaking. The beams 32 can be in one piece or in multiple pieces 34 that extend along the FFCV 10 (see FIG. 4 ).
Preferably the beam 32 is made as an integral part of the FFCV 10 . In this way the beam 32 is less likely to be separated from the FFCV 10 . One or more beams 32 can be woven as an integral part of a single woven tube 12 for the FFCV 10 . It is possible to not only weave the tube 12 that becomes the cargo carrying space, but also simultaneously weave the tubular structure or structures that become the beam or beams 32 in the FFCV 10 . Note that even in the situation where the stiffening beam is an integral part of the FFCV 10 , it may still be woven of a different material or different weave than the FFCV 10 , as will be apparent to the skilled artisan.
It might also, however, be desirable to make the inflatable stiffening beams 33 as separate units and, as shown in FIG. 3A . The tubular structure could have integrally woven sleeves 35 to receive the stiffening beams 33 . This allows for the stiffening beams to be made to meet different load requirements than the tubular structure. Also, the beam may be coated separately from the FFCV to render it impermeable and inflatable, allowing for a different coating for the tubular structure to be used, if so desired.
Similar beams 36 can also be made to run in the cross direction to the length of the FFCV 10 as shown in FIG. 4 . The beams 36 that run in the cross direction can be used to create deflectors along the side of the FFCV 10 . These deflectors can break up flow patterns of salt water along the side of the FFCV 10 , which, according to the prior art, leads to stable towing of the FFCV 10 . See U.S. Pat. No. 3,056,373.
In addition, the beams 32 and 36 , filled with pressurized air, provide buoyancy for the FFCV 10 . This added buoyancy has limited utility when the FFCV 10 is filled with cargo. This added buoyancy has greater utility when the cargo is being emptied from the FFCV 10 . As the cargo is removed from the FFCV 10 , the beams 32 and 36 will provide buoyancy to keep the FFCV 10 afloat. This feature is especially important when the density of the FFCV 10 material is greater than salt water. If the FFCV 10 is to be wound up on a reel as the FFCV 10 is emptied, the beams 32 and 36 can be gradually deflated via bleeder valves to simultaneously provide for ease of winding and flotation of the empty FFCV 10 . The gradually deflated beams 32 can also act to keep the FFCV 10 deployed in a straight fashion on the surface of the water during the winding, filling and discharging operation.
The placement or location of the beams 32 on the FFCV 10 is important for stability, durability and buoyancy of the FFCV 10 . A simple configuration of two beams 32 would place the beams 32 equidistant from each other along the side of the FFCV 10 as shown in FIG. 3 . If the cross sectional area of beams 32 is a small fraction of the total cross sectional area of the FFCV 10 , then the beams 32 will lie below the surface of the salt water when the FFCV 10 is filled to about 50% of the total capacity. As a result the stiffening beams 32 will not be subjected to strong wave action that can occur at the surface of the sea. If strong wave action were to act on the beams 32 , it is possible that the beams 32 would be damaged. Damage to the beams 32 would be detrimental to the durability of the FFCV 10 . Accordingly, it is preferable that the beams 32 are located below the salt water surface when the FFCV 10 is filled to the desired carrying capacity. These same beams 32 will rise to the surface of the salt water when the FFCV 10 is emptied as long as the combined buoyancy of the beams 32 and 36 is greater than any negative buoyancy force that would cause an empty FFCV 10 to sink.
The FFCV 10 can also be made stable against rollover by placing beams in such a way that the buoyancy of the beams counteracts rollover forces. One such configuration is to have three beams. Two beams 32 would be filled with pressurized gas or air and located on the opposite sides of the FFCV 10 . The third beam 38 would be filled with pressurized salt water and would run along the bottom of the FFCV 10 like a keel. If this FFCV 10 were subjected to rollover forces, the combined buoyancy of the side beams 32 and the ballast effect of the bottom beam 38 would result in forces that would act to keep the FFCV 10 from rolling over.
As aforesaid, it is preferable that the beams be an integral part of the structure of the FFCV. The weaving process therefore calls for weaving multiple tubes that are side by side with each tube having dimensions appropriate to the function of the individual tube. In this way it is possible to weave the structure as a unitized or one piece structure. A high modulus fibrous material in the weave for the beams would enhance the stiffening function of the beams. The woven structure can be coated after weaving to create the barriers to keep air, fresh water and salt water separate from each other.
The beams can also be made as separate woven, laid up, knit, nonwoven or braided tubes that are coated with a polymer to allow them to contain pressurized air or water. (For braiding, see U.S. Pat. Nos. 5,421,128 and 5,735,083 and an article entitled “3-D Braided Composite-Design and Applications” by D. Brookstein, 6 th European Conference on Composite Materials (September 1993).) If the beam is made as a separate tube, the beam must be attached to the main tube 12 . Such a beam can be attached by a number of means including thermal welding, sewing, hook and loop attachments, gluing or pin seaming.
The FFCV 10 can also take a pod shape 50 such as that shown in FIG. 5 . The pod shape 50 can be flat at one end 52 or both ends of the tube while being tubular in the middle 54 . As shown in FIG. 5 , it may include stiffening beams 56 as previously discussed along its length and, in addition, a beam 58 across its end 52 which is woven integrally or woven separately and attached.
The FFCV can also be formed in a series of pods 50 ′ woven endless or seamless, as shown in FIGS. 5A and 5B . In this regard, the pods 50 ′ can be created by weaving a flat portion 51 , then the tubular portion 53 , than flat 51 , then tubular 53 , and so on as shown in FIG. 5A . The ends can be sealed in an appropriate manner discussed herein. In FIG. 5B there is also shown a series of pods 50 ′ so formed, however, interconnecting the tubular portions 53 and woven therewith as part of the flat portions 51 , is a tube 55 which allows the pods 50 ′ to be filled and emptied.
Similar type beams have further utility in the transportation of fluids by FFCVs. In this regard, it is envisioned to transport a plurality of FFCVs together so as to, among other things, increase the volume and reduce the cost. Heretofore it was known to tow multiple flexible containers in tandem, side by side or in a pattern. However, in towing FFCVs side by side, there is a tendency for the ocean forces to cause lateral movement of one against the next or rollover. This may have a damaging effect on the FFCV among other things. To reduce the likelihood of such an occurrence, beam separators 60 , of a construction similar to the beam stiffeners previously discussed, are coupled between the FFCVs 10 along their length as shown in FIG. 6 .
The beam separators 60 could be attached by a simple mechanism to the FFCVs 10 such as by a pin seam or quick disconnect type mechanism and would be inflated and deflated with the use of valves. The deflated beams, after discharging the cargo, could be easily rolled up.
The beam separators 60 will also assist in the floatation of the empty FFCVs 10 during roll up operations, in addition to the stiffening beams 32 , if utilized. If the latter was not utilized, they will act as the primary floatation means during roll up.
The beam separators 60 will also act as a floatation device during the towing of the FFCVs 10 reducing drag and potentially provide for faster speeds during towing of filled FFCVs 10 . These beam separators will also keep the FFCV 10 in a relatively straight direction avoiding the need for other control mechanisms during towing.
The beam separators 60 make the two FFCVs 10 appear as a “catamaran”. The stability of the catamaran is predominantly due to its two hulls. The same principles of such a system apply here.
Stability is due to the fact that during the hauling of these filled FFCVs in the ocean, the wave motion will tend to push one of the FFCVs causing it to roll end-over-end as illustrated in FIG. 7 . However, a counter force is formed by the contents in the other FFCV and will be activated to nullify the rollover force generated by the first FFCV. This counter force will prevent the first FFCV from rolling over as it pushes it in the opposite direction. This force will be transmitted with the help of the beam separators 60 thus stabilizing or self correcting the arrangement.
As has been discussed, it is important to distribute as evenly as possible the forces acting on the FFCV 10 . Much of the prior art focuses especially, on the towing forces and provides for longitudinal reinforcements. This is typically addressed by providing reinforcing ropes or strips on the outside of the FFCV.
The present invention is intended to provide an improved and lower-cost option for reinforcement of FFCVs. The present invention is somewhat analogous to what is known as rip-stop fabric where the fabric is provided with reinforcement at predetermined intervals with larger and/or stronger yarn than that used in the rest of the fabric. A typical example of this is how parachutes are constructed. Such a structure not only provides for strength and tear resistance, but may allow for the reduction of the overall weight of the fabric.
In this regard, as illustrated in FIG. 2F , the present invention involves weaving tensile members 70 and 72 into the fabric of the FFCV, in at least one, but preferably both, principal fabric directions at predetermined intervals of possible one to three feet. While both directions are preferable, they need not be of the same strength in both fabric directions. A greater strength contribution may be required in the fore and aft direction. The tensile members may be larger yarns, and/or yarns of greater specific strength (strength per unit weight or unit cross-section) (e.g. Kelvar®, etc.), than the yarns that comprise most of the body of the tube. The member may be woven singly, at intervals as described, or in groups, at intervals. The reinforcing tensile members may also be rope or braid, for example.
The integrally woven tensile members 70 and 72 of the invention will reduce FFCV 10 costs by greatly simplifying fabrication. All steps associated with measuring, cutting, and attaching reinforcing members will be eliminated. The integrally woven reinforcements 70 and 72 will also contribute more to the overall structural integrity of FFCVs because they can be located optimally without regard for fabrication details. In addition to contributing the desired tensile strength, the integrally woven members 70 and 72 will improve tear resistance and reduce the probability of failure or failure propagation upon impact with floating debris.
A skilled worker in the art will appreciate the selection of the reinforcement material used and the intervals or spacing selected will depend upon, among other things, the towing forces involved, the size of the FFCV, the intended cargo and amount thereof, hoop stresses, along with cost factors and the desired results. Implementation and incorporation of the reinforcing material into the integral weave may be accomplished by existing weaving technology known, for example, in the papermaking cloth industry.
An alternative manner of reinforcing the FFCV is that shown in FIGS. 10-10B . In this regard the FFCV may be formed out of a woven fabric 100 which may be woven flat as shown in FIG. 10 . In such a case, the fabric 100 would ultimately be joined together to create a tube with an appropriate water tight seam along its length. Any seam suitable for purpose may be utilized such as a water tight zipper, a foldback seam, or a pin seam arrangement, for example. Alternatively, it may be woven tubular as shown in FIG. 10A . The fabric would be impermeable and have suitable end portions as have been described with regard to other embodiments herein.
As distinct therefrom, the fabric 100 would include woven pockets 102 which can be along its length, circumference, or both. Contained within the pockets 102 would be suitable reinforcement elements 104 and 106 such as rope, wire or other type suitable for the purpose. The number of pockets and spacing would be determined by the load requirements. Also, the type and size of the reinforcement elements 104 and 106 which are placed in the pockets 102 can be varied depending upon the load (e.g. towing force, hoop stress, etc.). The longitudinal reinforcing element 104 would be coupled at their ends to suitable end caps or tow bars, for example. The radial or circumferential reinforcing elements 106 would have their respective ends suitably joined together by clamping, braiding or other means suitable for the purpose.
By the foregoing arrangement, the load on the FFCV is principally on the reinforcing elements 104 and 106 with the load on the fabric being greatly reduced, thus allowing for, among other things, a lighter weight fabric. Also, the reinforcing elements 104 and 106 will act as rip stops so as to contain tears or damage to the fabric.
As shown in FIG. 10B , an FFCV can be fabricated in sections 110 and 112 and constructed with the pockets 102 aforedescribed. These sections 110 and 112 can then be joined together by way of loops 114 placed at the ends thereof to create a type of pin seam which would then be rendered impervious by way of a coating thereof. A water impermeable zipper may also be used, in addition to any other fabric joining technique suitable for the purpose such as a foldback seam or other seams used in, for example, the papermaking industry. In addition, the respective reinforcing members 104 would be coupled together in a suitable manner so as to convey the load therebetween.
Turning now to a method of rendering such a large structure impermeable, there are several ways to accomplish this.
One means for coating does not require that the inner surface of the tube be accessible. This means would utilize an inexpensive film or liner (such as polyethylene). This film or non-stick liner would be inserted in the inner surface of the tube during the weaving process. This can be done by stopping the loom during weaving of the tubular section and inserting the film into the tube via access gained between warp yarns located between the already woven fabric and the beat-up bar of the loom. This insertion process would probably have to be repeated many times during the weaving process in order to line the inner surface of the tube. Once the film has been inserted on the inside surface of the tube, the structure is sealed and the entire structure can be dip coated; spray coated or coated by some other means such that the woven base fabric is impregnated with the desired coating. The resin-impregnated structure is cured to an extent such that, via an opening cut in the tube surface, the film can be removed, the tube partially or totally inflated via pressurized air, and the curing process completed, if required. The film serves to prevent the coating resin from adhering one inner surface of the tube to another inner surface of the tube.
Another method for coating the tube is to dip coat or spray coat the entire structure without any provision being made for preventing the inner surfaces of the tube from contacting each other i.e., without lining the inner surface of the tube with a film or liner. It is possible to weave a structure such that the coating does not pass completely through the fabric, yet the coating penetrates the woven fabric such that the coating adheres to the fabric. This approach allows one to coat the structure and create a coated tube without concern for the inner surfaces adhering to each other.
Another approach involves the use of a fabric design in which the coating passes through the fabric and the inner surfaces do bond to each other upon coating. In this case, one would insert a manhole size piece of metal or plastic film between the inner surfaces of the tube before coating and before or after sealing the ends of the tube. If after, this piece of metal or plastic film would be inserted through a small hole cut in the woven tube. After coating one would insert or connect a pressurized air line to the space or gap created between the metal or plastic film and a coated surface of the tube. This pressurized air would be used to force the two inner surfaces of the tube away from each other i.e., expand the tube. In doing so the coating that bonds the two inner surfaces would fail in a peeling fashion until the entire inner surfaces of the tube are freed from each other. This approach requires a coating resin that can readily fail in a peeling mode of failure. While coating resins are usually designed to resist peeling, curable resins are susceptible to peeling failure when they are only partially cured. The present invention envisions a process whereby the tubular structure is coated, the coating is partially cured such that the coating no longer flows, forces are then applied while the coating is susceptible to peeling failure such that the inner surfaces are freed from each other. If desired, the inside of the expanded tube may now also be coated.
A further method for coating the tube is to spray coat the structure while making some provision to make sure that the inner surfaces of the tube are not in contact with each other. One way to do this is to inflate the tube with air and coat the structure while air holds the inner surfaces apart. This method depends upon the woven structure having a low permeability to air such that the tube can be inflated by inserting a pressurized air line into the tube. Alternatively, one can erect a scaffold within the tube. Such a scaffold might be a metal support structure or a rigid or semi-rigid tube or slinky type structure (with or without a membrane thereabouts) which will approximate the diameter of the inside of the tube and may be sized to allow it to be movable from section to section that is being coated. The scaffold could also be an inflatable arch or tube that is placed inside the tube. Such scaffolds would be placed inside the tube via a manhole sized access point that is cut in the woven tube surface. Once the scaffold is in place, it may be suitable to spray coat the structure from the outside of the tube, the inside of the tube, or both the inside and outside of the tube.
Note that the inflated arch or tube method may actually use the stiffening beams discussed previously. In this regard, such beams could be first made impermeable by being coated and then inflated to support the tube's expanded shape. Coating of the tube's both inner and outer surface can then be accomplished.
A still further method of coating is envisioned. In this regard, an elastic bladder having an outer circumference slightly less than the inner circumference of the tube is fabricated from an impermeable material. It's axial length would be equal to part or whole of the length of the tube. The outer surface of the bladder would have the characteristics of “release or non-adherence” to the resin or other material that will be used to coat and/or impregnate the tube. This can be accomplished by selecting the proper material for the bladder itself or applying a coating on the outside of the bladder. The bladder is placed inside the tube and is then inflated using a gas or liquid so it expands against the inner surface of the tube. The circumference of the bladder when inflated is such that it would apply circumferential tension to the tube along the full axial length of the bladder. A coating can then be applied to the exterior of the tube in the area where it is held under circumferential tension by the bladder. Hand application, spraying, or any other known application technique can be used to apply the coating. If the bladder axial length is less than the axial length of the tube, the bladder can be deflated after application of the coating and relocated to an uncoated length of the tube and the steps are repeated. Due to the “release or non-adherence” surface, the bladder does not “stick” to the coating that may pass through the tube. After the entire circumferential and axial length of the tube has been coated, the bladder is removed. At this point, if it is desired to coat the inside of the tube, the tube can be assembled and sealed at its ends and inflated. The inside of the tube can now be coated. Note, in all cases where the tube is coated on the inside and outside, the coatings used for each should be compatible to create proper bonding.
A yet further method for coating the tube employs a thermoplastic composite approach. In this approach the tube is woven from a mixture of at least two fibrous materials. One material would be the reinforcing fiber and the second material would be a low melting fiber or low melting component of a reinforcing fiber. The low melting fiber or component might be a thermoplastic polyurethane or polyethylene. The reinforcing fiber might be polyester or nylon tire cord or one of the other fiber hereinbefore discussed. The tube would be subjected to heat and pressure in a controlled fashion. This heat and pressure would cause the low melting fiber or component to melt and fill the void in the woven structure. After the heat and pressure are removed and the structure is cooled, a composite structure would form in which the low melting fiber or component has become the matrix for the reinforcing fiber. This approach requires applying heat and pressure while also providing a means to keep the inner surfaces of the tube from adhering or thermally bonding to each other.
FIGS. 8 and 9 show a device 71 which can apply heat and pressure to the tube 12 . The device 71 can be self-propelled or can be moved by external pulling cables. Each section 73 and 74 of the device includes heating or hot plates with respective magnets 76 and motors (not shown) and are positioned on either side of the fabric as shown in FIG. 9 . A power supply (not shown) is provided to energize the heating plates 76 and supply power to the motors that propel the device across the tube 12 . The magnets serve to pull the two hot plates 76 together which creates pressure to the fabric as the coating on the yarn liquefies from the heat. These magnets also keep the top heating plate 76 opposite to the inside heating plate 76 . The device 71 includes endless non-stick belts 78 that ride on rollers 80 located at the plate ends. The belts 78 ride over the plates 76 . In this way there is no movement of the belt 78 in relation to the fabric surface when it is in contact with the fabric. This eliminates smearing of the melted coating and uniform distribution between the yarns. The device moves across the length of the tube 12 at a speed that enables the melted coat to set prior to the fabric folding back upon itself and sticking. If faster speeds are desired, a means for temporarily keeping the inside surfaces apart while setting takes place, may be implemented. This may be, for example, a trailing member on the inside of the tube of similar design to that described but being only one section without, of course, a heating plate or magnet. Other means suitable for this purpose will be readily apparent to those skilled in the art.
As part of the coating process there is envisioned the use of a foamed coating on the inside or outside or both surfaces of the tube. A foamed coating would provide buoyancy to the FFCV, especially an empty FFCV. An FFCV constructed from materials such as, for example, nylon, polyester and rubber would have a density greater than salt water. As a result the empty FFCV or empty portions of the large FFCV would sink. This sinking action could result in high stresses on the FFCV and could lead to significant difficulties in handling the FFCV during filling and emptying of the FFCV. The use of a foam coating provides an alternative or additional means to provide buoyancy to the FFCV to that previously discussed.
Also, in view of the closed nature of the FFCV, if it is intended to transport fresh water, as part of the coating process of the inside thereof, it may provide for a coating which includes a germicide or a fungicide so as to prevent the occurrence of bacteria or mold or other contaminants.
In addition, since sunlight also has a degradation effect on fabric, the FFCV may include as part of its coating or the fiber used to make up the FFCV, a UV protecting ingredient in this regard.
Although preferred embodiments have been disclosed and described in detail herein, their scope should not be limited thereby rather their scope should be determined by that of the appended claims. | A seamless, woven, flexible fluid containment vessel or vessels for transporting and containing a large volume of fluid, particularly fresh water, having beam stabilizers, beam separators, reinforcing, and the method of making the same. | 3 |
FIELD OF THE INVENTION
[0001] This application is in the field of medicinal chemistry. The application relates to novel pyridone-sulfone morphinan analogs, and pharmaceutical compositions comprising one or more of these compounds.
BACKGROUND OF THE INVENTION
[0002] Pain is the most common symptom for which patients seek medical advice and treatment. While acute pain is usually self-limited, chronic pain can persist for 3 months or longer and lead to significant changes in a patient's personality, lifestyle, functional ability and overall quality of life (K. M. Foley, Pain, in Cecil Textbook of Medicine 100-107, J. C. Bennett and F. Plum eds., 20th ed. 1996).
[0003] Pain has traditionally been managed by administering either a non-opioid analgesic (such as acetylsalicylic acid, choline magnesium trisalicylate, acetaminophen, ibuprofen, fenoprofen, diflunisal or naproxen), or an opioid analgesic (such as morphine, hydromorphone, methadone, levorphanol, fentanyl, oxycodone, oxymorphone, or buprenorphine).
[0004] Until recently, there was evidence of three major classes of opioid receptors in the central nervous system (CNS), with each class having subtype receptors. These receptor classes are known as μ, δ and κ. As opiates have a high affinity to these receptors while not being endogenous to the body, research followed in order to identify and isolate the endogenous ligands to these receptors. These ligands were identified as endorphins, enkephalins, and dynorphins, respectively. Additional experimentation has led to the identification of the opioid receptor-like (ORL-1) receptor, which has a high degree of homology to the known opioid receptor classes. This more recently discovered receptor was classified as an opioid receptor based only on structural grounds, as the receptor did not exhibit pharmacological homology. It was initially demonstrated that non-selective ligands having a high affinity for μ, δ and κ receptors had low affinity for the ORL-1 receptor. This characteristic, along with the fact that an endogenous ligand had not yet been discovered, led to the ORL-1 receptor being designated as an “orphan receptor”.
[0005] Kappa (κ) opioid receptor agonists have been evaluated as alternatives to existing analgesics for the treatment of pain. Centrally penetrating κ agonists produce antinociceptive effects in conventional preclinical assays of basal, inflammatory and neuropathic pain (Vanderah et al., J. Pharmacol. Exp. Ther. 310:326-333 (2004); Negus et al., Psychopharmacology ( Berl ) 210:149-159 (2010)). However, centrally penetrating κ agonists can also produce undesirable side-effects, such as sedative and psychotomimetic effects (Pande et al., Clin. Neuropharmacol. 19:92-97 (1996); Pande et al., Clin. Neuropharmacol. 19:451-456 (1996); and Wadenberg, CNS Drug Rev. 9:187-198 (2003)).
[0006] Opioid receptor agonists that do not readily cross the blood-brain barrier are peripherically restricted and distribute poorly to the central nervous system after systemic administration. Such compounds would retain an ability to produce analgesia by acting on peripheral opioid receptors, such as peripheral κ-opioid receptors, but their potency to produce centrally mediated side-effects would be reduced.
[0007] There is a need for effective analgesics that work by acting on opioid receptors. There is also a need for analgesics that work by acting on peripheral opioid receptors. There is also a need for analgesics that work by acting on central opioid receptors. There is also a need for analgesics that work by acting on κ-opioid receptors. There is also a need for analgesics that work by acting on peripheral κ-opioid receptors.
BRIEF SUMMARY OF THE INVENTION
[0008] In one aspect, the present disclosure provides compounds represented by Formulae I-VIII, VIII(A) and IX, below, and the pharmaceutically acceptable salts and solvates thereof, collectively referred to herein as “Compounds of the Invention” (each is individually referred to hereinafter as a “Compound of the Invention”).
[0009] In another aspect, the present disclosure provides the use of Compounds of the Invention as synthesis intermediates.
[0010] In another aspect, the present disclosure provides the use of Compounds of the Invention as modulators of one or more opioid receptors. Specifically, the present disclosure provides the use of Compounds of the Invention as modulators of μ, δ, κ, and/or ORL-1 opioid receptors, and especially modulators of μ and/or κ opioid receptors.
[0011] In another aspect, the present disclosure provides a method of treating or preventing a disorder responsive to the modulation of one or more opioid receptors in a patient, comprising administering to the patient an effective amount of a Compound of the Invention.
[0012] In another aspect, the present disclosure provides a use of a Compound of the Invention as an analgesic to treat or prevent pain; or as an agent to treat or prevent withdrawal from alcohol or drug addiction; or as an agent to treat or prevent addictive disorders; or as an agent to treat a pruritic condition; or as an agent to treat or prevent constipation; or as an agent to treat or prevent diarrhea (each of pain, alcohol withdrawal, drug withdrawal, addictive disorders, pruritis, constipation, and diarrhea being a “Condition”).
[0013] The present invention further provides methods of treating or preventing a Condition, comprising administering to a patient in need thereof a therapeutically effective amount of a Compound of the Invention. In certain embodiments, the Condition is pain (including acute pain, chronic pain (which includes but is not limited to, neuropathic pain, postoperative pain, and inflammatory pain), and surgical pain). The Compounds of the Invention are particularly useful for treating or preventing chronic pain.
[0014] In another aspect, the present disclosure provides a pharmaceutical composition comprising a therapeutically effective amount of a Compound of the Invention and one or more pharmaceutically acceptable carriers. Such compositions are useful for treating or preventing a Condition in a patient.
[0015] In another aspect, the present disclosure provides Compounds of the Invention for use in treatment or prevention of a disorder responsive to the modulation of one or more opioid receptors. Preferably, the disorder is responsive to modulation of the μ-opioid receptor or the κ-opioid receptor, or to modulation of a combination thereof.
[0016] In another aspect, the present disclosure provides a method of modulating one or more opioid receptors in a patient in need of said modulation, comprising administering to the patient an opioid receptor modulating amount of a Compound of the Invention.
[0017] In another aspect, the present disclosure provides Compounds of the Invention for use in treatment or prevention of one or more Conditions in a patient in need of said treatment or prevention.
[0018] In another aspect, the present disclosure provides Compounds of the Invention for use in treatment or prevention of pain in a patient, such as acute pain, chronic pain (which includes but is not limited to, neuropathic pain, postoperative pain, and inflammatory pain), or surgical pain.
[0019] In another aspect, the present disclosure provides Compounds of the Invention for use in modulation of one or more opioid receptors in a patient.
[0020] In another aspect, the present disclosure provides use of Compounds of the Invention in the manufacture of a medicament for treating or preventing a disorder responsive to the modulation of one or more opioid receptors.
[0021] In another aspect, the present disclosure provides use of Compounds of the Invention in the manufacture of a medicament for modulating of one or more opioid receptors in a patient. Preferably, the μ- or κ-opioid receptor is modulated, or both the μ- and κ-opioid receptors are modulated.
[0022] In another aspect, the present disclosure provides Compounds of the Invention for use as a medicament.
[0023] In another aspect, the present disclosure provides use of a Compound of the Invention in the manufacture of a medicament for treating or preventing a Condition in a patient.
[0024] In another aspect, the present disclosure provides use of a Compound of the Invention in the manufacture of a medicament for treating or preventing pain in a patient, such as acute pain, chronic pain, or surgical pain.
[0025] In another aspect, the present disclosure provides a pharmaceutical composition, comprising a Compound of the Invention for treating or preventing a disorder responsive to the modulation of one or more opioid receptors.
[0026] The present invention further provides methods for preparing a pharmaceutical composition, comprising admixing a Compound of the Invention and a pharmaceutically acceptable carrier to form the pharmaceutical composition.
[0027] In another aspect, the present invention provides radiolabeled Compounds of the Invention, especially 1 H, 11 C and 14 C radiolabeled Compounds of the Invention, and the use of such compounds as radioligands to detect binding to an opioid receptor in screening assays.
[0028] In another aspect, the present invention provides a method for screening a candidate compound for the ability to bind to an opioid receptor, comprising a) introducing a fixed concentration of a radiolabeled Compound of the Invention to the receptor under conditions that permit binding of the radiolabeled compound to the receptor to form a complex; b) titrating the complex with a candidate compound; and c) determining the binding of the candidate compound to said receptor.
[0029] In a further aspect, the invention relates to a kit, comprising a sterile container containing an effective amount of a Compound of the Invention and instructions for therapeutic use.
[0030] Additional embodiments and advantages of the disclosure will be set forth, in part, in the description that follows, and will flow from the description, or can be learned by practice of the disclosure. The embodiments and advantages of the disclosure will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
[0031] It is to be understood that both the foregoing summary and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Certain Compounds of the Invention are useful for modulating a pharmacodynamic response from one or more opioid receptors (μ, δ, κ, ORL-1) either centrally or peripherally, or both. The pharmacodynamic response may be attributed to the compound either stimulating (agonizing) or inhibiting (antagonizing) the one or more receptors. Certain Compounds of the Invention may antagonize one opioid receptor, while also agonizing one or more other receptors. Compounds of the Invention having agonist activity may be either full or partial agonists.
[0033] One aspect of the invention is based on the use of certain Compounds of the Invention as synthesis intermediates.
[0034] In one embodiment, Compounds of the Invention are compounds represented by Formula I:
[0000]
[0000] and pharmaceutically acceptable salts and solvates thereof, wherein:
[0035] R 1 is hydrogen, hydroxy, halo, cyano, carboxy, or aminocarbonyl; or alkyl, alkenyl, alkynyl, alkoxy, alkenyloxy, or alkynyloxy, any of which is optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, halo, haloalkyl, amino, alkylamino, dialkylamino, carboxy, alkoxy, alkoxycarbonyl, aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl, wherein said aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl are optionally substituted with 1, 2, or 3 independently selected R 8 groups; or —O-PG, wherein PG is a hydroxyl protecting group;
[0036] R 2 is
a) hydrogen or carboxamido; or b) alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, heterocyclo, aryl, heteroaryl, (cycloalkyl)alkyl, (cycloalkenyl)alkyl, (heterocyclo)alkyl, arylalkyl, heteroarylalkyl, alkylcarbonyl, alkoxycarbonyl, (arylalkoxy)carbonyl, or (heteroarylalkoxy)carbonyl, any of which is optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, alkyl, halo, haloalkyl, amino, alkylamino, dialkylamino, carboxy, alkoxy, alkoxycarbonyl, aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl, wherein said aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl are optionally substituted with 1, 2, or 3 independently selected R 8 groups;
[0039] R 3 is hydrogen, hydroxy, or halo; or alkoxy, alkylamino, or dialkylamino, any of which is optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, halo, haloalkyl, amino, alkylamino, dialkylamino, carboxy, alkoxy, alkoxycarbonyl, aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl, wherein said aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl are optionally substituted with 1, 2, or 3 independently selected R 8 groups;
[0040] is a single bond or a double bond;
[0041] R 4 is absent, hydrogen or alkyl;
[0042] Y is C(═O) or COR 4a ;
[0043] R 4a is hydrogen or alkyl; provided that
[0044] 1) when R 4 is hydrogen or alkyl, then is a single bond and Y is C(═O); and
[0045] 2) when R 4 is absent, then is a double bond and Y is COR 4a ;
[0046] Z is (SO 2 )R 5 ;
[0047] R 5 is selected from the group consisting of:
[0048] a) OH;
[0049] b) optionally substituted alkyl;
[0050] c) optionally substituted alkoxy;
[0051] d) NR 6 R 7 ;
[0052] e) optionally substituted aryl;
[0053] f) optionally substituted heteroaryl;
[0054] g) optionally substituted cycloalkyl;
[0055] h) optionally substituted cycloalkenyl;
[0056] i) optionally substituted heterocyclo;
[0057] j) optionally substituted arylalkyl;
[0058] k) optionally substituted heteroarylalkyl;
[0059] l) optionally substituted (cycloalkyl)alkyl;
[0060] m) optionally substituted (cycloalkenyl)alkyl; and
[0061] n) optionally substituted (heterocyclo)alkyl;
wherein two adjacent carbon atoms of said optionally substituted cycloalkyl and optionally substituted cycloalkenyl rings are optionally fused to a phenyl ring;
[0063] R 6 is hydrogen or alkyl;
[0064] R 7 is selected from the group consisting of hydrogen, optionally substituted carboxyalkyl, optionally substituted (alkoxycarbonyl)alkyl, optionally substituted (carboxamido)alkyl, hydroxyalkyl, alkyl, cycloalkyl, cycloalkenyl, heterocyclo, aryl, heteroaryl, (cycloalkyl)alkyl, (cycloalkenyl)alkyl, (heterocyclo)alkyl, arylalkyl, and heteroarylalkyl, wherein two adjacent carbon atoms of said cycloalkyl and cycloalkenyl rings are optionally fused to a phenyl ring; and wherein said cycloalkyl, cycloalkenyl, heterocyclo, aryl and heteroaryl, and said cycloalkyl, cycloalkenyl, heterocyclo, aryl and heteroaryl portions are optionally substituted with 1, 2, or 3 independently selected R 8 groups; or
[0065] R 6 and R 7 together with the nitrogen atom to which they are attached form an optionally substituted heterocyclic ring; and
[0066] each R 8 is independently selected from the group consisting of hydroxy, halo, alkyl, haloalkyl, cyano, nitro, amino, alkylamino, dialkylamino, carboxy, alkoxy, and alkoxycarbonyl.
[0067] In another embodiment, Compounds of Invention are compounds represented by Formula II:
[0000]
[0000] and the pharmaceutically acceptable salts and solvates thereof, wherein R 1 , R 2 , R 3 , R 4 , Y and Z are as defined for Formula I.
[0068] In another embodiment, Compounds of the Invention are compounds represented by Formula III:
[0000]
[0000] and the pharmaceutically acceptable salts and solvates thereof, wherein R 1 , R 2 , R 3 , R 4 , Y and Z are as defined for Formula I.
[0069] In another embodiment, Compounds of the Invention are compounds represented by Formula IV:
[0000]
[0000] and the pharmaceutically acceptable salts and solvates thereof, wherein R 1 , R 2 , R 3 , R 4 , Y and Z are as defined for Formula I.
[0070] In another embodiment, Compounds of the Invention are compounds represented by Formula V:
[0000]
[0000] and the pharmaceutically acceptable salts and solvates thereof, wherein R 1 , R 2 , R 3 , R 4 , Y and Z are as defined for Formula I.
[0071] In another embodiment, Compounds of the Invention are compounds represented by Formula VI:
[0000]
[0000] and the pharmaceutically acceptable salts and solvates thereof, wherein R 1 , R 2 , R 3 , R 4 , Y and Z are as defined for Formula I.
[0072] In another embodiment, Compounds of the Invention are compounds represented by Formula VII:
[0000]
[0000] and the pharmaceutically acceptable salts and solvates thereof, wherein R 1 , R 2 , R 3 , R 4 , Y and Z are as defined for Formula I.
[0073] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein is a single bond, R 4 is hydrogen or alkyl, and Y is C(═O).
[0074] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein is a double bond, R 4 is absent, Y is COR 4a , and R 4a is hydrogen or alkyl.
[0075] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 1 is hydrogen, hydroxy, halo, cyano, carboxy, or aminocarbonyl; or alkyl, alkenyl, alkynyl, alkoxy, alkenyloxy or alkynyloxy, any of which is optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, halo, haloalkyl, amino, alkylamino, dialkylamino, carboxy, alkoxy, alkoxycarbonyl, aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl, wherein said aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl are optionally substituted with 1, 2, or 3 independently selected R 8 groups.
[0076] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 1 is hydroxy or unsubstituted C 1-6 alkoxy.
[0077] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 1 is hydroxy or methoxy.
[0078] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 1 is —O-PG.
[0079] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein PG is selected from the group consisting of alkyl, arylalkyl, heterocyclo, (heterocyclo)alkyl, acyl, silyl, and carbonate, any of which is optionally substituted.
[0080] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein PG is selected from the group consisting of alkyl, arylalkyl, heterocyclo, (heterocyclo)alkyl, benzoyl, (benzyloxy)carbonyl, alkoxycarbonyl, alkylcarbonyl, and silyl, any of which is optionally substituted.
[0081] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein PG is selected from the group consisting of methyl, tert-butyl, optionally substituted benzyl, optionally substituted benzoyl, acetyl, trimethyl silyl, tert-butyldimethyl silyl, tert-butyldiphenyl silyl, and tri-isopropyl silyl.
[0082] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 2 is hydrogen or carboxamido.
[0083] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 2 is alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, heterocyclo, aryl, heteroaryl, (cycloalkyl)alkyl, (cycloalkenyl)alkyl, (heterocyclo)alkyl, arylalkyl, heteroarylalkyl, alkylcarbonyl, alkoxycarbonyl, (arylalkoxy)carbonyl, or (heteroarylalkoxy)carbonyl, any of which is optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, alkyl, halo, haloalkyl, amino, alkylamino, dialkylamino, carboxy, alkoxy, alkoxycarbonyl, aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl, wherein said aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl are optionally substituted with 1, 2, or 3 independently selected R 8 groups. In one embodiment of any one of Formulae I-VII, R 2 is unsubstituted (C 1-6 )alkyl. In another embodiment, R 2 is unsubstituted (C 1-4 )alkyl.
[0084] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 2 is C 3-7 (cycloalkyl)(C 1-4 )alkyl or C 3-7 (cycloalkenyl)(C 1-4 )alkyl, optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, C 1-4 alkyl, halo, halo(C 1-4 )alkyl, amino, C 1-4 alkylamino, di(C 1-4 )alkylamino, carboxy, C 1-4 alkoxy, and C 1-4 alkoxycarbonyl.
[0085] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 2 is unsubstituted C 1-4 alkyl, or cyclopropyl(C 1-4 )alkyl, cyclobutyl(C 1-4 )alkyl, cyclopentyl(C 1-4 )alkyl, or cyclohexyl(C 1-4 )alkyl, optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, C 1-4 alkyl, halo, halo(C 1-4 )alkyl, amino, C 1-4 alkylamino, di(C 1-4 )alkylamino, carboxy, C 1-4 alkoxy, and C 1-4 alkoxycarbonyl.
[0086] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 2 is methyl, cyclopropylmethyl, benzyl, 2-phenylethyl, 2,2,2-trifluoroethyl, or 2-fluoroethyl.
[0087] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 3 is hydrogen.
[0088] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 3 is hydroxy.
[0089] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, wherein R 3 is unsubstituted C 1-6 alkoxy or C 1-6 alkoxy substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, halo, halo(C 1-4 )alkyl, amino, C 1-4 alkylamino, di(C 1-4 )alkylamino, carboxy, C 1-4 alkoxy, and C 1-4 alkoxycarbonyl.
[0090] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 4 is hydrogen.
[0091] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 4 is C 1-4 alkyl.
[0092] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 4 is absent and R 4a is hydrogen or alkyl.
[0093] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is OH.
[0094] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted alkoxy.
[0095] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is unsubstituted C 1-6 alkoxy or C 1-6 alkoxy substituted with 1, 2, or 3 substituents independently selected from the group consisting of hydroxy, halo, haloalkyl, cyano, nitro, amino, alkylamino, dialkylamino, carboxy, alkoxy, and alkoxycarbonyl.
[0096] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is unsubstituted methoxy.
[0097] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted aryl.
[0098] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted phenyl, naphthyl, phenanthryl, anthracyl, indenyl, azulenyl, biphenyl, biphenylenyl, or fluorenyl.
[0099] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted arylalkyl.
[0100] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted benzyl or phenethyl.
[0101] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted heteroaryl.
[0102] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted thienyl, benzo[b]thienyl, naphtho[2,3-b]thienyl, thianthrenyl, furyl, benzofuryl, pyranyl, isobenzofuranyl, benzooxazonyl, chromenyl, xanthenyl, 2H-pyrrolyl, pyrrolyl, imidazolyl, pyrazolyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, isoindolyl, 3H-indolyl, indolyl, indazolyl, purinyl, isoquinolyl, quinolyl, phthalazinyl, naphthyridinyl, cinnolinyl, quinazolinyl, pteridinyl, 4aH-carbazolyl, carbazolyl, β-carbolinyl, phenanthridinyl, acridinyl, pyrimidinyl, phenanthrolinyl, phenazinyl, thiazolyl, isothiazolyl, phenothiazolyl, isoxazolyl, furazanyl, or phenoxazinyl.
[0103] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted heteroarylalkyl.
[0104] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is (thien-2-yl)methyl, 2-furylmethyl, (pyrrol-1-yl)methyl, or 2-(1H-pyrrol-2-yl)ethyl.
[0105] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted cycloalkyl.
[0106] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, norbornyl, decalin, or adamantly.
[0107] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted (cycloalkyl)alkyl.
[0108] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is optionally substituted (cyclopropyl)methyl, 2-(cyclopropyl)ethyl, (cyclopropyl)propyl, (cyclobutyl)methyl, (cyclopentyl)methyl, or (cyclohexyl)methyl.
[0109] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , wherein R 6 is hydrogen or alkyl; and R 7 is selected from the group consisting of hydrogen, optionally substituted carboxyalkyl, optionally substituted (alkoxycarbonyl)alkyl, optionally substituted (carboxamido)alkyl, hydroxyalkyl, alkyl, cycloalkyl, cycloalkenyl, heterocyclo, aryl, heteroaryl, (cycloalkyl)alkyl, (cycloalkenyl)alkyl, (heterocyclo)alkyl, arylalkyl, and heteroarylalkyl, wherein said cycloalkyl, cycloalkenyl, heterocyclo, aryl and heteroaryl, and said cycloalkyl, cycloalkenyl, heterocyclo, aryl and heteroaryl portions are optionally substituted with 1, 2, or 3 independently selected R 8 groups.
[0110] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , wherein R 6 is hydrogen or C 1-6 alkyl, and R 7 is hydrogen.
[0111] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , wherein R 6 and R 7 are each independently alkyl.
[0112] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , wherein R 6 and R 7 are both hydrogen.
[0113] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , wherein R 6 is hydrogen or alkyl and R 7 is selected from the group consisting of optionally substituted carboxyalkyl, optionally substituted (alkoxycarbonyl)alkyl, optionally substituted (carboxamido)alkyl, and hydroxyalkyl.
[0114] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , wherein R 6 is hydrogen or alkyl, and R 7 is selected from the group consisting of cycloalkyl, cycloalkenyl, heterocyclo, aryl, heteroaryl, (cycloalkyl)alkyl, (cycloalkenyl)alkyl, (heterocyclo)alkyl, arylalkyl, and heteroarylalkyl, wherein two adjacent carbon atoms of said cycloalkyl and cycloalkenyl rings are optionally fused to a phenyl ring; and wherein said cycloalkyl, cycloalkenyl, heterocyclo, aryl and heteroaryl portions are optionally substituted with 1, 2, or 3 independently selected R 8 groups.
[0115] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, and R 7 is optionally substituted carboxy(C 1-6 )alkyl, optionally substituted (C 1-6 alkoxycarbonyl)(C 1-6 )alkyl, or optionally substituted (carboxamido)(C 1-6 )alkyl.
[0116] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, and R 7 is —CHR 9 —C(═O)—Z 1 , wherein:
R 9 is selected from the group consisting of hydrogen, alkyl, hydroxyalkyl, carboxyalkyl, aminoalkyl, (aminocarbonyl)alkyl, (alkylaminocarbonyl)alkyl, (dialkylaminocarbonyl)alkyl, mercaptoalkyl, (alkylthio)alkyl, guanidinoalkyl, arylalkyl, (cyclo alkyl)alkyl, (cycloalkenyl)alkyl, (heterocyclo)alkyl, and (heteroaryl)alkyl, wherein the aryl, cycloalkyl, cycloalkenyl, heterocyclo, and heteroaryl portions are optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, halo, alkyl, haloalkyl, cyano, nitro, amino, alkylamino, dialkylamino, carboxy, alkoxy, and alkoxycarbonyl; and
[0118] Z 1 is OR 10 or NR 11 R 12 , wherein
R 10 is hydrogen or alkyl; and R 11 and R 12 are each independently selected from the group consisting of hydrogen and alkyl.
[0121] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, R 7 is —CHR 9 —C(═O)—Z 1 , and R 9 is selected from the group consisting of hydrogen, C 1-6 alkyl, monohydroxy(C 1-6 )alkyl, carboxy(C 1-6 )alkyl, amino(C 1-6 )alkyl, (aminocarbonyl)(C 1-6 )alkyl, (C 1-4 alkylaminocarbonyl)(C 1-6 )alkyl, (di(C 1-4 )alkylaminocarbonyl)(C 1-6 )alkyl, mercapto(C 1-6 )alkyl, (C 1-4 alkylthio)(C 1-6 )alkyl, guanidino(C 1-6 )alkyl, (C 6-12 aryl)(C 1-6 )alkyl, (C 3-7 cycloalkyl)(C 1-6 )alkyl, (C 3-7 cycloalkenyl)(C 1-6 )alkyl, (5- or 6-membered heterocyclo)(C 1-6 )alkyl, and (5- or 6-membered heteroaryl)(C 1-6 )alkyl, wherein the aryl, cycloalkyl, cycloalkenyl, heterocyclo, and heteroaryl portions are optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, halo, C 1-4 alkyl, halo(C 1-4 )alkyl, cyano, nitro, amino, C 1-4 alkylamino, di(C 1-4 )alkylamino, carboxy, C 1-4 alkoxy, and C 1-4 alkoxycarbonyl.
[0122] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, R 7 is —CHR 9 —C(═O)—Z 1 , and R 9 is selected from the group consisting hydrogen, methyl, iso-propyl, and aminocarbonylmethyl.
[0123] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, R 7 is —CHR 9 —C(═O)—Z 1 , and Z 1 is OR 10 , wherein R 10 is hydrogen or C 1-4 alkyl.
[0124] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, R 7 is —CHR 9 —C(═O)—Z 1 , and Z 1 is NR 11 R 12 , wherein R 11 and R 12 are each independently selected from the group consisting of hydrogen and C 1-4 alkyl.
[0125] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, and R 7 is hydroxyalkyl.
[0126] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , R 6 is hydrogen or C 1-6 alkyl, and R 7 is 1,2-dihydroxyethyl.
[0127] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 and R 6 and R 7 together with the nitrogen atom form an optionally substituted heterocyclic ring.
[0128] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , and wherein R 6 and R 7 together with the nitrogen atom to which they are attached form an optionally substituted 5- or 6-membered heterocyclic ring.
[0129] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , and wherein R 6 and R 7 together with the nitrogen atom form an optionally substituted 7-10 membered bicyclic ring system.
[0130] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is —NR 6 R 7 , and wherein R 6 and R 7 together with the nitrogen atom form an optionally substituted pyrrolidine, piperidine, morpholine, 1,1-dioxothiomorpholine, or iso-indoline.
[0131] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is selected from the group consisting of optionally substituted aryl, optionally substituted heteroaryl, optionally substituted cycloalkyl, optionally substituted cycloalkenyl, optionally substituted heterocyclo, optionally substituted arylalkyl, optionally substituted heteroarylalkyl, optionally substituted (cycloalkyl)alkyl, optionally substituted (cycloalkenyl)alkyl, and optionally substituted (heterocyclo)alkyl, wherein two adjacent carbon atoms of said cycloalkyl or cycloalkenyl rings are optionally fused to a phenyl ring.
[0132] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 5 is unsubstituted phenyl or phenyl substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, alkyl, halo, haloalkyl, amino, alkylamino, dialkylamino, carboxy, alkoxy, alkoxycarbonyl, aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl, wherein said aryl, heteroaryl, heterocyclo, cycloalkyl, and cycloalkenyl are optionally substituted with 1, 2, or 3 independently selected R 8 groups.
[0133] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein Z is selected from the group consisting of (as Z-A list):
[0000]
[0134] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein Z is selected from the group consisting of (as Z-B list):
[0000]
[0135] In other embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein Z is selected from the group Z—B and wherein:
R 1 is hydroxy or unsubstituted C 1-6 alkoxy; R 2 is cyclopropyl(C 1-4 )alkyl, cyclobutyl(C 1-4 )alkyl, cyclopentyl(C 1-4 )alkyl, or cyclohexyl(C 1-4 )alkyl, optionally substituted with 1, 2, or 3 substituents, each independently selected from the group consisting of hydroxy, C 1-4 alkyl, halo, halo(C 1-4 )alkyl, amino, C 1-4 alkylamino, di(C 1-4 )alkylamino, carboxy, C 1-4 alkoxy, and C 1-4 alkoxycarbonyl; R 3 is hydrogen; and R 4 is hydrogen or methyl.
[0140] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 2 is unsubstituted cyclopropyl(C 1-4 )alkyl.
[0141] In certain embodiments, Compounds of the Invention are compounds of any one of Formulae I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein:
[0142] R 1 is hydroxy or unsubstituted C 1-6 alkoxy;
[0143] R 2 is
a) C 1-6 alkyl substituted with 1, 2, or 3 substituents independently selected from the group consisting of halo, halo(C 1-4 )alkyl, phenyl, and heterocyclo; b) unsubstituted C 2-6 alkenyl; or c) C 2-6 alkenyl substituted with 1, 2, or 3 substituents independently selected from the group consisting of C 1-4 alkyl, halo, halo(C 1-4 )alkyl, phenyl, and heterocyclo;
[0147] R 3 is hydrogen or hydroxy; and
[0148] R 4 is hydrogen.
[0149] In certain embodiments, Compounds of the Invention are compounds represented by Formula VIII:
[0000]
[0000] and the pharmaceutically acceptable salts and solvates thereof, wherein R 14 is H or C 1-6 alkyl optionally substituted with 1 or 2 substituents, each independently selected from the group consisting of hydroxy, halo, halo(C 1-4 )alkyl, amino, C 1-4 alkylamino, di(C 1-4 )alkylamino, carboxy, C 1-4 alkoxy, and C 1-4 alkoxycarbonyl;
[0150] R 3 is hydrogen or OH; and
[0151] Z 2 is selected from the group consisting of:
[0000]
[0000] wherein R 15 is hydrogen, C 1-4 alkyl or —(C 1-4 )alkyl-C(═O)NH 2 , R 16 is selected from the group consisting of hydrogen, C 1-4 alkyl, hydroxy, halo, halo(C 1-2 )alkyl, C 1-2 alkoxy, C 1-2 alkoxycarbonyl, and aminocarbonyl.
[0152] In other embodiments, Compounds of the Invention are compounds represented by Formula VIII(A):
[0000]
[0000] and pharmaceutically acceptable salts and solvates thereof, wherein R 14 is H or C 1-6 alkyl optionally substituted with 1 or 2 substituents, each independently selected from the group consisting of hydroxy, halo, halo(C 1-4 )alkyl, amino, C 1-4 alkylamino, di(C 1-4 )alkylamino, carboxy, C 1-4 alkoxy, and C 1-4 alkoxycarbonyl;
[0153] R 3 is hydrogen or OH; and
[0154] Z 2 is selected from the group consisting of:
[0000]
[0000] wherein R 15 is hydrogen, C 1-4 alkyl or —(C 1-4 )alkyl-C(═O)NH 2 ;
[0155] R 16 is selected from the group consisting of hydrogen, C 1-4 alkyl, hydroxy, halo, halo(C 1-2 )alkyl, C 1-2 alkoxy, C 1-2 alkoxycarbonyl, and aminocarbonyl.
[0156] In one embodiment in accordance with Formula VIII or VIII(A), R 14 is H.
[0157] In other embodiments in accordance with Formula VIII or VIII(A), Z 2 is selected from the group consisting of:
[0000]
[0000] In one embodiment, Z 2 is
[0000]
[0000] In another embodiment, Z 2 is
[0000]
[0158] Representative Compounds of the Invention include:
(6R,6aS,12aR)-15-(cyclopropylmethyl)-2,6a-dihydroxy-9-(methylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 5); (6R,6aS,12aR)-15-(cyclopropylmethyl)-2,6a-dihydroxy-9-(phenylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 6); (6R,6aS,12aR)-2,6a-dihydroxy-15-methyl-9-(methylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 7); (6R,6aS,12aR)-2,6a-dihydroxy-15-methyl-9-(phenylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 8); (6R,6aR,12aS)-15-(cyclopropylmethyl)-2-hydroxy-9-(methylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 9); (6R,6aR,12aS)-15-(cyclopropylmethyl)-2-hydroxy-9-(phenylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 10);
and the pharmaceutically acceptable salts and solvates thereof.
[0165] In another embodiment, representative Compounds of the Invention also include:
(6R,6aR,12aS)-2-hydroxy-15-methyl-9-(methylsulfonyl)-6,6a,7,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(11H)-one (Compound 11); and (6R,6aR,12aS)-2-hydroxy-15-methyl-9-(phenylsulfonyl)-6,6a,7,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(11H)-one (Compound 12);
and pharmaceutically acceptable salts and solvates thereof.
[0168] In another embodiment, Compounds of the invention are compounds of any one of Formula I-VII, or a pharmaceutically acceptable salt or solvate thereof, wherein R 1 is —O-PG, wherein PG is a hydroxyl protecting group.
[0169] In another embodiment, Compounds of the Invention are compounds of Formula I, represented by Formula IX:
[0000]
[0000] wherein R 2 , R 3 , R 4 , Y and Z are as defined for Formula I. In certain embodiments, suitable definitions for R 2 , R 3 and Z are those described above for any of Formulae I-VIII and VIII(A).
[0170] Suitable hydroxyl protecting groups for PG are well known and include, for example, any suitable hydroxyl protecting group disclosed in Wuts, P. G. M. & Greene, T. W., Greene's Protective Groups in Organic Synthesis, 4rd Ed., pp. 16-430 (J. Wiley & Sons, 2007), herein incorporated by reference in its entirety. The term “hydroxyl protecting group” as used herein refers to a group that blocks (i.e., protects) the hydroxy functionality while reactions are carried out on other functional groups or parts of the molecule. Those skilled in the art will be familiar with the selection, attachment, and cleavage of protecting groups and will appreciate that many different protective groups are known in the art, the suitability of one protective group or another being dependent on the particular synthetic scheme planned. Suitable hydroxy protecting groups are generally able to be selectively introduced and removed using mild reaction conditions that do not interfere with other portions of the subject compounds. These protecting groups can be introduced or removed at a convenient stage using methods known in the art. The chemical properties of such groups, methods for their introduction and removal are known in the art and can be found, for example, in Greene, T. W. and Wuts, P. G. M., above. Additional hydroxyl protecting groups can be found, for example, in U.S. Pat. No. 5,952,495, U.S. Patent Appl. Pub. No. 2008/0312411, WO 2006/035195, and WO 98/02033, which are herein incorporated in their entireties. Suitable hydroxyl protecting groups include the methoxymethyl, tetrahydropyranyl, tert-butyl, allyl, tert-butyldimethylsilyl, tert-butyldiphenylsilyl, acetyl, pivaloyl, benzoyl, benzyl (Bn), and p-methoxybenzyl group.
[0171] It will be apparent to a person of ordinary skill in the art in view of this disclosure that certain groups included in the definitions of —O-PG overlap with the other definitions for R 1 , such as methoxy, tert-butoxy, etc., and, thus, certain Compounds of the Invention having R 1 groups that include groups acting as hydroxyl protecting groups can be pharmaceutically active as described herein.
[0172] In one embodiment, the hydroxyl protecting group PG is selected from the group consisting of alkyl, arylalkyl, heterocyclo, (heterocyclo)alkyl, acyl, silyl, and carbonate, any of which are optionally substituted.
[0173] In another embodiment, the hydroxyl group PG is an alkyl group, typically an optionally substituted C 1-6 alkyl group, and suitably unsubstituted methyl or tert-butyl.
[0174] In another embodiment, the hydroxyl protecting group PG is an arylalkyl group. Suitable arylalkyl groups include, for example, an unsubstituted benzyl group, substituted benzyl groups, such as p-methoxybenzyl, and naphthylmethyl.
[0175] In another embodiment, the hydroxyl protecting group PG is a heterocyclo group, such as unsubstituted tetrahydropyranyl or optionally substituted tetrahydropyranyl.
[0176] In another embodiment, the hydroxyl protecting group PG is a (heterocyclo)alkyl group. Suitable (heterocyclo)alkyl groups include, for example, 4-morpholinyl(C 1-4 )alkyl groups, such as, 2-(4-morpholinyl)ethyl.
[0177] In another embodiment, the hydroxyl protecting group PG is a silyl group. The term “silyl” as employed herein refers to the group having the following structure:
[0000]
[0000] wherein R 17 , R 18 , and R 19 are each independently selected from the group consisting of alkyl, cycloalkyl, aryl, (cycloalkyl)alkyl, or arylalkyl, any of which is optionally substituted. In one embodiment, the silyl group is trimethyl silyl, tert-butyldimethyl silyl, tert-butyldiphenyl silyl, or tri-isopropyl silyl.
[0178] In another embodiment, the hydroxyl protecting group PG is an acyl group. The term “acyl” as employed herein refers to the following structure:
[0000]
[0000] wherein R 20 is alkyl, cycloalkyl, aryl, (cycloalkyl)alkyl, or arylalkyl, any of which is optionally substituted. The acyl group can be, for example, C 1-4 alkylcarbonyl (such as, for example, acetyl), arylcarbonyl (such as, for example, benzoyl), levulinoyl, or pivaloyl. In another embodiment, the acyl group is benzoyl.
[0179] In another embodiment, the hydroxyl protecting group is a carbonate group. The term “carbonate” as employed herein refers to the following structure:
[0000]
[0000] wherein R 21 is alkyl, alkenyl, cycloalkyl, aryl, (cycloalkyl)alkyl, or arylalkyl, any of which is optionally substituted. Typically, R 21 is C 1-10 alkyl (e.g., 2,4-dimethylpent-3-yl), C 2-6 alkenyl (e.g., ethenyl or prop-2-enyl, i.e., allyl), C 3-12 cycloalkyl (e.g., adamantyl), phenyl, or benzyl. In one embodiment, the carbonate is (benzyloxy)carbonyl.
[0180] Optional substituents attached to aryl, phenyl and heteroaryl rings each take the place of a hydrogen atom that would otherwise be present in any position on the aryl, phenyl or heteroaryl rings.
[0181] Useful halo or halogen groups include fluorine, chlorine, bromine and iodine.
[0182] Useful alkyl groups are selected from straight-chain and branched-chain C 1-10 alkyl groups. Typical C 1-10 alkyl groups include methyl (Me), ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, and n-decyl, isopropyl, sec-butyl, tert-butyl, iso-butyl, iso-pentyl, neopentyl, 1-methylbutyl, 2-methylbutyl, 3-methylbutyl, 1,1-dimethylpropyl, 1,2-dimethylpropyl, 1-methylpentyl, 2-methylpentyl, 3-methylpentyl, 4-methylpentyl, 1-ethylbutyl, 2-ethylbutyl, 3-ethylbutyl, 1,1-dimethylbutyl, 1,2-dimethylbutyl, 1,3-dimethylbutyl, 2,2-dimethylbutyl, 2,3-dimethylbutyl, 3,3-dimethylbutyl, 1-methylhexyl, 2-methylhexyl, 3-methylhexyl, 4-methylhexyl, 5-methylhexyl, 1,2-dimethylpentyl, 1,3-dimethylpentyl, 1,2-dimethylhexyl, 1,3-dimethylhexyl, 3,3-dimethylhexyl, 1,2-dimethylheptyl, 1,3-dimethylheptyl, and 3,3-dimethylheptyl, among others. In one embodiment, useful alkyl groups are selected from straight chain C 1-6 alkyl groups and branched chain C 3-6 alkyl groups. Typical C 1-6 alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, iso-butyl, pentyl, 3-pentyl, hexyl, among others. In one embodiment, useful alkyl groups are selected from straight chain C 2-6 alkyl groups and branched chain C 3-6 alkyl groups. Typical C 2-6 alkyl groups include ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, iso-butyl, pentyl, 3-pentyl, hexyl among others. In one embodiment, useful alkyl groups are selected from straight chain C 1-4 alkyl groups and branched chain C 3-4 alkyl groups. Typical C 1-4 alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, and iso-butyl.
[0183] Useful alkenyl groups are selected from straight-chain and branched-chain C 2-6 alkenyl groups, preferably C 2-4 alkenyl. Typical C 2-6 alkenyl groups include ethenyl, propenyl, isopropenyl, butenyl, sec-butenyl, pentenyl, and hexenyl. Typical C 2-4 alkenyl groups include ethenyl, propenyl, isopropenyl, butenyl, and sec-butenyl.
[0184] Useful alkynyl groups are selected from straight-chain and branched-chain C 2-6 alkynyl groups, preferably C 2-4 alkynyl. Typical C 2-6 alkynyl groups include ethynyl, propynyl, butynyl, 2-butynyl, pentynyl, and hexynyl groups. Typical C 2-4 alkynyl groups include ethynyl, propynyl, butynyl, and 2-butynyl groups.
[0185] Useful haloalkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably C 1-6 alkyl groups, and preferably any of the above-mentioned C 1-4 alkyl groups, substituted by one or more fluorine, chlorine, bromine or iodine atoms (e.g., fluoromethyl, difluoromethyl, trifluoromethyl, pentafluoroethyl, 1,1-difluoroethyl, 2,2-difluoroethyl, 2,2,2-trifluoroethyl, 3,3,3-trifluoropropyl, 4,4,4-trifluorobutyl, and trichloromethyl groups).
[0186] Useful hydroxyalkyl groups include any of the above-mentioned C 1-10 alkyl groups, preferably any of the above-mentioned C 1-6 alkyl groups, and more preferably any of the above-mentioned C 1-4 alkyl groups, substituted by one or more hydroxy groups, such as monohydroxyalkyl and dihydroxyalkyl groups (e.g., hydroxymethyl, hydroxyethyl, hydroxypropyl, hydroxybutyl, hydroxypentyl, and hydroxyhexyl groups, and especially hydroxymethyl, 1-hydroxyethyl, 2-hydroxyethyl, 1,2-dihydroxyethyl, 2-hydroxypropyl, 2-hydroxyprop-2-yl, 3-hydroxypropyl, 2,3-dihydroxypropyl, 3-hydroxybutyl, 4-hydroxybutyl, 2-hydroxy-1-methylpropyl, and 1,3-dihydroxyprop-2-yl). In one embodiment, the monohydroxyalkyl is monohydroxy(C 1-4 )alkyl. In one embodiment, the dihydroxyalkyl is dihydroxy(C 1-4 )alkyl.
[0187] Useful cycloalkyl groups are selected from saturated cyclic hydrocarbon groups containing 1, 2, or 3 rings having 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 carbon atoms (i.e., C 3 -C 12 cycloalkyl) or the number of carbons designated. In one embodiment, the cycloalkyl has one or two rings. In another embodiment, the cycloalkyl is a C 3 -C 8 cycloalkyl. In another embodiment, the cycloalkyl is a C 3-7 cycloalkyl. In another embodiment, the cycloalkyl is a C 3-6 cycloalkyl. Exemplary cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, norbornyl, decalin, and adamantyl.
[0188] Useful cycloalkenyl groups are selected from partially unsaturated (i.e., containing one or two double bonds) cyclic hydrocarbon groups containing 1, 2, or 3 rings having 4, 5, 6, 7, 8, 9, 10, 11, or 12 carbon atoms (i.e., C 4 -C 12 cycloalkenyl) or the number of carbons designated. In one embodiment, the cycloalkenyl has one or two rings. In another embodiment, the cycloalkenyl is a C 3 -C 8 cycloalkenyl. In another embodiment, the cycloalkenyl is a C 3 -C 7 cycloalkenyl. In another embodiment, the cycloalkenyl is a C 3 -C 6 cycloalkenyl. In one embodiment, the cycloalkenyl group contains one double bond. Exemplary cycloalkenyl groups containing one double bond include cyclobutenyl, cyclopentenyl, cyclohexenyl, cycloheptenyl, cyclooctenyl, cyclononenyl, and cyclodecenyl. In another embodiment, the cycloalkenyl group contains two double bonds. Preferably, the cycloalkenyl groups containing two double bonds have 5, 6, 7, 8, 9, 10, 11, or 12 carbon atoms (i.e., C 5 -C 12 cycloalkadienyl). Exemplary cycloalkenyl groups having two double bonds include cyclopentadienyl, cyclohexadienyl, cycloheptadienyl, cyclooctadienyl, cyclononadienyl, and cyclodecadienyl.
[0189] Useful alkoxy groups include oxygen substituted by one of the C 1-10 alkyl groups mentioned above (e.g., methoxy, ethoxy, propoxy, iso-propoxy, butoxy, tert-butoxy, iso-butoxy, sec-butoxy, pentyloxy, hexyloxy, heptyloxy, octyloxy, nonyloxy and decyloxy), preferably by one of the C 1-6 alkyl groups, and more preferably one of the C 1-4 alkyl groups.
[0190] Useful alkenyloxy groups include oxygen substituted by one of the C 2-6 alkenyl groups, and preferably the C 2-4 alkenyl groups, mentioned above (e.g., ethenyloxy, propenyloxy, isopropenyloxy, butenyloxy, sec-butenyloxy, pentenyloxy, and hexenyloxy).
[0191] Useful alkynyloxy groups include oxygen substituted by one of the C 2-6 alkynyl groups, preferably the C 2-4 alkynyl groups, mentioned above (e.g., ethynyloxy, propynyloxy, butynyloxy, 2-butynyloxy, pentynyloxy, and hexynyloxy).
[0192] Useful alkoxyalkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with any of the above-mentioned alkoxy groups (e.g., methoxymethyl, methoxyethyl, methoxypropyl, methoxybutyl, ethoxymethyl, 2-ethoxyethyl, 3-ethoxypropyl, 4-ethoxybutyl, propoxymethyl, iso-propoxymethyl, 2-propoxyethyl, 3-propoxypropyl, butoxymethyl, tert-butoxymethyl, isobutoxymethyl, sec-butoxymethyl, and pentyloxymethyl).
[0193] Useful haloalkoxy groups include oxygen substituted by one of the C 1-10 haloalkyl groups, and preferably one of the C 1-6 haloalkyl groups, mentioned above (e.g., fluoromethoxy, difluoromethoxy, trifluoromethoxy, and 2,2,2-trifluoroethoxy).
[0194] Useful (cycloalkyl)alkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with any of the above-mentioned cycloalkyl groups (e.g., (cyclopropyl)methyl, 2-(cyclopropyl)ethyl, (cyclopropyl)propyl, (cyclobutyl)methyl, (cyclopentyl)methyl, and (cyclohexyl)methyl).
[0195] Useful (cycloalkenyl)alkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with any of the above-mentioned cycloalkenyl groups (e.g., (cyclobutenyl)methyl, 2-(cyclobutenyl)ethyl, (cyclobutenyl)propyl, (cyclopentenyl)methyl, (cyclohexenyl)methyl, and (cyclopentadienyl)methyl).
[0196] Useful aryl groups are C 6-14 aryl, especially C 6-10 aryl. Typical C 6-14 aryl groups include phenyl (Ph), naphthyl, phenanthryl, anthracyl, indenyl, azulenyl, biphenyl, biphenylenyl, and fluorenyl groups, more preferably phenyl, naphthyl, and biphenyl groups.
[0197] Useful aryloxy groups include oxygen substituted by one of the aryl groups mentioned above (e.g., phenoxy).
[0198] Useful arylalkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted by any of the above-mentioned aryl groups (e.g., benzyl and phenethyl).
[0199] Useful arylalkenyl groups include any of the above-mentioned C 2-6 alkenyl groups substituted by any of the above-mentioned aryl groups (e.g., phenylethenyl).
[0200] Useful arylalkynyl groups include any of the above-mentioned C 2-6 alkynyl groups substituted by any of the above-mentioned aryl groups (e.g., phenylethynyl).
[0201] Useful aralkyloxy or arylalkoxy groups include oxygen substituted by one of the above-mentioned arylalkyl groups (e.g., benzyloxy).
[0202] Useful (arylalkoxy)carbonyl groups include a carbonyl group substituted by any of the above-mentioned arylalkoxy groups (e.g., (benzyloxy)carbonyl).
[0203] The term “heteroaryl” or “heteroaromatic” as employed herein refers to groups having 5 to 14 ring atoms, with 6, 10 or 14 r electrons shared in a cyclic array, and containing carbon atoms and 1, 2, or 3 oxygen, nitrogen or sulfur heteroatoms, or 4 nitrogen atoms. In one embodiment, the heteroaryl group is a 5- to 10-membered heteroaryl group. Examples of heteroaryl groups include thienyl, benzo[b]thienyl, naphtho[2,3-b]thienyl, thianthrenyl, furyl, benzofuryl, pyranyl, isobenzofuranyl, benzooxazonyl, chromenyl, xanthenyl, 2H-pyrrolyl, pyrrolyl, imidazolyl, pyrazolyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, isoindolyl, 3H-indolyl, indolyl, indazolyl, purinyl, isoquinolyl, quinolyl, phthalazinyl, naphthyridinyl, cinnolinyl, quinazolinyl, pteridinyl, 4aH-carbazolyl, carbazolyl, β-carbolinyl, phenanthridinyl, acridinyl, pyrimidinyl, phenanthrolinyl, phenazinyl, thiazolyl, isothiazolyl, phenothiazolyl, isoxazolyl, furazanyl, and phenoxazinyl. Typical heteroaryl groups include thienyl (e.g., thien-2-yl and thien-3-yl), furyl (e.g., 2-furyl and 3-furyl), pyrrolyl (e.g., pyrrol-1-yl, 1H-pyrrol-2-yl and 1H-pyrrol-3-yl), imidazolyl (e.g., imidazol-1-yl, 1H-imidazol-2-yl and 1H-imidazol-4-yl), tetrazolyl (e.g., tetrazol-1-yl and tetrazol-5-yl), pyrazolyl (e.g., 1H-pyrazol-3-yl, 1H-pyrazol-4-yl, and 1H-pyrazol-5-yl), pyridyl (e.g., pyridin-2-yl, pyridin-3-yl, and pyridin-4-yl), pyrimidinyl (e.g., pyrimidin-2-yl, pyrimidin-4-yl, pyrimidin-5-yl, and pyrimidin-5-yl), thiazolyl (e.g., thiazol-2-yl, thiazol-4-yl, and thiazol-5-yl), isothiazolyl (e.g., isothiazol-3-yl, isothiazol-4-yl, and isothiazol-5-yl), oxazolyl (e.g., oxazol-2-yl, oxazol-4-yl, and oxazol-5-yl) and isoxazolyl (e.g., isoxazol-3-yl, isoxazol-4-yl, and isoxazol-5-yl). A 5-membered heteroaryl can contain up to 4 heteroatoms. A 6-membered heteroaryl can contain up to 3 heteroatoms. Each heteroatom is independently selected from nitrogen, oxygen and sulfur.
[0204] Useful heteroarylalkyl groups include any of the above-mentioned C 1-10 alkyl groups substituted by any of the above-mentioned heteroaryl groups (e.g., (thien-2-yl)methyl, 2-furylmethyl, (pyrrol-1-yl)methyl, and 2-(1H-pyrrol-2-yl)ethyl).
[0205] Useful heteroarylalkoxy groups include oxygen substituted by one of the above-mentioned heteroaryl groups.
[0206] Useful (heteroarylalkoxy)carbonyl groups include a carbonyl group substituted by any of the above-mentioned heteroarylalkoxy groups.
[0207] The terms “heterocyclic” and “heterocyclo” are used herein to mean saturated or partially unsaturated 3-7 membered monocyclic, or 7-10 membered bicyclic ring system, which consist of carbon atoms and from one to four heteroatoms independently selected from the group consisting of O, N, and S, wherein the nitrogen and sulfur heteroatoms can be optionally oxidized, the nitrogen can be optionally quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring, and wherein the heterocyclic ring can be substituted on a carbon atom or on a nitrogen atom if the resulting compound is stable. In one embodiment, the 3- to 7-membered monocyclic heterocyclic ring is either a saturated, or unsaturated non-aromatic ring. A 3-membered heterocyclo can contain up to 1 heteroatom, a 4-membered heterocyclo can contain up to 2 heteroatoms, a 5-membered heterocyclo can contain up to 4 heteroatoms, a 6-membered heterocyclo can contain up to 4 heteroatoms, and a 7-membered heterocyclo can contain up to 5 heteroatoms. Each heteroatom is independently selected from nitrogen, which can be quaternized; oxygen; and sulfur, including sulfoxide and sulfone. The 3- to 7-membered heterocyclo can be attached via a nitrogen or carbon atom. A 7- to 10-membered bicyclic heterocyclo contains from 1 to 4 heteroatoms independently selected from nitrogen, which can be quaternized; oxygen; and sulfur, including sulfoxide and sulfone. The 7- to 10-membered bicyclic heterocyclo can be attached via a nitrogen or carbon atom. Examples of the heterocyclic rings include, but are not limited to, pyrrolidinyl, piperidinyl, piperazinyl, morpholinyl, imidazolinyl, pyrazolidinyl, tetrahydrofuranyl, oxazolidinyl, 2-oxooxazolidinyl, tetrahydrothienyl, imidazolidinyl, hexahydropyrimidinyl, and benzodiazepines.
[0208] Useful (heterocyclo)alkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted by any of the above-mentioned heterocyclic groups (e.g., (pyrrolidin-2-yl)methyl, (pyrrolidin-1-yl)methyl, (piperidin-1-yl)methyl, (morpholin-4-yl)methyl, (2-oxooxazolidin-4-yl)methyl, 2-(2-oxooxazolidin-4-yl)ethyl, (2-oxo-imidazolidin-1-yl)methyl, (2-oxo-imidazolidin-1-yl)ethyl, and (2-oxo-imidazolidin-1-yl)propyl).
[0209] As used herein, the term “amino” or “amino group” refers to —NH 2 .
[0210] Useful aminoalkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with one or more amino group.
[0211] Useful alkylamino and dialkylamino groups are —NHR 22 and —NR 22 R 23 , respectively, wherein R 22 and R 23 are each independently selected from a C 1-10 alkyl group. As used herein, the term “aminocarbonyl” refers to —C(═O)NH 2 .
[0212] Useful (aminocarbonyl)alkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with one or more aminocarbonyl groups.
[0213] Useful alkylcarbonyl groups include a carbonyl group, i.e., —C(═O)—, substituted by any of the above-mentioned C 1-10 alkyl groups.
[0214] Useful alkoxycarbonyl groups include a carbonyl group substituted by any of the above-mentioned alkoxy groups (e.g., methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, iso-propoxycarbonyl, butoxycarbonyl, tert-butoxycarbonyl, iso-butoxycarbonyl, sec-butoxycarbonyl, and pentyloxycarbonyl).
[0215] Useful (alkoxycarbonyl)alkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted by any of the above-mentioned alkoxycarbonyl groups.
[0216] Useful arylcarbonyl groups include a carbonyl group substituted by any of the above-mentioned aryl groups (e.g., benzoyl).
[0217] Useful alkylcarbonyloxy or acyloxy groups include oxygen substituted by one of the above-mentioned alkylcarbonyl groups.
[0218] Useful alkylcarbonylamino or acylamino groups include any of the above-mentioned alkylcarbonyl groups attached to an amino nitrogen, such as methylcarbonylamino.
[0219] As used herein, the term “carboxamido” refers to a radical of formula —C(═O)NR 24 R 25 , wherein R 24 and R 25 are each independently hydrogen, optionally substituted C 1-10 alkyl, or optionally substituted aryl. Exemplary carboxamido groups include —CONH 2 , —CON(H)CH 3 , —CON(CH 3 ) 2 , and —CON(H)Ph.
[0220] Useful (carboxamido)alkyl groups are any of the above-mentioned C 1-10 groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with any of the above-mentioned carboxamido groups.
[0221] Useful alkylaminocarbonyl and dialkylaminocarbonyl groups are any of the above-mentioned carboxamido groups, where R 24 is H and R 25 is C 1-10 alkyl or where R 24 and R 25 are each independently selected from a C 1-10 alkyl group, respectively.
[0222] Useful (alkylaminocarbonyl)alkyl groups include any of the of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with any of the above-mentioned alkylaminocarbonyl groups.
[0223] Useful (dialkylaminocarbonyl)alkyl groups include any of the of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with any of the above-mentioned dialkylaminocarbonyl groups.
[0224] As used herein, the term “sulfonamido” refers to a radical of formula —SO 2 NR 26 R 27 , wherein R 26 and R 27 are each independently hydrogen, optionally substituted C 1-10 alkyl, or optionally substituted aryl. Exemplary sulfonamido groups include —SO 2 NH 2 , —SO 2 N(H)CH 3 , and —SO 2 N(H)Ph.
[0225] As used herein, the term “thiol” refers to —SH.
[0226] Useful mercaptoalkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted by a —SH group.
[0227] Useful alkylthio groups include sulphur substituted by one of the C 1-10 alkyl groups mentioned above (e.g., methylthio, ethylthio, propylthio, iso-propylthio, butylthio, tert-butylthio, iso-butylthio, sec-butylthio, pentylthio, hexylthio, heptylthio, octylthio, nonylthio and decylthio), and preferably by one of the C 1-6 alkyl groups.
[0228] Useful (alkylthio)alkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted with one more of the above-mentioned alkylthio groups (e.g., methylthiomethyl, methylthioethyl, methylthiopropyl, methylthiobutyl, ethylthiomethyl, 2-ethylthioethyl, 3-ethylthiopropyl, 4-ethylthiobutyl, propylthiomethyl, iso-propylthiomethyl, 2-propylthioethyl, 3-propylthiopropyl, butylthiomethyl, tert-butylthiomethyl, isobutylthiomethyl, sec-butylthiomethyl, and pentylthiomethyl).
[0229] As used herein, the term “carboxy” refers to —COOH.
[0230] Useful carboxyalkyl groups include any of the above-mentioned C 1-10 alkyl groups, and preferably any of the above-mentioned C 1-6 alkyl groups, substituted by —COOH.
[0231] As used herein, the terms “hydroxyl” or “hydroxy” refer to —OH.
[0232] As used herein, the term “cyano” refers to —CN.
[0233] As used herein, the term “nitro” refers to —NO 2 .
[0234] As used herein, the term “ureido” refers to —NH—C(═O)—NH 2 .
[0235] As used herein, the term “azido” refers to —N 3 .
[0236] The term “guanidino” refers to —NH(NH═)CNH 2 .
[0237] Useful guanidinoalkyl groups include any of the above-mentioned C 1-10 alkyl groups, preferably any of the above-mentioned C 1-6 alkyl groups, substituted by —NH(NH═)CNH 2 .
[0238] The term “ambient temperature” as used herein means the temperature of the surroundings. The ambient temperature indoors is the same as room temperature, which is from about 20° C. to about 25° C.
[0239] The term “about,” as used herein in connection with a measured quantity, refers to the normal variations in that measured quantity, as expected by the skilled artisan making the measurement and exercising a level of care commensurate with the objective of measurement and the precision of the measuring equipment. Typically, the term “about” includes the recited number ±10%. Thus, “about 10” means 9 to 11.
[0240] As used herein, the term “optionally substituted” refers to a group that may be unsubstituted or substituted.
[0241] As used herein, the term “optionally fused to a phenyl ring” refers to a group that may have a fused phenyl ring or may not have a fused phenyl ring.
[0242] As used herein, the phrase “two adjacent carbon atoms of said cycloalkyl or cycloalkenyl rings are fused to a phenyl ring” refers to a group where any of the above-mentioned cycloalkyl and cycloalkenyl groups that have a fused phenyl ring. Such groups include, for example,
[0000]
[0243] Optional substituents on optionally substituted groups, when not otherwise indicated, include one or more groups, typically 1, 2, or 3 groups, independently selected from the group consisting of halo, halo(C 1-6 )alkyl, aryl, heterocycle, cycloalkyl, C 1-6 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, aryl(C 1-6 )alkyl, aryl(C 2-6 )alkenyl, aryl(C 2-6 )alkynyl, cycloalkyl(C 1-6 )alkyl, heterocyclo(C 1-6 )alkyl, hydroxy(C 1-6 )alkyl, amino(C 1-6 )alkyl, carboxy(C 1-6 )alkyl, alkoxy(C 1-6 )alkyl, nitro, amino, ureido, cyano, alkylcarbonylamino, hydroxy, thiol, alkylcarbonyloxy, aryloxy, ar(C 1-6 )alkyloxy, carboxamido, sulfonamido, azido, C 1-6 alkoxy, halo(C 1-6 )alkoxy, carboxy, aminocarbonyl, (═O), and mercapto(C 1-6 )alkyl groups mentioned above. Preferred optional substituents include halo, halo(C 1-6 )alkyl, hydroxy(C 1-6 )alkyl, amino(C 1-6 )alkyl, hydroxy, nitro, C 1-6 alkyl, C 1-6 alkoxy, halo(C 1-6 )alkoxy, and amino.
[0244] Compounds of the Invention encompass all the salts of the disclosed compounds of Formulae I-VIII, VIII(A) and IX. The present invention preferably includes all non-toxic pharmaceutically acceptable salts thereof of the disclosed compounds. Examples of pharmaceutically acceptable addition salts include inorganic and organic acid addition salts and basic salts. The pharmaceutically acceptable salts include, but are not limited to, metal salts such as sodium salt, potassium salt, cesium salt and the like; alkaline earth metals such as calcium salt, magnesium salt and the like; organic amine salts such as triethylamine salt, pyridine salt, picoline salt, ethanolamine salt, triethanolamine salt, dicyclohexylamine salt, N,N′-dibenzylethylenediamine salt and the like; inorganic acid salts such as hydrochloride, hydrobromide, phosphate, sulphate and the like; organic acid salts such as citrate, lactate, tartrate, maleate, fumarate, mandelate, acetate, dichloroacetate, trifluoroacetate, oxalate, formate and the like; sulfonates such as methanesulfonate, benzenesulfonate, p-toluenesulfonate and the like; and amino acid salts such as arginate, asparginate, glutamate and the like.
[0245] Acid addition salts can be formed by mixing a solution of the particular compound of the present invention with a solution of a pharmaceutically acceptable non-toxic acid such as hydrochloric acid, fumaric acid, maleic acid, succinic acid, acetic acid, citric acid, tartaric acid, carbonic acid, phosphoric acid, oxalic acid, dichloroacetic acid, or the like. Basic salts can be formed by mixing a solution of the compound of the present invention with a solution of a pharmaceutically acceptable non-toxic base such as sodium hydroxide, potassium hydroxide, choline hydroxide, sodium carbonate and the like.
[0246] Compounds of the Invention also encompass solvates of any of the disclosed compounds of Formulae I-VIII, VIII(A) and IX. Solvates typically do not significantly alter the physiological activity or toxicity of the compounds, and as such may function as pharmacological equivalents. The term “solvate” as used herein is a combination, physical association and/or solvation of a compound of the present invention with a solvent molecule such as, e.g. a disolvate, monosolvate or hemisolvate, where the ratio of solvent molecule to compound of the present invention is about 2:1, about 1:1 or about 1:2, respectively. This physical association involves varying degrees of ionic and covalent bonding, including hydrogen bonding. In certain instances, the solvate can be isolated, such as when one or more solvent molecules are incorporated into the crystal lattice of a crystalline solid. Thus, “solvate” encompasses both solution-phase and isolatable solvates. Compounds of the Invention may be present as solvated forms with a pharmaceutically acceptable solvent, such as water, methanol, ethanol, and the like, and it is intended that the invention includes both solvated and unsolvated forms of compounds of any of Formulae I-VIII, VIII(A) and IX. One type of solvate is a hydrate. A “hydrate” relates to a particular subgroup of solvates where the solvent molecule is water. Solvates typically can function as pharmacological equivalents. Preparation of solvates is known in the art. See, for example, M. Caira et al., J. Pharmaceut. Sci., 93(3):601-611 (2004), which describes the preparation of solvates of fluconazole with ethyl acetate and with water. Similar preparation of solvates, hemisolvates, hydrates, and the like are described by E. C. van Tonder et al., AAPS Pharm. Sci. Tech., 5(1):Article 12 (2004), and A. L. Bingham et al., Chem. Commun.: 603-604 (2001). A typical, non-limiting, process of preparing a solvate would involve dissolving a compound of any of Formulae I-VIII, VIII(A) and IX in a desired solvent (organic, water, or a mixture thereof) at temperatures above about 20° C. to about 25° C., then cooling the solution at a rate sufficient to form crystals, and isolating the crystals by known methods, e.g., filtration. Analytical techniques such as infrared spectroscopy can be used to confirm the presence of the solvent in a crystal of the solvate.
[0247] Compounds of the Invention can be isotopically-labeled (i.e., radio-labeled). Examples of isotopes that can be incorporated into the disclosed compounds include isotopes of hydrogen, carbon, nitrogen, oxygen, phosphorous, fluorine and chlorine, such as 2 H, 3 H, 11 C, 13 C, 14 C, 15 N, 18 O, 17 O, 31 P, 32 P, 35 S, 18 F and 36 Cl, respectively, and preferably 3 H, 11 C, and 14 C. Isotopically-labeled Compounds of the Invention can be prepared by methods known in the art in view of this disclosure. For example, tritiated Compounds of the Invention can be prepared by introducing tritium into the particular compound by catalytic dehalogenation with tritium. This method may include reacting a suitable halogen-substituted precursor of a Compound of the Invention with tritium gas in the presence of an appropriate catalyst such as Pd/C in the presence of a base. Other suitable methods for preparing tritiated compounds can be found in Filer, Isotopes in the Physical and Biomedical Sciences, Vol. 1, Labeled Compounds ( Part A ), Chapter 6 (1987). 14 C-labeled compounds can be prepared by employing starting materials having a 14 C carbon.
[0248] Isotopically labeled Compounds of the Invention, as well as the pharmaceutically acceptable salts and solvates thereof, can be used as radioligands to test for the binding of compounds to an opioid receptor. For example, a radio-labeled Compound of the Invention can be used to characterize specific binding of a test or candidate compound to the receptor. Binding assays utilizing such radio-labeled compounds can provide an in vitro alternative to animal testing for the evaluation of chemical structure-activity relationships. For example, the receptor assay may be performed at a fixed concentration of a radiolabeled Compound of the Invention and at increasing concentrations of a test compound in a competition assay. In a non-limiting embodiment, the present invention provides a method for screening a candidate compound for the ability to bind to an opioid receptor, comprising a) introducing a fixed concentration of a radio-labeled Compound of the Invention to the receptor under conditions that permit binding of the radio-labeled compound to the receptor to form a complex; b) titrating the complex with a candidate compound; and c) determining the binding of the candidate compound to said receptor.
[0249] Some of the compounds disclosed herein may contain one or more asymmetric centers and may thus give rise to enantiomers, diastereomers, and other stereoisomeric forms, such as epimers. The present invention is meant to encompass the uses of all such possible forms, as well as their racemic and resolved forms and mixtures thereof. The individual enantiomers may be separated according to methods known to those of ordinary skill in the art in view of the present disclosure. When the compounds described herein contain olefinic double bonds or other centers of geometric asymmetry, and unless specified otherwise, it is intended that they include both E and Z geometric isomers. All tautomers are intended to be encompassed by the present invention as well.
[0250] As used herein, the term “stereoisomers” is a general term for all isomers of individual molecules that differ only in the orientation of their atoms in space. It includes enantiomers and isomers of compounds with more than one chiral center that are not mirror images of one another (diastereomers).
[0251] The term “chiral center” refers to a carbon atom to which four different groups are attached.
[0252] The term “epimer” refers to diastereomers that have opposite configuration at only one of two or more tetrahedral stereogenic centres present in the respective molecular entities.
[0253] The term “stereogenic center” is an atom, bearing groups such that an interchanging of any two groups leads to a stereoisomer.
[0254] The terms “enantiomer” and “enantiomeric” refer to a molecule that cannot be superimposed on its mirror image and hence is optically active wherein the enantiomer rotates the plane of polarized light in one direction and its mirror image compound rotates the plane of polarized light in the opposite direction.
[0255] The term “racemic” refers to a mixture of equal parts of enantiomers and which mixture is optically inactive.
[0256] The term “resolution” refers to the separation or concentration or depletion of one of the two enantiomeric forms of a molecule.
[0257] The terms “a” and “an” refer to one or more.
[0258] The term “treating” or “treatment” refers to administering a therapy in an amount, manner, or mode effective to improve a condition, symptom, or parameter associated with a disorder or to prevent progression of a disorder, to either a statistically significant degree or to a degree detectable to one skilled in the art. An effective amount, manner, or mode can vary depending on the subject and may be tailored to the patient.
[0259] Open terms such as “include,” “including,” “contain,” “containing” and the like mean “comprising.”
[0260] As used herein, compounds that bind to receptors and mimic the regulatory effects of endogenous ligands are defined as “agonists”. Compounds that bind to receptors and are only partly effective as agonists are defined as “partial agonists”. Compounds that bind to a receptor but produce no regulatory effect, but rather block the binding of ligands to the receptor are defined as “antagonists”. (Ross and Kenakin, “Ch. 2: Pharmacodynamics: Mechanisms of Drug Action and the Relationship Between Drug Concentration and Effect”, pp. 31-32, in Goodman & Gilman's the Pharmacological Basis of Therapeutics, 10 th Ed. (J. G. Hardman, L. E. Limbird and A. Goodman-Gilman eds., 2001)).
[0261] In certain embodiments, the Compound of the Invention is an agonist at one or more of the μ, δ and/or κ opioid receptors. In certain non-limiting embodiments, the Compound of the Invention produces fewer side effects and/or less severe side effects than currently available analgesic opioid compounds when administered at doses producing equivalent levels of analgesia and/or anti-hyperalgesia. In certain embodiments, the Compound of the Invention is an agonist at ORL-1 opioid receptor.
[0262] In certain embodiments, Compounds of the Invention can be used in combination with at least one other therapeutic agent. The other therapeutic agent can be, but is not limited to, a μ-opioid agonist, a non-opioid analgesic, a non-steroidal anti-inflammatory agent, a Cox-II inhibitor, an anti-emetic, a β-adrenergic blocker, an anticonvulsant, an antidepressant, a Ca 2+ -channel blocker, an anticancer agent, or a mixture thereof.
[0263] Compounds of the Invention potently bind to the μ and/or κ and/or δ and/or ORL-1 opioid receptors. Compounds of the Invention can be modulators at the μ and/or κ and/or δ and/or ORL-1 opioid receptors, and therefore Compounds of the Invention can be used/administered to treat, ameliorate, or prevent pain.
[0264] In some embodiments, Compounds of the Invention are antagonists of one or more opioid receptors. In another embodiment, Compounds of the Invention are antagonists of the μ and/or κ opioid receptors.
[0265] In some embodiments, Compounds of the Invention are partial agonists of one or more opioid receptors. In another embodiment, Compounds of the Invention are partial agonists of the μ and/or κ opioid receptors.
[0266] In another embodiments, Compounds of the Invention are agonists of one or more opioid receptors. In another embodiment, Compounds of the Invention are agonists of the μ and/or κ opioid receptors.
[0267] Compounds of the Invention that are antagonists of the μ-opioid receptor or agonists of κ-opioid receptor, or both, can be used/administered to treat or ameliorate constipation. Compounds of the Invention that are agonists of μ-opioid receptor can be used/administered to treat or ameliorate diarrhea.
[0268] Compounds of the Invention can be used to treat or prevent acute, chronic pain (which includes but is not limited to, neuropathic pain, postoperative pain, and inflammatory pain), or surgical pain. Examples of pain that can be treated or prevented using a Compound of the Invention include, but are not limited to, cancer pain, neuropathic pain, labor pain, myocardial infarction pain, pancreatic pain, colic pain, post-operative pain, headache pain, muscle pain, arthritic pain, and pain associated with a periodontal disease, including gingivitis and periodontitis.
[0269] Acute pain includes, but is not limited to, perioperative pain, postoperative pain, post-traumatic pain, acute disease related pain, and pain related to diagnostic procedures, orthopedic manipulations, and myocardial infarction. Acute pain in the perioperative setting includes pain because of pre-existing disease, the surgical procedure, e.g., associated drains, chest or nasogastric tubes, or complications, or a combination of disease-related and procedure-related sources.
[0270] Chronic pain includes, but is not limited to, inflammatory pain, postoperative pain, cancer pain, osteoarthritis pain associated with metastatic cancer, trigeminal neuralgia, acute herpetic and postherpetic neuralgia, diabetic neuropathy, causalgia, brachial plexus avulsion, occipital neuralgia, reflex sympathetic dystrophy, fibromyalgia, gout, phantom limb pain, burn pain, and other forms of neuralgia, neuropathic, and idiopathic pain syndromes.
[0271] Compounds of the Invention can be used to treat or prevent pain associated with inflammation or with an inflammatory disease in a patient. Such pain can arise where there is an inflammation of the body tissue which can be a local inflammatory response or a systemic inflammation. For example, a Compound of the Invention can be used to treat or prevent pain associated with inflammatory diseases including, but not limited to, organ transplant rejection; reoxygenation injury resulting from organ transplantation (see Grupp et al., J. Mol, Cell Cardiol. 31:297-303 (1999)) including, but not limited to, transplantation of the heart, lung, liver, or kidney; chronic inflammatory diseases of the joints, including arthritis, rheumatoid arthritis, osteoarthritis and bone diseases associated with increased bone resorption; inflammatory bowel diseases, such as ileitis, ulcerative colitis, Barrett's syndrome, and Crohn's disease; inflammatory lung diseases, such as asthma, adult respiratory distress syndrome, and chronic obstructive airway disease; inflammatory diseases of the eye, including corneal dystrophy, trachoma, onchocerciasis, uveitis, sympathetic ophthalmitis and endophthalmitis; chronic inflammatory disease of the gum, including gingivitis and periodontitis; tuberculosis; leprosy; inflammatory diseases of the kidney, including uremic complications, glomerulonephritis and nephrosis; inflammatory disease of the skin, including sclerodermatitis, psoriasis and eczema; inflammatory diseases of the central nervous system, including chronic demyelinating diseases of the nervous system, multiple sclerosis, AIDS-related neurodegeneration and Alzheimer's disease, infectious meningitis, encephalomyelitis, Parkinson's disease, Huntington's disease, amyotrophic lateral sclerosis and viral or autoimmune encephalitis; autoimmune diseases, including Type I and Type II diabetes mellitus; diabetic complications, including, but not limited to, diabetic cataract, glaucoma, retinopathy, nephropathy (such as microaluminuria and progressive diabetic nephropathy), gangrene of the feet, atherosclerotic coronary arterial disease, peripheral arterial disease, nonketotic hyperglycemic-hyperosmolar coma, foot ulcers, joint problems, and a skin or mucous membrane complication (such as an infection, a shin spot, a candidal infection or necrobiosis lipoidica diabeticorum), immune-complex vasculitis, and systemic lupus erythematosus (SLE); inflammatory disease of the heart, such as cardiomyopathy, ischemic heart disease hypercholesterolemia, and artherosclerosis; as well as various other diseases that can have significant inflammatory components, including preeclampsia, chronic liver failure, brain and spinal cord trauma, and cancer. Compounds of the Invention can also be used to treat or prevent pain associated with inflammatory disease that can, for example, be a systemic inflammation of the body, exemplified by gram-positive or gram negative shock, hemorrhagic or anaphylactic shock, or shock induced by cancer chemotherapy in response to pro-inflammatory cytokines, e.g., shock associated with pro-inflammatory cytokines. Such shock can be induced, e.g., by a chemotherapeutic agent that is administered as a treatment for cancer.
[0272] Compounds of the Invention can be used to treat or prevent pain associated with nerve injury (i.e., neuropathic pain). Chronic neuropathic pain is a heterogeneous disease state with an unclear etiology. In chronic pain, the pain can be mediated by multiple mechanisms. This type of pain generally arises from injury to the peripheral or central nervous tissue. The syndromes include pain associated with spinal cord injury, multiple sclerosis, post-herpetic neuralgia, trigeminal neuralgia, phantom pain, causalgia, and reflex sympathetic dystrophy and lower back pain. The chronic pain is different from acute pain in that chronic neuropathic pain patients suffer the abnormal pain sensations that can be described as spontaneous pain, continuous superficial burning and/or deep aching pain. The pain can be evoked by heat-, cold-, and mechano-hyperalgesia or by heat-, cold-, or mechano-allodynia.
[0273] Chronic neuropathic pain can be caused by injury or infection of peripheral sensory nerves. It includes, but is not limited to pain from peripheral nerve trauma, herpes virus infection, diabetes mellitus, causalgia, plexus avulsion, neuroma, limb amputation, and vasculitis. Neuropathic pain can also be caused by nerve damage from chronic alcoholism, human immunodeficiency virus infection, hypothyroidism, uremia, or vitamin deficiencies. Stroke (spinal or brain) and spinal cord injury can also induce neuropathic pain. Cancer-related neuropathic pain results from tumor growth compression of adjacent nerves, brain, or spinal cord. In addition, cancer treatments, including chemotherapy and radiation therapy, can cause nerve injury. Neuropathic pain includes but is not limited to pain caused by nerve injury such as, for example, the pain from which diabetics suffer.
[0274] Compounds of the Invention can be used to treat or prevent pain associated with migraine including, but not limited to, migraine without aura (“common migraine”), migraine with aura (“classic migraine”), migraine without headache, basilar migraine, familial hemiplegic migraine, migrainous infarction, and migraine with prolonged aura.
[0275] Compounds of the Invention can also be used as an agent to treat withdrawal from alcohol addiction or drug addiction; as an agent to treat or prevent addictive disorders; an agent to treat a pruritic condition; and in treating or ameliorating constipation and diarrhea.
[0276] The present invention is also directed to the use of a compound represented by any of the above defined Formulae I-VIII, VIII(A) and IX, or a pharmaceutically acceptable salt or solvate thereof, in the manufacture of a medicament for treating a disorder responsive to the modulation of one or more opioids receptors (e.g., any of the disorders listed above) in a patient suffering from said disorder.
[0277] Furthermore, the present invention is directed to a method of modulating, in particular activating, one or more opioid receptors in a patient in need thereof, said method comprising administering to the patient at least one compound represented by any of the above defined Formulae I-VIII, VIII(A) and IX, or a pharmaceutically acceptable salt or solvate thereof.
[0278] The present invention is also directed to the use of a compound represented by any of the above defined Formulae I-VIII, VIII(A) and IX, or a pharmaceutically acceptable salt or solvate thereof, in the manufacture of a medicament, in particular a medicament for modulating, in particular activating, one or more opioid receptors, in a patient in need thereof.
Synthesis of the Compounds
[0279] Compounds of the Invention can be prepared using methods known to those skilled in the art in view of this disclosure, or by the illustrative methods shown in the schemes below. Additional methods of synthesis are described and illustrated in the working examples set forth below.
[0000]
[0280] Compound A (as described, for example, in Hupp C. D., et al., Tetrahedron Lett. 2010, 51, 2359) is converted to Compound B by treatment with a formate ester in the presence of a suitable base such as NaOEt in a suitable solvent such as Et 2 O. Compound B is converted to Compound C by treatment with a suitable cyanomethyl sulfone in the presence of a suitable base such as piperidine in a suitable solvent such as ACN. Compound C is deprotected to give Compound D by appropriate techniques (e.g. Wuts, P. G. M.; Greene, T. W., “Greene's Protective Groups in Organic Synthesis”, 4th Ed., J. Wiley & Sons, N Y, 2007) known to one skilled in the art.
Testing of the Compounds
In Vitro Assay Protocols
[0281] μ-Opioid Receptor Binding Assay Procedures:
[0282] Radioligand dose-displacement binding assays for μ-opioid receptors used 0.3 nM [ 3 H]-diprenorphine (Perkin Elmer, Shelton, Conn.), with 5 mg membrane protein/well in a final volume of 500 μl binding buffer (10 mM MgCl 2 , 1 mM EDTA, 5% DMSO, 50 mM HEPES, pH 7.4). Reactions were carried out in the absence or presence of increasing concentrations of unlabeled naloxone. All reactions were conducted in 96-deep well polypropylene plates for 2 hours at room temperature. Binding reactions were terminated by rapid filtration onto 96-well Unifilter GF/C filter plates (Perkin Elmer, Shelton, Conn.), presoaked in 0.5% polyethylenimine using a 96-well tissue harvester (Perkin Elmer, Shelton, Conn.) followed by performing three filtration washes with 500 μl of ice-cold binding buffer. Filter plates were subsequently dried at 50° C. for 2-3 hours. BetaScint scintillation cocktail (Perkin Elmer, Shelton, Conn.) was added (50 μl/well), and plates were counted using a Packard Top-Count for 1 min/well. The data were analyzed using the one-site competition curve fitting functions in GraphPad PRISM™ v. 3.0 or higher (San Diego, Calif.), or an in-house function for one-site competition curve-fitting.
[0283] μ-Opioid Receptor Binding Data:
[0284] Generally, the lower the K i value, the more effective Compounds of the Invention will be at treating or preventing pain or another Condition. Typically, Compounds of the Invention exhibit a K i (nM) of about 1000 or less for binding to μ-opioid receptors. In one embodiment, Compounds of the Invention exhibit a K i (nM) of about 300 or less for binding to μ-opioid receptors. In another embodiment, Compounds of the Invention exhibit a K i (nM) of about 100 or less for binding to μ-opioid receptors. In another embodiment, Compounds of the Invention exhibit a K i (nM) of about 10 or less for binding to μ-opioid receptors. In still another embodiment, Compounds of the Invention exhibit a K i (nM) of about 1 or less for binding to μ-opioid receptors. In still another embodiment, Compounds of the Invention exhibit a K i (nM) of about 0.1 or less for binding to μ-opioid receptors.
[0285] μ-Opioid Receptor Functional Assay Procedures:
[0286] [ 35 S]GTPγS functional assays were conducted using freshly thawed μ-receptor membranes prepared in-house from a cell line expressing recombinant μ opioid receptor in a HEK-293, CHO, or U-2 OS cell background or purchased from a commercial source (Perkin Elmer, Shelton, Conn.). Assay reactions were prepared by sequentially adding the following reagents to binding buffer (100 mM NaCl, 10 mM MgCl 2 , 20 mM HEPES, pH 7.4) on ice (final concentrations indicated): membrane protein (0.026 mg/mL), saponin (10 mg/mL), GDP (3 mM) and [ 35 S]GTPγS (0.20 nM; Perkin Elmer, Shelton, Conn.). The prepared membrane solution (190 μl/well) was transferred to 96-shallow well polypropylene plates containing 10 μl of 20× concentrated stock solutions of the agonist [D-Ala 2 , N-methyl-Phe 4 Gly-ol 5 ]-enkephalin (DAMGO) prepared in dimethyl sulfoxide (DMSO). Plates were incubated for 30 min at about 25° C. with shaking. Reactions were terminated by rapid filtration onto 96-well Unifilter GF/B filter plates (Perkin Elmer, Shelton, Conn.) using a 96-well tissue harvester (Perkin Elmer, Shelton, Conn.) followed by three filtration washes with 200 μl of ice-cold wash buffer (10 mM NaH 2 PO 4 , 10 mM Na 2 HPO 4 , pH 7.4). Filter plates were subsequently dried at 50° C. for 2-3 hours. BetaScint scintillation cocktail (Perkin Elmer, Shelton, Conn.) was added (50 μl/well) and plates were counted using a Packard Top-Count for 1 min/well. Data were analyzed using the sigmoidal dose-response curve fitting functions in GraphPad PRISM v. 3.0, or an in-house function for non-linear, sigmoidal dose-response curve-fitting. [ 35 S]GTPγS functional assays can also be conducted using freshly thawed μ-receptor membranes prepared from a cell line expressing recombinant opioid receptor in a CHO-K1 cell background.
[0287] μ-Opioid Receptor Functional Data:
[0288] μ GTP EC 50 is the concentration of a compound providing 50% of the maximal response for the compound at a μ-opioid receptor. Certain Compounds of the Invention can exhibit a μ GTP EC 50 (nM) of about 20,000 or less; or about 10,000 or less. In certain embodiments, Compounds of the Invention exhibit a μ GTP EC 50 (nM) of about 5000 or less. In certain embodiments, Compounds of the Invention exhibit a μ GTP EC 50 (nM) of about 2000 or less; or about 1000 or less; or about 100 or less; or about 10 or less; or about 1 or less; or about 0.1 or less.
[0289] μ GTP E max (%) is the maximal effect elicited by a compound relative to the effect elicited by DAMGO, a standard μ agonist. Generally, the μ GTP E max (%) value measures the efficacy of a compound to treat or prevent pain or other Conditions. Typically, Compounds of the Invention exhibit a μ GTP E max (%) of greater than about 10%; or greater than about 20%. In certain embodiments, Compounds of the Invention exhibit a μ GTP Emax (%) of greater than about 50%; or greater than about 65%; or greater than about 75%; or greater than about 85%; or greater than about 100%.
[0290] κ-Opioid Receptor Binding Assay Procedures:
[0291] Membranes from HEK-293 cells, CHO cells, or U-2 OS cells expressing the recombinant human kappa opioid receptor (κ) were prepared by lysing cells in ice cold hypotonic buffer (2.5 mM MgCl 2 , 50 mM HEPES, pH 7.4) (10 mL/10 cm dish) followed by homogenization with a tissue grinder/Teflon pestle. Membranes from a cell line naturally expressing kappa opioid receptor can also be used. Membranes were collected by centrifugation at 30,000×g for 15 min at 4° C. and pellets were resuspended in hypotonic buffer to a final concentration of 1-3 mg/mL. Protein concentrations were determined using the BioRad protein assay reagent with bovine serum albumen as standard. Aliquots of κ receptor membranes were stored at −80° C.
[0292] Radioligand dose displacement assays used 0.4 nM [ 3 H]-U69,593 (GE Healthcare, Piscataway, N.J.; 40 Ci/mmole) with 15 μg membrane protein (recombinant κ opioid receptor expressed in HEK 293 cells; in-house prep) in a final volume of 200 μl binding buffer (5% DMSO, 50 mM Trizma base, pH 7.4). Non-specific binding was determined in the presence of 10 μM unlabeled naloxone or U69,593. All reactions were performed in 96-well polypropylene plates for 1 hour at a temperature of about 25° C. Binding reactions were terminated by rapid filtration onto 96-well Unifilter GF/C filter plates (Perkin Elmer, Shelton, Conn.) presoaked in 0.5% polyethylenimine (Sigma). Harvesting was performed using a 96-well tissue harvester (Perkin Elmer, Shelton, Conn.) followed by five filtration washes with 200 μl ice-cold binding buffer. Filter plates were subsequently dried at 50° C. for 1-2 hours. Fifty μl/well scintillation cocktail (Perkin Elmer, Shelton, Conn.) was added and plates were counted in a Packard Top-Count for 1 min/well.
[0293] κ-Opioid Receptor Binding Data:
[0294] In certain embodiments, Compounds of the Invention exhibit a K i (nM) for κ receptors of about 10,000 or more (which, for purposes of this invention, is interpreted as having no binding to the κ receptors). Certain Compounds of the Invention exhibit a K i (nM) of about 20,000 or less for κ receptors. In certain embodiments, Compounds of the Invention exhibit a K i (nM) of about 10,000 or less; or about 5000 or less; or about 1000 or less; or about 500 or less; or about 450 or less; or about 350 or less; or about 200 or less; or about 100 or less; or about 50 or less; or about 10 or less; or about 1 or less; or about 0.1 or less for κ receptors.
[0295] κ-Opioid Receptor Functional Assay Procedures:
[0296] Functional [ 35 S]GTPγS binding assays were conducted as follows. κ opioid receptor membrane solution was prepared by sequentially adding final concentrations of 0.026 μg/μl κ membrane protein (in-house), 10 μg/mL saponin, 3 μM GDP and 0.20 nM [ 35 S]GTPγS to binding buffer (100 mM NaCl, 10 mM MgCl 2 , 20 mM HEPES, pH 7.4) on ice. The prepared membrane solution (190 μl/well) was transferred to 96-shallow well polypropylene plates containing 10 μl of 20× concentrated stock solutions of agonist prepared in DMSO. Plates were incubated for 30 min at a temperature of about 25° C. with shaking. Reactions were terminated by rapid filtration onto 96-well Unifilter GF/B filter plates (Perkin Elmer, Shelton, Conn.) using a 96-well tissue harvester (Packard) and followed by three filtration washes with 200 μl ice-cold binding buffer (10 mM NaH 2 PO 4 , 10 mM Na 2 HPO 4 , pH 7.4). Filter plates were subsequently dried at 50° C. for 2-3 hours. Fifty μl/well scintillation cocktail (Perkin Elmer, Shelton, Conn.) was added and plates were counted in a Packard Top-Count for 1 min/well.
[0297] κ-Opioid Receptor Functional Data:
[0298] κ GTP EC 50 is the concentration of a compound providing 50% of the maximal response for the compound at a κ receptor. Certain Compounds of the Invention exhibit a κ GTP EC 50 (nM) of about 20,000 or less to stimulate opioid receptor function. In certain embodiments, Compounds of the Invention exhibit a κ GTP EC 50 (nM) of about 10,000 or less; or about 5000 or less; or about 2000 or less; or about 1500 or less; or about 1000 or less; or about 600 or less; or about 100 or less; or about 50 or less; or about 25 or less; or about 10 or less; or about 1 or less; or about 0.1 or less.
[0299] κ GTP E max (%) is the maximal effect elicited by a compound relative to the effect elicited by U69,593. Certain Compounds of the Invention exhibit a κ GTP E max (%) of greater than about 1%; or greater than about 5%; or greater than about 10%; or greater than about 20%. In certain embodiments, Compounds of the Invention exhibit a κ GTP E max (%) of greater than about 50%; or greater than about 75%; or greater than about 90%; or greater than about 100%.
[0300] δ-Opioid Receptor Binding Assay Procedures:
[0301] δ-Opioid Receptor Binding Assay Procedures are conducted as follows. Radioligand dose-displacement assays use 0.3 nM [ 3 H]-Naltrindole (Perkin Elmer, Shelton, Conn.; 33.0 Ci/mmole) with 5 μg membrane protein (Perkin Elmer, Shelton, Conn.) in a final volume of 500 μl binding buffer (5 mM MgCl 2 , 5% DMSO, 50 mM Trizma base, pH 7.4). Non-specific binding is determined in the presence of 25 μM unlabeled naloxone. All reactions are performed in 96-deep well polypropylene plates for 1 hour at a temperature of about 25° C. Binding reactions are terminated by rapid filtration onto 96-well Unifilter GF/C filter plates (Perkin Elmer, Shelton, Conn.) presoaked in 0.5% polyethylenimine (Sigma). Harvesting was is performed using a 96-well tissue harvester (Perkin Elmer, Shelton, Conn.) followed by five filtration washes with 500 μl ice-cold binding buffer. Filter plates are subsequently dried at 50° C. for 1-2 hours. Fifty μl/well scintillation cocktail (Perkin Elmer, Shelton, Conn.) is added and plates are counted in a Packard Top-Count for 1 min/well.
[0302] δ-Opioid Receptor Binding Data:
[0303] In certain embodiments, Compounds of the Invention exhibit a K i (nM) for δ receptors of about 10,000 or more (which, for the purposes of this invention, is interpreted as having no binding to the δ receptors). Certain Compounds of the Invention exhibit a K i (nM) of about 20,000 or less for δ receptors. In one embodiment, Compounds of the Invention exhibit a K i (nM) of about 10,000 or less; or of about 9000 or less for δ receptors. In another embodiment, Compounds of the Invention exhibit a K i (nM) of about 7500 or less; or of about 6500 or less; or of about 5000 or less; or of about 3000 or less; or of about 2500 or less for δ receptors. In another embodiment, Compounds of the Invention exhibit a K i (nM) of about 1000 or less; or of about 500 or less; or of about 350 or less; or of about 250 or less; or of about 100 or less; or of about 10 or less for δ receptors.
[0304] δ-Opioid Receptor Functional Assay Procedures:
[0305] Functional [ 35 S]GTPγS binding assays are conducted as follows. δ-Opioid receptor membrane solution is prepared by sequentially adding final concentrations of 0.026 μg/μl δ membrane protein (Perkin Elmer, Shelton, Conn.), 10 μg/mL saponin, 3 μM GDP and 0.20 nM [ 35 S]GTPγS to binding buffer (100 mM NaCl, 10 mM MgCl 2 , 20 mM HEPES, pH 7.4) on ice. The prepared membrane solution (190 μl/well) is transferred to 96-shallow well polypropylene plates containing 10 μl of 20× concentrated stock solutions of agonist prepared in DMSO. Plates are incubated for 30 min at a temperature of about 25° C. with shaking. Reactions are terminated by rapid filtration onto 96-well Unifilter GF/B filter plates (Perkin Elmer, Shelton, Conn.) using a 96-well tissue harvester (Packard) and followed by three filtration washes with 200 μl ice-cold binding buffer (10 mM NaH 2 PO 4 , 10 mM Na 2 HPO 4 , pH 7.4). Filter plates are subsequently dried at 50° C. for 1-2 hours. Fifty μl/well scintillation cocktail (Perkin Elmer, Shelton, Conn.) is added and plates are counted in a Packard Top-count for 1 min/well.
[0306] δ-Opioid Receptor Functional Data:
[0307] δ GTP EC 50 is the concentration of a compound providing 50% of the maximal response for the compound at a δ receptor. Certain Compounds of the Invention exhibit a δ GTP EC 50 (nM) of about 20,000 or less; or about 10,000 or less. In certain embodiments, Compounds of the Invention exhibit a δ GTP EC 50 (nM) of about 3500 or less; or of about 1000 or less; or of about 500 or less; or of about 100 or less; or of about 90 or less; or of about 50 or less; or of about 25 or less; or of about 10 or less.
[0308] δ GTP E max (%) is the maximal effect elicited by a compound relative to the effect elicited by met-enkephalin. Certain Compounds of the Invention exhibit a δ GTP E max (%) of greater than about 1%; or of greater than about 5%; or of greater than about 10%. In one embodiment, Compounds of the Invention exhibit a δ GTP E max (%) of greater than about 30%. In another embodiment, Compounds of the Invention exhibit a δ GTP E max (%) of greater than about 50%; or of greater than about 75%; or of greater than about 90%. In another embodiment, Compounds of the Invention exhibit a δ GTP E max (%) of greater than about 100%.
[0309] ORL-1 Receptor Binding Assay Procedure:
[0310] Membranes from recombinant HEK-293 cells expressing the human opioid receptor-like receptor (ORL-1) (Perkin Elmer, Shelton, Conn.) are prepared by lysing cells in ice-cold hypotonic buffer (2.5 mM MgCl 2 , 50 mM HEPES, pH 7.4) (10 ml/10 cm dish) followed by homogenization with a tissue grinder/Teflon pestle. Membranes are collected by centrifugation at 30,000×g for 15 min at 4° C. and pellets resuspended in hypotonic buffer to a final concentration of 1-3 mg/ml. Protein concentrations are determined using the BioRad protein assay reagent with bovine serum albumen as standard. Aliquots of the ORL-1 receptor membranes are stored at −80° C.
[0311] Radioligand binding assays (screening and dose-displacement) use 0.1 nM [ 3 H]-nociceptin (Perkin Elmer, Shelton, Conn.; 87.7 Ci/mmole) with 12 μg membrane protein in a final volume of 500 μl binding buffer (10 mM MgCl 2 , 1 mM EDTA, 5% DMSO, 50 mM HEPES, pH 7.4). Non-specific binding is determined in the presence of 10 nM unlabeled nociceptin (American Peptide Company). All reactions are performed in 96-deep well polypropylene plates for 1 h at room temperature. Binding reactions are terminated by rapid filtration onto 96-well Unifilter GF/C filter plates (Perkin Elmer, Shelton, Conn.) presoaked in 0.5% polyethylenimine (Sigma). Harvesting is performed using a 96-well tissue harvester (Perkin Elmer, Shelton, Conn.) followed by three filtration washes with 500 μl ice-cold binding buffer. Filter plates are subsequently dried at 50° C. for 2-3 hours. Fifty μl/well scintillation cocktail (Perkin Elmer, Shelton, Conn.) is added and plates are counted in a Packard Top-Count for 1 min/well. The data from screening and dose-displacement experiments are analyzed using Microsoft Excel and the curve fitting functions in GraphPad PRISM™, v. 3.0 or higher, respectively, or an in-house function for one-site competition curve-fitting.
[0312] ORL-1 Receptor Binding Data:
[0313] Certain Compounds of the Invention have a K i (nM) of about 5000 or less. In one embodiment, certain Compounds of the Invention have a K i (nM) of about 1000 or less. In one embodiment, certain Compounds of the Invention have a K i (nM) of about 500 or less. In other embodiments, the Compounds of the Invention have a K i (nM) of about 300 or less; or of about 100 or less; or of about 50 or less; or of about 20 or less. In yet other embodiments, the Compounds of the Invention will have a K i (nM) of about 10 or less; or of about 1 or less; or of about 0.1 or less.
[0314] ORL-1 Receptor Functional Assay Procedure:
[0315] Membranes from recombinant HEK-293 cells expressing the human opioid receptor-like (ORL-1) (Perkin Elmer, Shelton, Conn.) can be prepared by lysing cells in ice-cold hypotonic buffer (2.5 mM Mg Cl 2 , 50 mM HEPES, pH 7.4) (10 ml/10 cm dish) followed by homogenization with a tissue grinder/Teflon pestle. Membranes are collected by centrifugation at 30,000×g for 15 min at 4° C., and pellets resuspended in hypotonic buffer to a final concentration of 1-3 mg/ml. Protein concentrations are determined using the BioRad protein assay reagent with bovine serum albumen as standard. Aliquots of the ORL-1 receptor membranes are stored at −80° C.
[0316] Functional [ 35 S]GTPγS binding assays are conducted as follows. ORL-1 membrane solution is prepared by sequentially adding final concentrations of 0.026 μg/μl ORL-1 membrane protein, 10 μg/ml saponin, 3 μM GDP and 0.20 nM [ 35 S]GTPγS to binding buffer (100 mM NaCl, 10 mM MgCl 2 , 20 mM HEPES, pH 7.4) on ice. The prepared membrane solution (190 μl/well) is transferred to 96-shallow well polypropylene plates containing 10 μl of 20× concentrated stock solutions of agonist/nociceptin prepared in DMSO. Plates are incubated for 30 min at room temperature with shaking. Reactions are terminated by rapid filtration onto 96-well Unifilter GF/B filter plates (Perkin Elmer, Shelton, Conn.) using a 96-well tissue harvester (Packard) and followed by three filtration washes with 200 μl ice-cold binding buffer (10 mM NaH 2 PO 4 , 10 mM Na 2 HPO 4 , pH 7.4). Filter plates are subsequently dried at 50° C. for 2-3 hours. Fifty μl/well scintillation cocktail (Perkin Elmer, Shelton, Conn.) is added and plates are counted in a Packard Top-Count for 1 min/well. Data are analyzed using the sigmoidal dose-response curve fitting functions in GraphPad PRISM v. 3.0 or higher, or an in-house function for non-linear, sigmoidal dose-response curve-fitting.
[0317] ORL-1 Receptor Functional Data:
[0318] ORL-1 GTP EC 50 is the concentration of a compound providing 50% of the maximal response for the compound at an ORL-1 receptor. In certain embodiments, the Compounds of the Invention that have a high binding affinity (i.e. low K i value) can have an ORL-1 GTP EC 50 (nM) of greater than about 10,000 (i.e. will not stimulate at therapeutic concentrations) In certain embodiments Compounds of the Invention can have an ORL-1 GTP EC 50 (nM) of about 20,000 or less. In one embodiment, the Compounds of the Invention can have an ORL-1 GTP EC 50 (nM) of about 10,000 or less; or of about 5000 or less; or of about 1000 or less. In still other embodiments, the Compounds of the Invention can have an ORL-1 GTP EC 50 (nM) of about 100 or less; or of about 10 or less; or of about 1 or less; or of about 0.1 or less.
[0319] ORL-1 GTP E max % is the maximal effect elicited by a compound relative to the effect elicited by nociceptin, a standard ORL-1 agonist. In certain embodiments, Compounds of the Invention can have an ORL-1 GTP E max of less than 10% (which, for the purposes of this invention, is interpreted as having antagonist activity at ORL-1 receptors). Certain Compounds of the Invention can have an ORL-1 GTP E max (%) of greater than 1%; or of greater than 5%; or of greater than 10%. In other embodiments the Compounds of the Invention can have an ORL-1 GTP E max of greater than 20%; or of greater than 50%; or of greater than 75%; or of greater than 88%; or of greater than 100%.
In Vivo Assays for Pain
[0320] Test Animals:
[0321] Each experiment uses rats weighing between 200-260 g at the start of the experiment. The rats are group-housed and have free access to food and water at all times, except prior to oral administration of a Compound of the Invention when food is removed for about 16 hours before dosing. A control group acts as a comparison to rats treated with a Compound of the Invention. The control group is administered the carrier for the Compound of the Invention. The volume of carrier administered to the control group is the same as the volume of carrier and Compound of the Invention administered to the test group.
[0322] Acute Pain:
[0323] To assess the actions of a Compound of the Invention for the treatment or prevention of acute pain, the rat tail flick can be used. Rats are gently restrained by hand and the tail exposed to a focused beam of radiant heat at a point 5 cm from the tip using a tail flick unit (Model 7360, commercially available from Ugo Basile of Italy). Tail flick latencies are defined as the interval between the onset of the thermal stimulus and the flick of the tail. Animals not responding within 20 seconds are removed from the tail flick unit and assigned a withdrawal latency of 20 seconds. Tail flick latencies are measured immediately before (pre-treatment) and 1, 3, and 5 hours following administration of a Compound of the Invention. Data are expressed as tail flick latency(s) and the percentage of the maximal possible effect (% MPE), i.e., 20 seconds, is calculated as follows:
[0000]
%
MPE
=
[
(
post
administration
latency
)
-
(
pre
-
administration
latency
)
]
(
20
s
-
pre
-
administration
latency
)
×
100
[0324] The rat tail flick test is described in F. E. D'Amour et al., “A Method for Determining Loss of Pain Sensation,” J. Pharmacol. Exp. Ther. 72:74-79 (1941).
[0325] To assess the actions of a Compound of the Invention for the treatment or prevention of acute pain, the rat hot plate test can also be used. Rats are tested using a hot plate apparatus consisting of a clear plexiglass cylinder with a heated metal floor maintained at a temperature of 48-52° C. (Model 7280, commercially available from Ugo Basile of Italy). A rat is placed into the cylinder on the hot plate apparatus for a maximum duration of 30 s, or until it exhibits a nocifensive behavior (behavioral endpoint), at which time it is removed from the hot plate, and the response latency recorded. Hot plate latencies are measured immediately before (pre-treatment) and 1, 3, and 5 hours following administration of a Compound of the Invention. The nocifensive behavioral endpoint is defined as any of the following: 1) paw withdrawal, either as a sustained lift or with shaking or licking; 2) alternating foot lifting; 3) excape or attempted escape from the testing device; or 4) vocalization. Data are expressed as response latency(s) and the percentage of the maximal possible effect is calculated as described above for the tail flick test. The hot plate test is described in G. Woolfe and A. D. MacDonald, J. Pharmacol. Exp. Ther. 80:300-307 (1944).
[0326] Inflammatory Pain:
[0327] To assess the actions of a Compound of the Invention for the treatment or prevention of inflammatory pain, the Freund's complete adjuvant (“FCA”) model of inflammatory pain can be used. FCA-induced inflammation of the rat hind paw is associated with the development of persistent inflammatory mechanical hyperalgesia and provides reliable prediction of the anti-hyperalgesic action of clinically useful analgesic drugs (L. Bartho et al., “Involvement of Capsaicin-sensitive Neurones in Hyperalgesia and Enhanced Opioid Antinociception in Inflammation,” Naunyn - Schmiedeberg's Archives of Pharmacol. 342:666-670 (1990)). The left hind paw of each animal is administered a 50 μL, intraplantar injection of 50% FCA. Prior to injection of FCA (baseline) and 24 hour post injection, the animal is assessed for response to noxious mechanical stimuli by determining the PWT, as described below. Rats are then administered a single injection of 1, 3, or 10 mg/kg of either a Compound of the Invention; 30 mg/kg of a control drug selected from Celebrex, indomethacin or naproxen; or carrier. Responses to noxious mechanical stimuli are determined 1, 3, 5 and 24 hours post administration. Percentage reversal of hyperalgesia for each animal is defined as:
[0000]
%
Reversal
=
[
(
post
administration
PWT
)
-
(
pre
-
administration
PWT
)
]
[
(
baseline
PWT
)
-
(
pre
-
administration
PWT
)
]
×
100
[0328] Neuropathic Pain:
[0329] To assess the actions of a Compound of the Invention for the treatment or prevention of neuropathic pain, either the Seltzer model or the Chung model can be used.
[0330] In the Seltzer model, the partial sciatic nerve ligation model of neuropathic pain is used to produce neuropathic hyperalgesia in rats (Z. Seltzer et al., “A Novel Behavioral Model of Neuropathic Pain Disorders Produced in Rats by Partial Sciatic Nerve Injury,” Pain 43:205-218 (1990)). Partial ligation of the left sciatic nerve is performed under isoflurane/O 2 inhalation anaesthesia. Following induction of anesthesia, the left thigh of the rat is shaved and the sciatic nerve exposed at high thigh level through a small incision and is carefully cleared of surrounding connective tissues at a site near the trocanther just distal to the point at which the posterior biceps semitendinosus nerve branches off of the common sciatic nerve. A 7-0 silk suture is inserted into the nerve with a ⅜ curved, reversed-cutting mini-needle and tightly ligated so that the dorsal ⅓ to ½ of the nerve thickness is held within the ligature. The wound is closed with a single muscle suture (4-0 nylon (Vicryl)) and vetbond tissue glue. Following surgery, the wound area is dusted with antibiotic powder. Sham-treated rats undergo an identical surgical procedure except that the sciatic nerve is not manipulated. Following surgery, animals are weighed and placed on a warm pad until they recover from anesthesia. Animals are then returned to their home cages until behavioral testing begins. The animal is assessed for response to noxious mechanical stimuli by determining PWT, as described below, prior to surgery (baseline), then immediately prior to and 1, 3, and 5 hours after drug administration. Percentage reversal of neuropathic hyperalgesia is defined as:
[0000]
%
Reversal
=
[
(
post
administration
PWT
)
-
(
pre
-
administration
PWT
)
]
[
(
baseline
PWT
)
-
(
pre
-
administration
PWT
)
]
×
100
[0331] In the Chung model, the spinal nerve ligation model of neuropathic pain is used to produce mechanical hyperalgesia, thermal hyperalgesia and tactile allodynia in rats. Surgery is performed under isoflurane/O 2 inhalation anaesthesia. Following induction of anaesthesia, a 3 cm incision is made and the left paraspinal muscles are separated from the spinous process at the L 4 -S 2 levels. The L 6 transverse process is carefully removed with a pair of small rongeurs to identify visually the L 4 -L 6 spinal nerves. The left L 5 (or L 5 and L 6 ) spinal nerve(s) is isolated and tightly ligated with silk thread. A complete hemostasis is confirmed and the wound is sutured using non-absorbable sutures, such as nylon sutures or stainless steel staples. Sham-treated rats undergo an identical surgical procedure except that the spinal nerve(s) is not manipulated. Following surgery animals are weighed, administered a subcutaneous (s.c.) injection of saline or ringers lactate, the wound area is dusted with antibiotic powder and they are kept on a warm pad until they recover from the anesthesia. Animals are then returned to their home cages until behavioral testing begins. The animals are assessed for response to noxious mechanical stimuli by determining PWT, as described below, prior to surgery (baseline), then immediately prior to and 1, 3, and 5 hours after being administered a Compound of the Invention. The animal can also be assessed for response to noxious thermal stimuli or for tactile allodynia, as described below. The Chung model for neuropathic pain is described in S. H. Kim, “An Experimental Model for Peripheral Neuropathy Produced by Segmental Spinal Nerve Ligation in the Rat,” Pain 50(3):355-363 (1992).
[0332] Response to Mechanical Stimuli as an Assessment of Mechanical Hyperalgesia:
[0333] The paw pressure assay can be used to assess mechanical hyperalgesia. For this assay, hind paw withdrawal thresholds (PWT) to a noxious mechanical stimulus are determined using an analgesymeter (Model 7200, commercially available from Ugo Basile of Italy) as described in C. Stein, “Unilateral Inflammation of the Hindpaw in Rats as a Model of Prolonged Noxious Stimulation: Alterations in Behavior and Nociceptive Thresholds,” Pharmacol. Biochem. and Behavior 31:451-455 (1988). The rat is gently restrained, its hindpaw is placed on a small round platform, and punctate pressure is applied to the dorsal surface of the hindpaw in a graded manner. The maximum weight that is applied to the hind paw is set at 250 g and the end point is taken as complete withdrawal of the paw. PWT is determined once for each rat at each time point and either only the affected (ipsilateral; same side as the injury) rear paw is tested, or both the ipsilateral and contralateral (non-injured; opposite to the injury) rear paw are tested.
[0334] Response to Thermal Stimuli as an Assessment of Thermal Hyperalgesia:
[0335] The plantar test can be used to assess thermal hyperalgesia. For this test, hind paw withdrawal latencies to a noxious thermal stimulus applied to the plantar surface of the hindpaw are determined using a plantar test apparatus (commercially available from Ugo Basile of Italy) following the technique described by K. Hargreaves et al., “A New and Sensitive Method for Measuring Thermal Nociception in Cutaneous Hyperalgesia,” Pain 32(1):77-88 (1988). The maximum exposure time is set at 32 seconds to avoid tissue damage and any directed paw withdrawal from the heat source is taken as the end point. Three latencies are determined at each time point and averaged. Either only the affected (ipsilateral) paw is tested, or both the ipsilateral and contralateral (non-injured) paw are tested.
[0336] Assessment of Tactile Allodynia:
[0337] To assess tactile allodynia, rats are placed in clear, plexiglass compartments with a wire mesh floor and allowed to habituate for a period of at least 15 minutes. After habituation, a series of von Frey monofilaments are presented to the plantar surface of the affected (ipsilateral) foot of each rat. The series of von Frey monofilaments consists of six monofilaments of increasing diameter, with the smallest diameter fiber presented first. Five trials are conducted with each filament with each trial separated by approximately 2 minutes. Each presentation lasts for a period of 4-8 seconds or until a nociceptive withdrawal behavior is observed. Flinching, paw withdrawal or licking of the paw are considered nociceptive behavioral responses.
[0338] Assessment of Respiratory Depression:
[0339] To assess respiratory depression, rats can be prepared by implanting a femoral artery cannula via which blood samples are taken. Blood samples are taken prior to drug administration, then 1, 3, 5 and 24 hours post-treatment. Blood samples are processed using an arterial blood gas analyzer (e.g., IDEXX VetStat with Respiratory/Blood Gas test cartridges). Comparable devices are a standard tool for blood gas analysis (e.g., D. Torbati et al., Intensive Care Med. (26): 585-591 (2000).
[0340] Assessment of Gastric Motility:
[0341] Animals are treated with vehicle, reference compound or test article by oral gavage at a volume of 10 mL/kg. At one hour post-dose, all animals are treated with charcoal meal solution (5% non-activated charcoal powder in a solution of 1% carboxymethylcellulose in water) at a volume of 10 mL/kg. At two hours post-dose (one hour post-charcoal), animals are sacrificed by carbon dioxide inhalation or isoflurane overdose and the transit of charcoal meal identified. The stomach and small intestine are removed carefully and each placed on a saline-soaked absorbent surface. The distance between the pylorus and the furthest progression of charcoal meal is measured and compared to the distance between the pylorus and the ileocecal junction. The charcoal meal transit is expressed as a percentage of small intestinal length traveled.
Pharmaceutical Compositions
[0342] Due to their activity, the Compounds of the Invention are advantageously useful in human and veterinary medicine. As described above, the Compounds of the Invention are useful for treating or preventing a Condition in a patient in need thereof. The Compounds of the Invention can be administered to any patient requiring modulation of the opioid receptors. The term “patient” as used herein refers to any animal that may experience the beneficial effects of a Compound of the Invention. Foremost such animals are mammals, e.g., humans and companion animals, although the invention is not intended to be so limited.
[0343] When administered to a patient, a Compound of the Invention can be administered as a component of a composition that comprises a pharmaceutically acceptable carrier or excipient. A Compound of the Invention can be administered by any appropriate route, as determined by the medical practitioner. Methods of administration may include intradermal, intramuscular, intraperitoneal, parenteral, intravenous, subcutaneous, intranasal, epidural, oral, sublingual, buccal, intracerebral, intravaginal, transdermal, transmucosal, rectal, by inhalation, or topical (particularly to the ears, nose, eyes, or skin). Delivery can be either local or systemic. In certain embodiments, administration will result in the release of a Compound of the Invention into the bloodstream.
[0344] Pharmaceutical compositions of the invention can take the form of solutions, suspensions, emulsions, tablets, pills, pellets, powders, multi-particulates, capsules, capsules containing liquids, capsules containing powders, capsules containing multi-particulates, lozenges, sustained-release formulations, suppositories, transdermal patches, transmucosal films, sub-lingual tablets or tabs, aerosols, sprays, or any other form suitable for use. In one embodiment, the composition is in the form of a tablet. In another embodiment, the composition is in the form of a capsule (see, e.g., U.S. Pat. No. 5,698,155). Other examples of suitable pharmaceutical excipients are described in Remington's Pharmaceutical Sciences 1447-1676 (Alfonso R. Gennaro ed., 19th ed. 1995), incorporated herein by reference.
[0345] Pharmaceutical compositions of the invention preferably comprise a suitable amount of a pharmaceutically acceptable excipient so as to provide the form for proper administration to the patient. Such a pharmaceutical excipient can be a diluent, suspending agent, solubilizer, binder, disintegrant, preservative, coloring agent, lubricant, and the like. The pharmaceutical excipient can be a liquid, such as water or an oil, including those of petroleum, animal, vegetable, or synthetic origin, such as peanut oil, soybean oil, mineral oil, sesame oil, and the like. The pharmaceutical excipient can be saline, gum acacia, gelatin, starch paste, talc, keratin, colloidal silica, urea, and the like. In addition, auxiliary, stabilizing, thickening, lubricating, and coloring agents can be used. In one embodiment, the pharmaceutically acceptable excipient is sterile when administered to a patient. Water is a particularly useful excipient when a Compound of the Invention is administered intravenously. Saline solutions and aqueous dextrose and glycerol solutions can also be employed as liquid excipients, particularly for injectable solutions. Suitable pharmaceutical excipients also include starch, glucose, lactose, sucrose, gelatin, malt, rice, flour, chalk, silica gel, sodium stearate, glycerol monostearate, talc, sodium chloride, dried skim milk, glycerol, propylene glycol, water, ethanol, and the like. The invention compositions, if desired, can also contain minor amounts of wetting or emulsifying agents, or pH buffering agents. Specific examples of pharmaceutically acceptable carriers and excipients that can be used to formulate oral dosage forms are described in the Handbook of Pharmaceutical Excipients, American Pharmaceutical Association (1986).
[0346] In certain embodiments, the Compounds of the Invention are formulated for oral administration. A Compound of the Invention to be orally delivered can be in the form of tablets, capsules, gelcaps, caplets, lozenges, aqueous or oily solutions, suspensions, granules, powders, emulsions, syrups, or elixirs, for example. When a Compound of the Invention is incorporated into oral tablets, such tablets can be compressed, tablet triturates, enteric-coated, sugar-coated, film-coated, multiply compressed or multiply layered.
[0347] An orally administered Compound of the Invention can contain one or more additional agents such as, for example, sweetening agents such as fructose, aspartame or saccharin; flavoring agents such as peppermint, oil of wintergreen, or cherry; coloring agents; and preserving agents, and stabilizers, to provide stable, pharmaceutically palatable dosage forms. Techniques and compositions for making solid oral dosage forms are described in Pharmaceutical Dosage Forms: Tablets (Lieberman, Lachman and Schwartz, eds., 2nd ed.) published by Marcel Dekker, Inc. Techniques and compositions for making tablets (compressed and molded), capsules (hard and soft gelatin) and pills are also described in Remington's Pharmaceutical Sciences 1553-1593 (Arthur Osol, ed., 16 th ed., Mack Publishing, Easton, Pa. 1980). Liquid oral dosage forms include aqueous and nonaqueous solutions, emulsions, suspensions, and solutions and/or suspensions reconstituted from non-effervescent granules, optionally containing one or more suitable solvents, preservatives, emulsifying agents, suspending agents, diluents, sweeteners, coloring agents, flavoring agents, and the like. Techniques and compositions for making liquid oral dosage forms are described in Pharmaceutical Dosage Forms: Disperse Systems , (Lieberman, Rieger and Banker, eds.) published by Marcel Dekker, Inc.
[0348] When a Compound of the Invention is formulated for parenteral administration by injection (e.g., continuous infusion or bolus injection), the formulation can be in the form of a suspension, solution, or emulsion in an oily or aqueous vehicle, and such formulations can further comprise pharmaceutically necessary additives such as one or more stabilizing agents, suspending agents, dispersing agents, and the like. When a Compound of the Invention is to be injected parenterally, it can be, e.g., in the form of an isotonic sterile solution. A Compound of the Invention can also be in the form of a powder for reconstitution as an injectable formulation.
[0349] In certain embodiments, a Compound of the Invention is formulated into a pharmaceutical composition for intravenous administration. Typically, such compositions comprise sterile isotonic aqueous buffer. Where necessary, the compositions can also include a solubilizing agent. A Compound of the Invention for intravenous administration can optionally include a local anesthetic such as benzocaine or prilocaine to lessen pain at the site of the injection. Generally, the ingredients are supplied either separately or mixed together in unit dosage form, for example, as a dry lyophilized powder or water free concentrate in a hermetically sealed container such as an ampule or sachette indicating the quantity of active agent. Where a Compound of the Invention is to be administered by infusion, it can be dispensed, for example, with an infusion bottle containing sterile pharmaceutical grade water or saline. Where a Compound of the Invention is administered by injection, an ampule of sterile water for injection or saline can be provided so that the ingredients can be mixed prior to administration.
[0350] When a Compound of the Invention is to be administered by inhalation, it can be formulated into a dry aerosol, or an aqueous or partially aqueous solution.
[0351] In another embodiment, a Compound of the Invention can be delivered in a vesicle, in particular a liposome (see Langer, Science 249:1527-1533 (1990); and Treat et al., Liposomes in the Therapy of Infectious Disease and Cancer 317-327 and 353-365 (1989)).
[0352] In certain embodiments, a Compound of the Invention is administered locally. This can be achieved, for example, by local infusion during surgery, topical application, e.g., in conjunction with a wound dressing after surgery, by injection, by means of a catheter, by means of a suppository or enema, or by means of an implant, said implant being of a porous, non-porous, or gelatinous material, including membranes, such as sialastic membranes, or fibers.
[0353] In certain embodiments, a Compound of the Invention can be delivered in an immediate release form. In other embodiments, a Compound of the Invention can be delivered in a controlled-release system or sustained-release system. Controlled- or sustained-release pharmaceutical compositions can have a common goal of improving drug therapy over the results achieved by their non-controlled or non-sustained-release counterparts. In one embodiment, a controlled- or sustained-release composition comprises a minimal amount of a Compound of the Invention to treat or prevent the Condition (or a symptom thereof) in a minimum amount of time. Advantages of controlled- or sustained-release compositions include extended activity of the drug, reduced dosage frequency, and increased compliance. In addition, controlled- or sustained-release compositions can favorably affect the time of onset of action or other characteristics, such as blood levels of the Compound of the Invention, and can thus reduce the occurrence of adverse side effects.
[0354] Controlled- or sustained-release compositions can initially immediately release an amount of a Compound of the Invention that promptly produces the desired therapeutic or prophylactic effect, and gradually and continually release other amounts of the Compound of the Invention to maintain a level of therapeutic or prophylactic effect over an extended period of time. To maintain a constant level of the Compound of the Invention in the body, the Compound of the Invention can be released from the dosage form at a rate that will replace the amount of Compound of the Invention being metabolized and excreted from the body. Controlled- or sustained-release of an active ingredient can be stimulated by various conditions, including but not limited to, changes in pH, changes in temperature, concentration or availability of enzymes, concentration or availability of water, or other physiological conditions or compounds.
[0355] Controlled-release and sustained-release means for use according to the present invention may be selected from those known in the art. Examples include, but are not limited to, those described in U.S. Pat. Nos. 3,845,770; 3,916,899; 3,536,809; 3,598,123; 4,008,719; 5,674,533; 5,059,595; 5,591,767; 5,120,548; 5,073,543; 5,639,476; 5,354,556; and 5,733,566, each of which is incorporated herein by reference. Such dosage forms can be used to provide controlled- or sustained-release of one or more active ingredients using, for example, hydroxypropylmethyl cellulose, other polymer matrices, gels, permeable membranes, osmotic systems, multilayer coatings, microparticles, multiparticulates, liposomes, microspheres, or a combination thereof to provide the desired release profile in varying proportions. Suitable controlled- or sustained-release formulations known in the art, including those described herein, can be readily selected for use with the active ingredients of the invention in view of this disclosure. See also Goodson, “Dental Applications” (pp. 115-138) in Medical Applications of Controlled Release, Vol. 2 , Applications and Evaluation, R. S. Langer and D. L. Wise eds., CRC Press (1984). Other controlled- or sustained-release systems that are discussed in the review by Langer, Science 249:1527-1533 (1990) can be selected for use according to the present invention. In one embodiment, a pump can be used (Langer, Science 249:1527-1533 (1990); Sefton, CRC Crit. Ref. Biomed. Eng. 14:201 (1987); Buchwald et al., Surgery 88:507 (1980); and Saudek et al., N. Engl. J. Med. 321:574 (1989)). In another embodiment, polymeric materials can be used ( see Medical Applications of Controlled Release (Langer and Wise eds., 1974); Controlled Drug Bioavailability, Drug Product Design and Performance (Smolen and Ball eds., 1984); Ranger and Peppas, J. Macromol. Sci. Rev. Macromol. Chem. 23:61 (1983); Levy et al., Science 228:190 (1985); During et al., Ann. Neurol. 25:351 (1989); and Howard et al., J. Neurosurg. 71:105 (1989)). In yet another embodiment, a controlled- or sustained-release system can be placed in proximity of a target of a Compound of the Invention, e.g., the spinal column, brain, or gastrointestinal tract, thus requiring only a fraction of the systemic dose.
[0356] When in tablet or pill form, a pharmaceutical composition of the invention can be coated to delay disintegration and absorption in the gastrointestinal tract, thereby providing a sustained action over an extended period of time. Selectively permeable membranes surrounding an osmotically active driving compound are also suitable for orally administered compositions. In these latter platforms, fluid from the environment surrounding the capsule is imbibed by the driving compound, which swells to displace the agent or agent composition through an aperture. These delivery platforms can provide an essentially zero order delivery profile as opposed to the spiked profiles of immediate release formulations. A time-delay material such as glycerol monostearate or glycerol stearate can also be used. Oral compositions can include standard excipients such as mannitol, lactose, starch, magnesium stearate, sodium saccharin, cellulose, and magnesium carbonate. In one embodiment, the excipients are of pharmaceutical grade.
[0357] Pharmaceutical compositions of the invention include single unit dosage forms suitable for oral administration such as, but not limited to, tablets, capsules, gelcaps, and caplets that are adapted for controlled- or sustained-release.
[0358] The amount of the Compound of the Invention that is effective for the treatment or prevention of a condition can be determined by standard clinical techniques. In addition, in vitro and/or in vivo assays can optionally be employed to help identify optimal dosage ranges. The precise dose to be employed will also depend on, e.g., the route of administration and the extent of the Condition to be treated, and can be decided according to the judgment of a practitioner and/or each patient's circumstances. Variations in dosing may occur depending upon typical factors such as the weight, age, gender and physical condition (e.g., hepatic and renal function) of the patient being treated, the affliction to be treated, the severity of the symptoms, the frequency of the dosage interval, the presence of any deleterious side-effects, and the particular compound utilized, among other things.
[0359] Suitable effective dosage amounts can range from about 0.01 mg/kg of body weight to about 3000 mg/kg of body weight of the patient per day, although they are typically from about 0.01 mg/kg of body weight to about 2500 mg/kg of body weight of the patient per day or from about 0.01 mg/kg of body weight to about 1000 mg/kg of body weight of the patient per day. In one embodiment, the effective dosage amount is about 100 mg/kg of body weight of the patient per day or less. In another embodiment, the effective dosage amount ranges from about 0.01 mg/kg of body weight to about 100 mg/kg of body weight of the patient per day of a Compound of the Invention, in another embodiment, about 0.02 mg/kg of body weight to about 50 mg/kg of body weight of the patient per day, and in another embodiment, about 0.025 mg/kg of body weight to about 20 mg/kg of body weight of the patient per day.
[0360] Administration can be as a single dose or as a divided dose. In one embodiment, an effective dosage amount is administered about every 24 hours until the Condition is abated. In another embodiment, an effective dosage amount is administered about every 12 hours until the Condition is abated. In another embodiment, an effective dosage amount is administered about every 8 hours until the Condition is abated. In another embodiment, an effective dosage amount is administered about every 6 hours until the Condition is abated. In another embodiment, an effective dosage amount is administered about every 4 hours until the Condition is abated. The effective dosage amounts described herein refer to total amounts administered; that is, if more than one Compound of the Invention is administered, the effective dosage amounts correspond to the total amount administered.
[0361] Where a cell capable of expressing the μ-opioid receptors is contacted with a Compound of the Invention in vitro, the amount effective for inhibiting or activating the μ-opioid receptors function in a cell can typically range from about 10 −12 mol/L to about 10 −4 mol/L, or from about 10 −12 mol/L to about 10 −5 mol/L, or from about 10 −12 mol/L to about 10 −6 mol/L, or from about 10 −12 mol/L to about 10 −9 mol/L of a solution or suspension of the Compound of the Invention in a pharmaceutically acceptable carrier or excipient. In one embodiment, the volume of solution or suspension comprising the Compound of the Invention can be from about 0.01 μL to about 1 mL. In another embodiment, the volume of solution or suspension can be about 200 μL.
[0362] Where a cell capable of expressing the δ-opioid receptors is contacted with a Compound of the Invention in vitro, the amount effective for inhibiting or activating the δ-opioid receptors function in a cell can typically range from about 10 −12 mol/L to about 10 −4 mol/L, or from about 10 −12 mol/L to about 10 −5 mol/L, or from about 10 −12 mol/L to about 10 −6 mol/L, or from about 10 −12 mol/L to about 10 −9 mol/L of a solution or suspension of the Compound of the Invention in a pharmaceutically acceptable carrier or excipient. In one embodiment, the volume of solution or suspension comprising the Compound of the Invention can be from about 0.01 μL to about 1 mL. In another embodiment, the volume of solution or suspension can be about 200 μL.
[0363] Where a cell capable of expressing the κ-opioid receptors is contacted with a Compound of the Invention in vitro, the amount effective for inhibiting or activating the κ-opioid receptors function in a cell can typically range from about 10 −12 mol/L to about 10 −4 mol/L, or from about 10 −12 mol/L to about 10 −5 mol/L, or from about 10 −12 mol/L to about 10 −6 mol/L, or from about 10 −12 mol/L to about 10 −9 mol/L of a solution or suspension of the Compound of the Invention in a pharmaceutically acceptable carrier or excipient. In one embodiment, the volume of solution or suspension comprising the Compound of the Invention can be from about 0.01 μL to about 1 mL. In another embodiment, the volume of solution or suspension can be about 200 μL.
[0364] Where a cell capable of expressing the ORL-1 receptor is contacted with a Compound of the Invention in vitro, the amount effective for inhibiting or activating the ORL-1 receptor function in a cell can typically range from about 10 −12 mol/L to about 10 −4 mol/L, or from about 10 −12 mol/L to about 10 −5 mol/L, or from about 10 −12 mol/L to about 10 −6 mol/L, or from about 10 −12 mol/L to about 10 −9 mol/L of a solution or suspension of the compound in a pharmaceutically acceptable carrier or excipient. In one embodiment, the volume of solution or suspension comprising the Compound of the Invention can be from about 0.01 μL to about 1 mL. In another embodiment, the volume of solution or suspension can be about 200 μL.
[0365] Compounds of the Invention can be assayed in vitro or in vivo for the desired therapeutic or prophylactic activity prior to use in humans. Animal model systems can be used to demonstrate safety and efficacy. Certain Compounds of the Invention are expected to have an ED 50 for treating inflammatory pain ranging from about 0.5 mg/kg to about 20 mg/kg. Certain Compounds of the Invention are expected to produce significant analgesia and/or anti-hyperalgesia at doses that do not induce respiratory depression. In contrast, oxygen tension, oxygen saturation and pH are significantly decreased, while carbon dioxide is significantly increased, in blood samples from rats given effective doses of conventional opioids, such as morphine.
[0366] According to the present invention, methods for treating or preventing a Condition in a patient in need thereof can further comprise co-administering to the patient an effective amount of a second therapeutic agent in addition to a Compound of the Invention (i.e., a first therapeutic agent). An effective amount of the second therapeutic agent can be known or determinable by a medical practitioner in view of this disclosure and published clinical studies. In one embodiment of the invention, where a second therapeutic agent is administered to a patient for treatment of a Condition (e.g., pain), the minimal effective amount of the Compound of the Invention (i.e., the first therapeutic agent) will be less than its minimal effective amount would be in circumstances where the second therapeutic agent is not administered. In this embodiment, the Compound of the Invention and the second therapeutic agent can act either additively or synergistically to treat or prevent a Condition. Alternatively, the second therapeutic agent may be used to treat or prevent a disorder that is different from the Condition for which the first therapeutic agent is being administered, and which disorder may or may not be a Condition as defined hereinabove. In one embodiment, a Compound of the Invention is administered concurrently with a second therapeutic agent as a single composition comprising an effective amount of a Compound of the Invention and an effective amount of the second therapeutic agent. Alternatively, a composition comprising an effective amount of a Compound of the Invention and a second composition comprising an effective amount of the second therapeutic agent are concurrently administered. In another embodiment, an effective amount of a Compound of the Invention is administered prior or subsequent to administration of an effective amount of the second therapeutic agent. In this embodiment, the Compound of the Invention is administered while the second therapeutic agent exerts its therapeutic effect, or the second therapeutic agent is administered while the Compound of the Invention exerts its therapeutic effect for treating or preventing a Condition.
[0367] The second therapeutic agent can be, but is not limited to, an opioid agonist, a non-opioid analgesic, a non-steroidal anti-inflammatory agent, an antimigraine agent, a Cox-IA inhibitor, a 5-lipoxygenase inhibitor, an anti-emetic, a β-adrenergic blocker, an anticonvulsant, an antidepressant, a Ca 2+ -channel blocker, an anti-cancer agent, an agent for treating or preventing UI, an agent for treating or preventing anxiety, an agent for treating or preventing a memory disorder, an agent for treating or preventing obesity, an agent for treating or preventing constipation, an agent for treating or preventing cough, an agent for treating or preventing diarrhea, an agent for treating or preventing high blood pressure, an agent for treating or preventing epilepsy, an agent for treating or preventing anorexia/cachexia, an agent for treating or preventing drug abuse, an agent for treating or preventing an ulcer, an agent for treating or preventing IBD, an agent for treating or preventing IBS, an agent for treating or preventing addictive disorder, an agent for treating or preventing Parkinson's disease and parkinsonism, an agent for treating or preventing a stroke, an agent for treating or preventing a seizure, an agent for treating or preventing a pruritic condition, an agent for treating or preventing psychosis, an agent for treating or preventing Huntington's chorea, an agent for treating or preventing ALS, an agent for treating or preventing a cognitive disorder, an agent for treating or preventing a migraine, an agent for treating, preventing or inhibiting vomiting, an agent for treating or preventing dyskinesia, an agent for treating or preventing depression, or any mixture thereof.
[0368] A composition of the invention is prepared by a method comprising admixing a Compound of the Invention with a pharmaceutically acceptable carrier or excipient. Admixing can be accomplished using methods known for admixing a compound (or derivative) and a pharmaceutically acceptable carrier or excipient. In one embodiment, the Compound of the Invention is present in the composition in an effective amount.
[0369] The present invention also relates to a kit, comprising a sterile container containing an effective amount of a Compound of the Invention and instructions for therapeutic use.
[0370] The following examples are illustrative, but not limiting, of the compounds, compositions and methods of the present invention. Suitable modifications and adaptations of the variety of conditions and parameters normally encountered in clinical therapy and which are obvious to those skilled in the art in view of this disclosure are within the spirit and scope of the invention.
EXAMPLES
Example 1
(6R,6aS,12aR)-15-(cyclopropylmethyl)-2,6a-dihydroxy-9-(methylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 5)
[0371]
[0372] (4bR,8aS,9R)-11-(Cyclopropylmethyl)-8a-hydroxy-3-methoxy-8,8a,9,10-tetrahydro-5H-9,4b-(epiminoethano)phenanthren-6(7H)-one (Compound 1) can be prepared as described in, for example, Hupp C. D., et al., Tetrahedron Letters, 2010, 51, 2359-2361.
[0373] To a suspension of Compound 1 (10.021 g, 26.5 mmol) in Et 2 O (100 mL) was added methyl formate (3.60 mL, 58.4 mmol) and NaOEt (7.946 g, 117 mmol). After stirring at RT for 1 h the reaction was quenched by the addition of conc. aq. NH 4 OH (100 mL). The mixture was filtered to give Compound 2 as a tan powder: LC/MS, m/z=370 [M+H] + (Calc: 369).
[0374] To a suspension of Compound 2 (0.369 g, 1.00 mmol) in ACN (10 mL) in a pressure tube was added Compound 3 (0.146 g, 1.83 mmol) and piperidine (0.099 mL, 1.002 mmol). The tube was sealed and heated at 65° C. for 4 h. Additional Compound 3 (0.072 g, 0.90 mmol) was added and the reaction heated at 65° C. for 4 days and at RT for 4 days. The reaction mixture was concentrated and purified over silica gel with 0-15% (10% NH 4 OH in MeOH) in dichloromethane (DCM) to give Compound 4 as a brown powder: LC/MS, m/z=471 [M+H] + (Calc: 470).
[0375] To a suspension of Compound 4 (0.172 g, 0.366 mmol) in DCM (10 mL) was added 1 M BBr 3 in DCM (1.46 mL, 1.46 mmol). After stirring at RT for 2 h the reaction was quenched by the addition of 5 M NH 3 in MeOH (1.2 mL). The reaction mixture was concentrated and purified over silica gel with 0-25% (10% NH 4 OH in MeOH) in DCM followed by trituration with hexanes to give Compound 5 as a tan powder: 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.47 (s, 1H), 9.16 (s, 1H), 7.67 (s, 1H), 6.92 (d, J=7.9 Hz, 1H), 6.56-6.50 (m, 2H), 4.67 (s, 1H), 3.17 (s, 3H), 3.15-3.07 (m, 2H), 3.02 (d, J=18.7 Hz, 1H), 2.92-2.76 (m, 2H), 2.61-2.49 (m, 2H, overlap with DMSO), 2.43-2.33 (m, 3H), 2.10-1.96 (m, 2H), 1.18-1.10 (m, 1H), 0.92-0.81 (m, 1H), 0.53-0.43 (m, 2H), 0.17-0.07 (m, 2H); LC/MS, m/z=457.2 [M+H] + (Calc: 456.6).
[0376] In a similar manner the following compounds were prepared from Compound 1 or similar starting materials which can be prepared as described in, for example, Hupp C. D., et al., Tetrahedron Letters, 2010, 51, 2359-2361.
[0000]
(6R,6aS,12aR)-15-(cyclopropylmethyl)-2,6a-dihydroxy-9-(phenylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 6)
[0377] 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.26 (s, 1H), 9.10 (s, 1H), 7.94-7.88 (m, 3H), 7.67-7.62 (m, 1H), 7.58-7.52 (m, 2H), 6.92 (d, J=8.4 Hz, 1H), 6.53 (dd, J=8.1, 2.4 Hz, 1H), 6.47 (d, J=2.4 Hz, 1H), 4.67 (s, 1H), 3.14-2.99 (m, 3H), 2.87-2.78 (m, 2H), 2.60-2.52 (m, 2H), 2.42 (d, J=16.9 Hz, 1H), 2.40-2.31 (m, 2H), 2.07-1.95 (m, 2H), 1.16-1.06 (m, 1H), 0.92-0.81 (m, 1H), 0.54-0.43 (m, 2H), 0.17-0.07 (m, 2H).
[0378] LC/MS: m/z=519.2 [M+H] + (Calc: 518.6).
(6R,6aS,12aR)-2,6a-dihydroxy-15-methyl-9-(methylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 7)
[0379] 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.45 (s, 1H), 9.16 (s, 1H), 7.67 (s, 1H), 9.64 (d, J=8.1 Hz, 1H), 6.56-6.49 (m, 2H), 4.66 (s, 1H), 3.17 (s, 3H), 3.15-3.05 (m, 2H), 2.90-2.74 (m, 3H), 2.56-2.50 (m, 1H), 2.41-2.28 (m, 5H), 2.12-1.96 (m, 2H), 1.15-1.08 (m, 1H).
[0380] LC/MS: m/z=417.2 [M+H] + (Calc: 416.5).
(6R,6aS,12aR)-2,6a-dihydroxy-15-methyl-9-(phenylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 8)
[0381] 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.25 (s, 1H), 9.10 (s, 1H), 7.93-7.88 (m, 3H), 7.67-7.62 (m, 1H), 7.58-7.52 (m, 2H), 6.94 (d, J=8.4 Hz, 1H), 6.53 (dd, J=8.4, 2.2 Hz, 1H), 6.47 (d, J=2.4 Hz, 1H), 4.66 (s, 1H), 3.14-3.03 (m, 2H), 2.86-2.75 (m, 3H), 2.56 (d, J=16.9 Hz, 1H), 2.40 (d, J=16.9 Hz, 1H), 2.36-2.28 (m, 4H), 2.09-1.95 (m, 2H), 1.13-1.06 (m, 1H).
[0382] LC/MS: m/z=479.1 [M+H] + (Calc: 478.6).
(6R,6aR,12aS)-15-(cyclopropylmethyl)-2-hydroxy-9-(methylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 9)
[0383] 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.42 (br. s., 1H), 9.09 (s, 1H), 7.67 (s, 1H), 6.90 (d, J=7.9 Hz, 1H), 6.55-6.49 (m, 2H), 3.34-3.26 (m, 1H, overlap with water), 3.24-3.19 (m, 1H), 3.17 (s, 3H), 2.90-2.78 (m, 1H), 2.76-2.57 (m, 3H), 2.57-2.49 (m, 1H, overlap with DMSO), 2.41 (dd, J=12.5, 6.4 Hz, 1H), 2.28 (dd, J=12.5, 6.6 Hz, 1H), 2.23-2.06 (m, 2H), 2.02-1.91 (m, 1H), 1.80 (td, J=12.5, 4.5 Hz, 1H), 1.37 (d, J=12.1 Hz, 1H), 0.86-0.74 (m, 1H), 0.50-0.40 (m, 2H), 0.14-0.02 (m, 2H).
[0384] LC/MS: m/z=441.1 [M+H] + (Calc: 440.6).
(6R,6aR,12aS)-15-(cyclopropylmethyl)-2-hydroxy-9-(phenylsulfonyl)-6a,7,11,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(6H)-one (Compound 10)
[0385] 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.24 (br. s., 1H), 9.06 (s, 1H), 7.93-7.87 (m, 3H), 7.68-7.61 (m, 1H), 7.58-7.52 (m, 2H), 6.90 (d, J=8.4 Hz, 1H), 6.54-6.46 (m, 2H), 3.30-3.17 (m, 2H), 2.90-2.80 (m, 1H), 2.73-2.53 (m, 4H), 2.46-2.37 (m, 1H), 2.31-2.23 (m, 1H), 2.22-2.10 (m, 2H), 2.01-1.89 (m, 1H), 1.83-1.71 (m, 1H), 1.35 (d, J=12.1 Hz, 1H), 0.87-0.74 (m, 1H), 0.50-0.40 (m, 2H), 0.15-0.02 (m, 2H).
[0386] LC/MS: m/z=503.1 [M+H] + (Calc: 502.6).
(6R,6aR,12aS)-2-hydroxy-15-methyl-9-(methylsulfonyl)-6,6a,7,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(11H)-one (Compound 11)
[0387] 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.42 (br. s., 1H), 9.12 (br. s., 1H), 7.67 (s, 1H), 6.93 (d, J=8.9 Hz, 1H), 6.58-6.48 (m, 2H), 3.37-3.26 (m, 1H, overlap with water), 3.17 (s, 3H), 3.01-2.85 (m, 2H), 2.77-2.59 (m, 2H), 2.58-2.48 (m, 1H, overlap with DMSO), 2.44-2.24 (m, 4H), 2.23-2.07 (m, 2H), 2.07-1.92 (m, 1H), 1.86-1.73 (m, 1H), 1.38 (d, J=11.0 Hz, 1H).
[0388] LC/MS: m/z=401.2 [M+H] + (Calc: 400.5).
(6R,6aR,12aS)-2-hydroxy-15-methyl-9-(phenylsulfonyl)-6,6a,7,12-tetrahydro-5H-6,12a-(epiminoethano)naphtho[2,1-g]quinolin-10(11H)-one (Compound 12)
[0389] 1 H NMR (400 MHz, DMSO-d 6 ): δ 12.21 (s, 1H), 9.05 (s, 1H), 7.93-7.87 (m, 3H), 7.68-7.61 (m, 1H), 7.58-7.51 (m, 2H), 6.92 (d, J=8.3 Hz, 1H), 6.51 (dd, J=8.3, 2.3 Hz, 1H), 6.48 (d, J=2.3 Hz, 1H), 3.27 (d, J=18.1 Hz, 1H), 2.98-2.88 (m, 2H), 2.71-2.60 (m, 2H), 2.58-2.51 (m, 1H), 2.38-2.26 (m, 4H), 2.22-2.10 (m, 2H), 2.03-1.93 (m, 1H), 1.75 (td, J=12.4, 4.7 Hz, 1H), 1.34 (d, J=12.2 Hz, 1H).
[0390] LC/MS: m/z=463.2 [M+H] + (Calc: 462.6).
Example 2
[0391] The following TABLES 1, 2, and 2A provide results on the efficacy of binding and activity response of certain exemplified Compounds of the Invention at the μ- and κ-opioid receptors.
[0392] In TABLE 1, binding affinity of certain exemplified Compounds of the Invention to the μ-, and κ-opioid receptors in HEK-293 or CHO cells was determined through functional assays as above described.
[0393] In TABLE 2, activity response of certain exemplified Compounds of the Invention at the μ- and κ-opioid receptors using HEK-293 or CHO cells was determined through functional assays as above described.
[0394] In TABLE 2A, activity response of certain exemplified Compounds of the Invention at the μ- and κ-opioid receptors using U-2 OS cells was determined through functional assays as above described.
[0395] Further, TABLE 3 presents the structures of certain exemplified Compounds of the Invention.
[0000]
TABLE 1
Binding Affinity of Pyridone-Sulfone Morphinan Compounds
Comp.
Ki (nM)
No.
μ
κ
5
0.76 ± 0.13
0.36 ± 0.091
8
19.5 ± 2.69
11
13.1 ±2.27
12
2.78 ± 0.75
[0000]
TABLE 2
Activity Response of Pyridone-Sulfone Morphinan
Analog Compounds in HEK-293 or CHO Cells
GTPγS (EC 50 : nM, E max : %)
Comp.
μ
κ
No.
EC 50
E max
EC 50
E max
5
>20
μM
1.00 ± 0.00
1.27 ± 0.30
10.30 ± 0.67
9
>20
μM
2.50 ± 0.00
10
>20
μM
2.00 ± 0.00
11
258.9 ± 53.5
20.7 ± 1.76
106.9 ± 28.7
16.7 ± 1.21
12
83.1 ± 24.1
19.8 ± 2.63
17.2 ± 4.22
17.2 ± 1.04
[0000]
TABLE 2A
Activity Response of Pyridone-Sulfone Morphinan
Analog Compounds in U-2 OS Cells
GTPγS (EC 50 : nM, E max : %)
Comp.
μ
κ
No.
EC 50
E max
EC 50
E max
5
>20
μM
2.00 ± 0.00
0.85 ± 0.075
55.70 ± 2.40
6
>20
μM
2.00 ± 0.00
0.26 ± 0.055
33.20 ± 2.84
7
147.90 ± 6.21
68.00 ± 1.15
203.50 ± 47.70
71.30 ± 3.33
8
77.50 ± 10.90
61.70 ± 1.67
35.80 ± 3.77
82.30 ± 3.67
[0396] Further, the structures and corresponding names of certain exemplified Compounds of the Invention are provided in Table 3 as follows:
[0000]
TABLE 3
Comp.
No.
Compound
5
(6R,6aS,12aR)-15-(cyclopropylmethyl)- 2,6a-dihydroxy-9-(methylsulfonyl)- 6a,7,11,12-tetrahydro-5H-6,12a- (epiminoethano)-naphtha[2,1-g]quinolin- 10(6H)-one
6
(6R,6aS,12aR)-15-(cyclopropylmethyl)- 2,6a-dihydroxy-9-(phenylsulfonyl)- 6a,7,11,12-tetrahydro-5H-6,12a- (epiminoethano)-naphtha[2,1-g]quinolin- 10(6H)-one
7
(6R,6aS,12aR)-2,6a-dihydroxy-15-methyl- 9-(methylsulfonyl)-6a,7,11,12-tetrahydro- 5H-6,12a-(epiminoethano)naphtho[2,1- g]quinolin-10(6H)-one
8
(6R,6aS,12aR)-2,6a-dihydroxy-15-methyl- 9-(phenylsulfony0-6a,7,11,12-tetrahydro- 5H-6,12a-(epiminoethano)naphtho[2,1- g]quinolin-10(6H)-one
9
(6R,6aR,12aS)-15-(cyclopropylmethyl)-2- hydroxy-9-(methylsulfony)-6a,7,11,12- tetrahydro-5H-6,12a-(epiminoethano)- naphtho[2,1-g]quinolin-10(6H)-one
10
(6R,6aR,12aS)-15-(cyclopropylmethyl)-2- hydroxy-9-(phenylsulfonyl)-6a,7,11,12- tetrahydro-5H-6,12a-(epiminoethano)- naphtho[2,1-g]quinolin-10(6H)-one
11
(6R,6aR,12aS)-2-hydroxy-15-methyl-9- (methylsulfony)-6,6a,7,12-tetrahydro-5H- 6,12a-(epiminoethano)naphtho[2,1-g] quinolin-10(11H)-one
12
(6R,6aR,12aS)-2-hydroxy-15-methyl-9- (phenylsulfonyl)-6,6a,7,12-tetrahydro-5H- 6,12a-(epiminoethano)naphtho[2,1-g] quinolin-10(11H)-one
[0397] The in vitro test results of TABLES 1, 2 and 2A show that representative Compounds of the Invention generally have high binding affinity for opioid receptors, and that these compounds activate these receptors as partial to full agonists. Compounds of the Invention are therefore expected to be useful to treat Conditions, particularly pain, that are responsive to the activation of one or more opioid receptors.
[0398] Having now fully described this invention, it will be understood by those of ordinary skill in the art that the same can be performed within a wide and equivalent range of conditions, formulations and other parameters without affecting the scope of the invention or any embodiment thereof.
[0399] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
[0400] All patents, patent applications, and publications cited herein are fully incorporated by reference herein in their entirety. | The application is directed to Pyridone-sulfone morphinan analogs compounds of Formula I: or pharmaceutically acceptable salts and solvates thereof, wherein ==, R1, R2, R3, R4 and Z are as defined as set forth in the specification. The invention is also directed to use of the compounds of Formula I or the pharmaceutically acceptable salts and solvates thereof to treat disorders responsive to the odulation of one or more opioid receptors, or as synthetic intermediates. Certain compounds of the present invention are especially useful for treating pain. | 2 |
This application is a continuation of U.S. Pat. No. 7,492,406, issued on Feb. 17, 2009, which claims the benefit of Korean Patent Application No. 10-2003-0091341, filed on Dec. 15, 2003 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of controlling a digital photographing apparatus (e.g., a digital camera), and more particularly, to a method of controlling a digital photographing apparatus that receives an image having a resolution with a first pixel number and displays a display image on a displaying unit having a resolution with a second pixel number.
The method of controlling the digital photographing apparatus of the present invention can be adopted in any digital photographing apparatus that captures and stores images in addition to digital cameras. In the present application, a digital camera is used as a typical example in which the present invention can be adopted.
2. Description of the Related Art
FIG. 1 is a front perspective view of a conventional digital camera 1 . Referring to FIG. 1 , the digital camera 1 includes on its front surface, a microphone MIC, a self-timer lamp 11 , a flash 12 , a shutter button 13 , a mode dial 14 , a function-select button 15 , a photograph information display unit 16 , a view finder 17 a , a function-block button 18 , a flash-light amount sensor (FS) 19 , a lens unit 20 , and an external interface unit 21 .
When in a self-timer mode, the self-timer lamp 11 operates when the shutter button 13 is pressed until a shutter (not shown) operates. The mode dial 14 is used to select one of various operating modes, for example, a still image photographing mode, a night scene photographing mode, a moving picture photographing mode, a reproducing mode, a computer connecting mode, and a system setting mode. The function-select button 15 is used to select one of the operating modes, for example, a still image photographing mode, a night scene photographing mode, a moving picture photographing mode, or a reproducing mode. The photograph information displaying unit 16 displays various information regarding each function related to photographing. The function-block button 18 is used to select one of the functions displayed on the photograph information display unit 16 .
FIG. 2 is a rear view of the digital camera 1 of FIG. 1 . Referring to FIG. 2 , a speaker SP, a power button 31 , a monitor button 32 , an automatic focus lamp 33 , a view finder 17 b , a flash standby lamp 34 , a color liquid crystal display (LCD) panel 35 , a confirm/delete button 36 , an enter/play button 37 , a menu button 38 , a wide-angle zoom button 39 w , a telephoto zoom button 39 t , an up-movement button 40 up , a right-movement button 40 ri , a down-movement button 40 do , and a left-movement button 40 le are included on the back of the digital camera 1 .
The monitor button 32 is used to control the operation of the color LCD panel 35 . For example, if the user presses the monitor button 32 a first time, an image of a subject and photographing information is displayed on the color LCD panel 35 ; when the monitor button 32 is pressed a second time, only the image of the subject is displayed on the color LCD panel 35 ; and when the monitor button 32 is pressed a third time, power supplied to the color LCD panel 35 is blocked. The automatic focus lamp 33 operates when an automatic focusing operation is completed. The flash standby lamp 34 operates when the flash 12 (see FIG. 1 ) is on standby. The confirm/delete button 36 is used as a confirm or delete button in the process in which a user sets one of the modes. The enter/play button 37 is used to input data or perform various functions such as stop or play in the reproducing mode. The menu button 38 is used to display a menu of a mode selected from the mode dial 14 . The up-movement button 40 up , the right-movement button 40 ri , the down-movement button 40 do , and the left-movement button 40 le are used in the process in which a user selects one of the modes.
FIG. 3 is a view illustrating a structure of a surface of the digital camera 1 of FIG. 1 on which light is incident. FIG. 4 is a block diagram of the digital camera 1 of FIG. 1 .
An optical system OPS including the lens unit 20 and a filter unit 41 optically processes light reflected from a subject. The lens unit 20 of the optical system OPS includes a zoom lens ZL, a focus lens FL, and a compensation lens CL.
If a user presses the wide-angle zoom button 39 w (see FIG. 2 ) or the telephoto zoom button 39 t (see FIG. 2 ) included in a user inputting unit INP, a signal corresponding to the wide-angle zoom button 39 w or the telephoto zoom button 39 t is input to a micro-controller 512 . Accordingly, as the micro-controller 512 controls a lens driving unit 510 , a zoom motor M Z operates, thereby moving the zoom lens ZL. That is, if the wide-angle zoom button 39 w is pressed, the focal length of the zoom lens ZL is shortened, and thus increases a viewing angle. On the other hand, if the telephoto zoom button 39 t is pressed, the focal length of the zoom lens ZL is lengthened, and thus decreases a viewing angle. According to the above-mentioned characteristics, the micro-controller 512 can calculate a viewing angle based on the location of the zoom lens ZL from design data of the optical system OPS. Since the location of the focus lens FL is altered while the location of the zoom lens ZL is fixed, the viewing angle is hardly affected by the location of the focus lens FL.
When the focus on a subject is automatically or manually fixed, the current location of the focus lens FL changes with respect to a distance Dc to a subject. Since the location of the focus lens FL is changed when the location of the zoom lens ZL is fixed, the distance Dc to the subject is affected by the location of the zoom lens ZL. In the automatic focusing mode, the micro-controller 512 controls the lens driving unit 510 , thereby driving a focus motor M F . Accordingly, the focus lens FL moves from the very front to the very back. In this process, a number of steps of the location of the focus lens FL (e.g., a number of location steps of the focus motor M F ) are set at which an amount of high frequency in an image signal is increased the most.
The compensation lens CL is not separately operated since it acts to compensate for the overall refractive index.
A motor M A drives an aperture (not shown). A rotation angle of the aperture driving motor M A depends on whether the digital camera 1 is in a specified area exposure mode or in another mode. In the specified exposure mode, when a part of a subject region desired by a user coincides with a specified detected region displayed on the color LCD panel 35 of the digital camera 1 , a light amount of the digital camera 1 is set to a mean brightness value of the specified detected region.
An optical low pass filter (OLPF) included in the filter unit 41 of the optical system OPS removes optical noise with a high frequency. An infrared cut filter (IRF) included in the filter unit 41 blocks infrared components of incident light.
A photoelectric converter OEC of a charge-coupled device (CCD) or a complementary metal oxide semiconductor (CMOS) (not shown) converts light from the optical system OPS into an electrical analog signal. Here, a digital signal processor (DSP) 507 controls a timing circuit 502 and controls the operation of the photoelectric converter OEC and a correlation double sampler and analog-to-digital converter (CDS-ADC) device 501 . The CDS-ADC device 501 , which is an ADC, processes the analog signal output from the photoelectric converter OEC, and converts it into a digital signal after removing high frequency noise from the analog signal and altering the bandwidth of the analog signal. The DSP 507 processes the digital signal from the CDS-ADC device 501 , and generates a digital image signal divided into a chrominance signal and a luminance signal.
A light emitting unit LAMP that is operated by the micro-controller 512 includes the self-timer lamp 11 , the automatic focus lamp 33 (see FIG. 2 ), and the flash standby lamp 34 (see FIG. 2 ). The user inputting unit INP includes the shutter button 13 (see FIG. 1 ), the mode dial 14 (see FIG. 1 ), the function-select button 15 (see FIG. 1 ), the function-block button 18 (see FIG. 1 ), the monitor button 32 (see FIG. 2 ), the confirm/delete button 36 (see FIG. 2 ), the enter/play button 37 (see FIG. 2 ), the menu button 38 (see FIG. 2 ), the wide-angle zoom button 39 w (see FIG. 2 ), the telephoto zoom button 39 t , the up-movement button 40 up (see FIG. 2 ), the right-movement button 40 ri (see FIG. 2 ), the down-movement button 40 do (see FIG. 2 ), and the left-movement button 40 le (see FIG. 2 ).
The digital image signal output from the DSP 507 is temporarily stored in a dynamic random access memory (DRAM) 504 . Algorithms needed for the operation of the DSP 507 and for setting data are stored in an electrically erasable and programmable read-only memory (EEPROM) 505 . A memory card is inserted into a memory card interface (MCI) 506 .
The digital image signal output from the DSP 507 is input to an LCD driving unit 514 . As a result, an image is displayed on the color LCD panel 35 .
The digital image signal output from the DSP 507 can be transmitted in a series communication via a universal serial bus (USB) connector 21 a or an RS232C interface 508 and its connector 21 b , or can be transmitted as a video signal via a video filter 509 and a video outputting unit 21 c.
An audio processor 513 outputs an audio signal from the microphone MIC to the DSP 507 or the speaker SP, and outputs an audio signal from the DSP 507 to the speaker SP.
The micro-controller 512 controls the operation of a flash controller 511 according to a signal output from the FS 19 , and thus operates the flash 12 .
FIG. 5 is a flowchart illustrating a method of controlling photographing of the micro-controller 512 illustrated in FIG. 4 .
Referring to FIGS. 1 through 5 , the shutter button 13 included in the user inputting unit INP has a two-step structure. That is, if a user presses the shutter button 13 to a first step after the user operates the wide-angle zoom button 39 w or the telephoto zoom button 39 t , a first signal S 1 output from the shutter button 13 is activated, and if the shutter release button 13 is pressed to a second step, a second signal S 2 output from the shutter button 13 is activated. Therefore, the algorithm for controlling photographing illustrated in FIG. 5 starts when the shutter release button 13 is pressed up to the first step (Operation 101 ). Here, the current location of the zoom lens ZL is already set.
Remaining storage space of the memory card is detected (Operation 102 ), and it is determined whether the storage space is sufficient to record a digital image (Operation 103 ). If there is not enough storage space, a message indicating a lack of storage space in the memory card is displayed (Operation 104 ). If there is enough storage space, the following operations are performed.
Automatic white balance (AWB) is performed, and parameters related to the AWB process are set (Operation 105 ). Then, automatic exposure (AE) is performed in which a brightness of incident light is calculated, and the aperture driving motor M A is operated according to the calculated brightness amount (Operation 106 ). Then, automatic focusing is performed, and the location of the focus lens FL is set (Operation 107 ).
Then, it is determined whether a first signal S 1 , which is a signal generated when the shutter button 13 is at a first step, is activated (Operation 108 ). If the first signal S 1 is inactivated, the user has no intention of photographing, and thus, a perform-program is terminated. If the first signal S 1 is activated, the following operations are performed.
First, it is determined whether the second signal S 2 is activated (Operation 109 ). If the second signal S 2 is not activated, the user has not pressed the shutter button 13 to the second step for photographing, and thus the method moves to operation 106 .
If the second signal S 2 is activated, a photographing operation is performed since the user has pressed the shutter button 13 to the second step for photographing. That is, the micro-controller 512 operates the DSP 507 , and the timing circuit 502 operates the photoelectric converter OEC and the CDS-ADS 501 . Then, image data is compressed (Operation 111 ), and a compressed image file is generated (Operation 112 ). After the generated image file is stored in the memory card via the MCI 506 from the DSP 507 (Operation 113 ), the method is completed.
For reference, Japanese Patent Publication No. hei 11-196301, titled “Electronic Camera Device,” discloses an electronic camera device in which the state of an image, for example, a focusing or a shaking of the image at the moment of photographing, can be easily checked.
FIGS. 6A , 6 B, 6 B′, and 6 C are views illustrating a conventional method of controlling a digital photographing apparatus to enlarge an image to check a focus of the image.
Referring to FIGS. 6A , 6 B, 6 B′, and 6 C, in the conventional method of controlling the digital photographing apparatus, a predetermined region of an image displayed on an image displaying device 35 is set as a focus zone before photographing the image. After displaying an enlarged focus zone, a user focuses the image or presses a shutter switch to perform photographing.
To do so, first, a focus frame 61 for checking the focus of the image is displayed inside a monitor image 60 of the subject, which is displayed on the image displaying device 35 , in a recording mode ( FIG. 6A ). Then, a portion of the image inside the focus frame 61 is automatically or manually at a command of the user enlarged, and displayed on the entire screen 62 or on a portion 63 of the screen (FIGS. 6 B and 6 B′). Then, the user checks whether the image is in focus by looking at the enlarged image, changes the focus if necessary, and performs photographing, and thus a photographed image 64 is displayed ( FIG. 6C ).
Image sensors used in digital photographing apparatuses have an increasing number of pixels due to advancements in technology, and the size of an LCD display window, which is an image displaying device, is becoming smaller due to the miniaturization of digital photographing apparatuses. Therefore, there is a large difference between the resolutions of the image sensor and the LCD display window, which is the image displaying device.
However, in the conventional method of controlling the digital photographing apparatus, the focus region is simply enlarged and displayed and resolutions of an image sensor and the image displaying device are not considered. Thus, it is difficult to achieve a good effect in the situation in which there is a large difference between the resolutions of the image sensor and the LCD display window as the image displaying device.
SUMMARY OF THE INVENTION
The present invention provides a method of controlling a digital photographing apparatus that can check the quality of a photographed image by enlarging a portion of the photographed image and displaying it on an image displaying device after photographing considering the difference between the resolution of an image sensor and the resolution of the image displaying device.
According to an aspect of the present invention, there is provided a method of controlling a digital photographing apparatus in which a portion of an input image is enlarged and displayed as a display image on an image displaying unit so that a user may determine the clarity of the input image, the digital photographing apparatus receiving the input image having a resolution of a first pixel number and displaying the display image on the image displaying unit having a resolution of a second pixel number. The method includes: receiving the input image; setting an enlarged display region that is to be enlarged from the input image, dividing the enlarged display region into at least two display images, and continually displaying the display images on the image display unit.
According to another aspect of the present invention, there is provided a method of controlling a digital photographing apparatus in which a portion of an input image is enlarged and displayed as a display image on an image displaying unit so that a user may determine the clarity of the input image, the digital photographing apparatus receiving the input image having a resolution of a first pixel number and displaying the display image on the image displaying unit having a resolution of a second pixel number. The method includes: receiving the input image; determining whether to enlarge the input image; setting a portion of the input image that is to be enlarged as an enlarged display region having a resolution of a third pixel number; calculating a number of display frames that are to be displayed on the image displaying unit by dividing the third pixel number by the second pixel number and rounding the result to an integer, and dividing the enlarged display region into the display images according to the number of the display frames; and displaying the display images on the image displaying unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a front perspective view of a conventional digital camera;
FIG. 2 is a rear view of the digital camera of FIG. 1 ;
FIG. 3 is a view illustrating a structure of a surface of the digital camera of FIG. 1 on which light is incident;
FIG. 4 is a block diagram of the digital camera of FIG. 1 ;
FIG. 5 is a flowchart illustrating a method of controlling photographing of a micro-controller illustrated in FIG. 4 ;
FIGS. 6A , 6 B, 6 B′, and 6 C are views illustrating a conventional method of controlling a digital photographing apparatus to enlarge a screen to check a focus of an image;
FIG. 7 is a flowchart illustrating a method of controlling a digital photographing apparatus according to an embodiment of the present invention;
FIG. 8 is a flowchart illustrating a method of displaying an enlarged image in the method of controlling the digital camera illustrated in FIG. 7 ;
FIG. 9 is a view schematically illustrating the displaying of the enlarged image of FIG. 8 ;
FIG. 10 is a view illustrating a setting of an enlarged display region in the displaying of the enlarged image described in FIG. 8
FIG. 11 is a view illustrating dividing of the enlarged display region into display images in the displaying of the enlarged image described in FIG. 8 ; and
FIGS. 12A through 12D are views illustrating the displaying of the respective divided display images in FIG. 11 in an automatic slide show.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. The description of a digital photographing apparatus with reference to FIGS. 1 through 5 also applies to all digital photographing apparatuses in embodiments of the present invention.
FIG. 7 is a flowchart illustrating a method 200 of controlling a digital photographing apparatus according to an embodiment of the present invention.
Referring to FIG. 7 , in the method 200 , the digital photographing apparatus receives an input image having a first resolution and displays a display image on an image displaying unit having a second resolution. A portion of the input image is enlarged and displayed as the display image on the image displaying unit so that a user may determine the clarity of the input image.
To do this, the digital photographing apparatus receives an input image (S 201 ). Then, a portion of the input image that is to be enlarged is set as an enlarged display region, the enlarged display region is divided into at least two display images, and the display images are continually displayed on an image displaying unit (S 203 ). The method may further include an operation of determining whether to enlarge the input image (S 202 ).
In the present embodiment, the input image is input from the outside by photographing in operation S 201 . The input image may be input via an image sensor (a charge-coupled device (CCD)) as in a conventional digital photographing apparatus, and the image sensor has a first resolution.
Although the input image is input from the outside by photographing in operation S 201 in the present embodiment, an input image may be obtained from the outside from an external device, and the obtained image may be input as image data via a data input/output unit in operation S 201 . In this case, in order to apply the method 200 of controlling the digital photographing apparatus according to the present invention, the input image data has the first resolution.
In addition, the image data may be stored in a predetermined storage medium or a pre-photographed image may be stored as image data, and the stored input image may be checked by displaying the input image on the image displaying unit through the manipulation of the user. Operation S 203 may be performed by the manipulation of the user that makes the input image to be displayed on the image displaying unit.
When desiring to display the photographed input image or the input image stored in the storage on the image displaying unit in advance, whether to display the enlarged input image or not may be set as a default.
In operation S 202 , when displaying the input image on the image displaying unit using a setting, whether to enlarge and display the image can be determined. In this case, when not enlarging and displaying the input image according to the determination result of S 202 , the input image having the first resolution is converted into an image having a second resolution and displayed on the image displaying unit in S 204 .
Since an image sensor used in a digital photographing apparatus usually has a higher number of pixels due to the advancement in technology, and the size of a liquid crystal display (LCD) display window, which is an image displaying device, is becoming more limited due to the miniaturizing of the digital photographing apparatus. Therefore, the first pixel number is higher than the second pixel number in many cases, and thus an input image with a high resolution is not properly displayed on the image displaying unit that has a lower resolution than the input image. Therefore, there is a limit in properly recognizing the clarity of the input image only with the image displayed on the image displaying unit.
The image displaying unit maybe a display device such as an LCD or an organic electro luminescent may be used. In the present embodiment, an LCD panel is used.
In operation S 203 , when enlarging and displaying the input image according to the determination result from operation S 202 , a portion of the input image that is to be enlarged is set as the enlarged display region. The enlarged display region is divided into at least two display images, and is continually displayed on the image displaying unit. The displaying of the enlarged input image in operation S 203 will be described in more detail with reference to FIG. 8 . In this case, each of the display images may be automatically displayed continually using an automatic slide show, as illustrated in FIG. 8 .
In operation S 203 , one of the divided display images is displayed on the image displaying unit, and each of the display images selected by an input from the outside, for example, by the user, may be manually displayed.
When enlarging a portion of the input image and displaying it on the image displaying unit in operation S 203 , an entire input image may be reduced and displayed on a portion of the image displaying unit on which the display image is displayed. Here, the input image may be surrounded by, for example, a quadrangular line so that it is distinguishable from the display image. The reducing of the entire input image and displaying it on the portion of the image displaying unit is as illustrated in FIGS. 9 and 12 .
The displaying of the entire input image on the portion of the image displaying unit is used to indicate which portion of the entire input image is currently displayed as the display image on the image displaying unit.
The enlarged display region of the input image is divided into at least two display images and displayed in operation S 203 so that the user may determine the clarity of the input image from the display image displayed on the image displaying unit. Here, the clarity of the image may be affected by how much the focus, a white balance, an amount of exposure, the shaking of the hands etc., were controlled. If the clarity of the image is reduced, the quality of the image becomes poorer.
That is, when reproducing the photographed image on the image displaying unit and checking the photographed image in the present embodiment, the image is enlarged and reproduced in consideration of the resolution of the input image and the resolution of the image displaying unit, and thus making it easier for the user to determine the clarity of the input image. An image photographed when it is difficult to focus the image (e.g., when the hand shakes, the surrounding is dark, a manual focus is set, or a near subject is photographed) may be blurred. Even when the image appears to be well focused on the image displaying unit of the digital photographing apparatus, the clarity of the image may still be poor when displaying the image on an external displaying device having a much higher resolution than the image displaying unit.
In this case, a specific region (i.e., a focus zone) of the input image is enlarged and displayed to easily check the clarity of the input image, or the user may easily check the clarity of the input image using a digital zoom.
In addition, the method 200 of controlling the digital photographing apparatus may further include deleting the input image when the clarity of the display image is not satisfactory according to the determination of the user. That is, first, the specific region of the input image is enlarged and displayed so that the user may check the clarity of the input image. Then, when the input image does not have a satisfactory clarity according to the determination of the user and the user desires to delete the currently checked input image, the input image may be deleted.
Furthermore, after checking the clarity of the input image using the method 200 of controlling the digital photographing apparatus, a process of deleting the input image if the clarity of the display image is lower than a standard clarity may be performed automatically by the digital photographing apparatus. The clarity can be determined based on a focus, a white balance, an amount of exposure etc., and a satisfactory clarity may be pre-set as the standard clarity.
To do so, first, it is determined whether the input image is to be deleted by the selection of the user (S 205 ). In the case it is set for the user to delete the input image, the input image is deleted (S 206 ). The input image that does not have a desired quality is deleted so that a new input image may be obtained.
FIG. 8 is a flowchart illustrating the displaying the enlarged image (S 203 ) in the method 200 of controlling the digital camera of FIG. 7 . FIG. 9 is a view schematically illustrating the displaying of the enlarged image (S 203 ) of FIG. 8 .
Referring to FIGS. 7 through 9 , in the method 200 , the digital photographing apparatus receives the input signal having the first resolution and displays the display image on the image displaying unit having the second resolution. A portion of the input image is enlarged and displayed on the image displaying unit so that the user can determine the clarity of the input image.
The method 200 of controlling the digital photographing apparatus includes receiving the input image (S 201 ), and determining whether to enlarge the input image (S 202 ). The operation S 203 of displaying the enlarged image includes setting a portion of the input image that is to be enlarged as an enlarged display region having a resolution of a third pixel number (S 301 ); dividing the second pixel number by the third pixel number, rounding the result to the nearest integer, calculating the number of display frames that is to be displayed on the displaying unit, and dividing the enlarged display region into display images according to the number of the display frames (S 303 ); and displaying each of the display images on the image display unit (S 304 , S 305 , and S 306 ).
In operation S 301 , the portion of the input image that is to be enlarged is set as the enlarged display region, which has the resolution with the third number pixel. That is, the third pixel number expresses the size of the enlarged display region in pixel numbers.
The enlarged display region may be set in a variety of ways in operation S 301 . When enlarging and displaying the enlarged display region, a region in which the user can readily determine the clarity of the input image can be set as the enlarged display region. Here, the user may personally set the enlarged display region via a user input unit of the digital photographing apparatus.
As an example of the method of setting the enlarged display region of S 301 , an input image can be divided into at least two regions, and a region having the most edges may be set as an enlarged display region. That is, the divided regions are examined and a region with the most edge information is found and set as the enlarged display region.
Also in operation S 301 , when a face of a person is included in an input image, the face region may be set as the enlarged display region. Here, color information of the input image can be extracted and the face can be detected by comparing the color information with a face tone of a general person, and it can be determined whether the face of a person is included in the input image.
According to another embodiment of the present invention, in the method of setting the enlarged display region of S 301 , a focus zone for adjusting a focus when automatically focusing, which is used in a conventional method of controlling a digital photographing apparatus, may be set as an enlarged display region.
FIG. 10 is a view illustrating the setting of the enlarged display region (S 301 ) in the displaying of the enlarged input image described in FIG. 8 . In the present embodiment, the whole input image is displayed on the image displaying unit, and the user may select how far a region to be enlarged and displayed is from the center of the input image. For example, a region corresponding to, for example, 1/9, 1/16, and 1/25 region from the center of the input image may be selected as an enlarged display region.
In operation S 303 , the enlarged display region set in operation S 301 is divided into at least two display images. A number of display frames that are to be formed is calculated from the third pixel number of the enlarged display region and the second pixel number of the image displaying unit, and the enlarged display region is divided into equal number of display images and display frames. Here, the number of display frames can be calculated by dividing the third pixel number by the second pixel number and rounding the result into an integer. The result can be rounded to the nearest whole number, rounded up or rounded down.
Also, the method 200 of controlling the digital photographing may further include setting a displaying ratio of a pixel number of an input image that is to be displayed on the image displaying unit and a pixel number of a display image that is displayed on the image displaying unit (S 302 ). Here, the displaying ratio may be a ratio of a pixel number of an input image that is to be displayed on the image displaying unit and a pixel number of a display image that is displayed on the image displaying unit in which 1:1 displaying ratio is preferable.
Operation S 302 is further included in case the user desires to check a further enlarged image simultaneously, and thus the user may select to perform operation S 302 . For example, the display ratio may be 1:1, 2:1, 3:1, . . . , n:1, or set by the user.
FIG. 11 is a view illustrating the dividing of the enlarged display region into display images in the displaying of the enlarged input image described in FIG. 8 . In this case, when further including operation S 302 , the number of the display frames is calculated by dividing the third pixel number by the second pixel number, multiplying the result by a display ratio n, and then rounding the result into an integer in operation S 303 .
Here, it may be difficult to reproduce the set enlarged display region in the selected display ratio in a single operation. For example, when ⅖ of an input image is selected to be displayed after being enlarged in a 1:1 ratio, when the size of the input image is 1,000,000 pixels and the size of an LCD is 100,000 pixels, ⅖ of the 1,000,000 pixels, that is, 400,000 pixels, is divided into four display frames, each having 100,000 pixels, and the four display frames are reproduced.
The display images are displayed on the image displaying unit in operations S 304 , S 305 , and S 306 . In operation S 304 , a method of displaying the display images is determined, in operation S 305 , the display images are displayed in an automatic slide show, and in operation S 306 , the display images are manually displayed.
In operation S 304 , whether to display the display images in the automatic slide show or manually display the display images is determined from a default setting. When photographing using the digital photographing apparatus and checking the photographed image, a user may select whether to use a function in which an enlarged display region is automatically enlarged according to a photographing condition.
In operation S 305 , the display images are sequentially displayed on the image displaying unit when the automatic slide show is selected in operation S 304 .
The configuration of enlargement reproduction, the enlarged display region, the enlargement ratio, the method of displaying, etc. is set by a user with a menu. If the enlarged display function is to be performed on the enlarged display region of a photographed image, the image is photographed as described in FIG. 8 , immediately an entire image is briefly shown, and the enlarged display region is enlarged and displayed according to the settings. Here, the enlarged display function performed on the enlarged display region is selected when a photographing condition is in a manual focus control mode, when a near subject is being photographed, when photographing using a telephoto zoom, when over 1/30 second of exposure is needed, etc.
In operation S 305 , it is preferable that a display image at the center of the enlarged display region is displayed on the image displaying unit, and the display images in the clockwise direction are sequentially displayed on the image displaying unit in the enlarged display region. In FIG. 9 , which schematically illustrates the displaying of the enlarged image (S 203 ) described in FIG. 8 , an entire input image is divided into regions using vertical and horizontal lines as shown, and regions labeled 1 through 9 sequentially are set as the enlarged display region.
In each of operations S 305 and S 306 , region 1 is first enlarged and displayed on the entire image displaying unit. In operation S 305 , display images of region 1 through 9 are sequentially displayed on the entire image displaying unit, which is in the clockwise direction from the center of the image displaying unit.
FIGS. 12A through 12D are views illustrating the displaying of the respective divided display images in FIG. 11 in the automatic slide show. The region of the entire input image that is divided by dotted lines forming a quadrangle at the center thereof according to a setting is set as the enlarged display region. Then, the enlarged display region is divided into regions by horizontal and vertical lines.
The display images shown in FIGS. 12A through 12D are sequentially displayed on the entire image displaying unit in operation S 305 . In this case, the display images are sequentially displayed in the counterclockwise direction. Also, when displaying the display images on the image displaying unit using the automatic slide show, the slide show may stop if an interruption occurs in the middle of the slide show.
In operation S 306 , when manually displaying the display images according to the determination result in operation S 304 , one of the divided display images is displayed on the image displaying unit, and each of the display images selected by external input is displayed. When manually displaying the display images according to the external input, a region selected by the user may be displayed and not the images in display frame units which are formed in operation S 303 .
That is, when manual display is selected, a center frame is reproduced and an image may be displayed in a pre-set pitch units, and not frame units, by moving the enlarged display region little by little to a desired direction using user operating keys.
As illustrated in FIGS. 9 and 12A through 12 D, when enlarging a portion of the input image and displaying the display images on the image displaying unit in operations S 305 and S 306 , the entire input image can be reduced and displayed on a portion of the image displaying unit on which the display images are displayed. The reduced entire input image can be surrounded by, for example, a quadrangular line so that it is distinguishable from the display image. The reduced entire input image is displayed to indicate which part of the entire input image the display image is taken from and displayed on the image displaying unit.
In addition, the method 200 of controlling the digital photographing apparatus can be adopted in a digital photographing apparatus according to an embodiment the present invention.
As described above, in a method of controlling a digital photographing apparatus according to the present invention, a portion of a photographed image is enlarged and displayed on an image display device in consideration of a difference in a resolution of an image sensor and a resolution of the image displaying device. Thus, a user may check the quality of the photographed image and may conveniently determined whether the photographed image has the quality the user desires. In addition, the user may easily determine, for example, the clarity of the photographed image or whether the photographed image is well focused.
While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. | A method of controlling a digital photographing apparatus to enlarge and reproduce an image is provided. The method includes determining whether an instruction is given in an image reproduction mode, dividing the input image into a predetermined number of blocks when it is determined that the instruction is given, enlarging the small image corresponding to a specific block from among the predetermined number of blocks, and displaying the enlarged small image on an entire screen. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to the field of electrography and, more particularly, to magnetic brush development apparatus for applying a magnetically attractive developer to a latent electrostatic image to effect development thereof.
It is known, in the field of electrography, to develop electrostatic images by applying a magnetically-attractive, single-component, electrically conductive developer thereto. Typically, such developer is applied to the electrostatic image-bearing surface by means of a magnetic brush applicator comprising a non-magnetic sleeve having a rotatably driven, multi-pole magnetic core positioned therein. During development, the electrostatic forces associated with the latent image overcome the magnetic attraction between core and developer, causing the developer to selectively deposit in image configuration on the recording element. The attraction of the developer for the electrostatic image results from a charge, of opposite polarity, induced on the developer by the charge image.
In developing electrostatic images with single-component developer, an image defect known as "trailing-edge development" may arise. Such a defect is characterized by a deposition of a small amount of developer in a short region (e.g., 2-4 millimeters in length) beyond the trailing edge of a developed image area. This undesirable deposition of developer occurs after development of the electrostatic image, as the developed image exits from the development zone. At this time, the magnetic developer is still influenced by the rapidly changing magnetic field produced by the rotating magnetic core of the brush applicator, the result being that developer is drawn from within the boundary of the image area and applied to the non-image areas. While this trailing-edge development defect can be minimized by adjusting certain development parameters, e.g., development electrode bias, such an approach has the undesirable effect of altering the sensitometric properties of the development system.
SUMMARY OF THE INVENTION
In view of the foregoing discussion, an object of this invention is to minimize the aforementioned trailing edge development defect in single component, magnetic brush development systems of the type described, without reducing or otherwise altering the sensitometric response of the development system solely for this purpose.
This object is achieved by the provision of a strategically positioned magnetic shunt means which is located between the rotating core of a magnetic brush applicator and the electrostatic image-bearing surface. The effect of this shunt is to reduce or "knock-down" the magnetic field produced by the rotating brush magnets shortly after image development has occurred and to maintain such reduced field until the developed image exits from the development zone. The reduced field has the effect of reducing the tendency for the developer to become displaced from the electrostatic image after being applied thereto.
The invention and its various advantages will become more apparent to those skilled in the art from the ensuing detailed description of preferred embodiments, reference being made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of a magnetic brush applicator embodying the invention; and
FIG. 2 is a schematic sectional view of a magnetic brush sleeve structured in accordance with an alternative embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 shows a magnetic brush applicator 10 for applying a single component developer D to an electrostatic image-bearing surface of a recording element R. Magnetic brush applicator 10 comprises a stationary, non-magnetic, cylindrical sleeve 12. Concentrically arranged within the sleeve is a cylindrically shaped, multi-pole, magnetic core 14 comprising a plurality of elongated permanent magnets which alternate in polarity, north-south-north, etc., around the circumference of the core. Motor means M are provided for rotating the core at high speed, e.g. 2000 rpm, in the direction indicated by arrow 16. Developer supply means 17 are provided for supplying the outer surface of sleeve 12 with a fresh supply of electrically conductive and magnetically attractive developer particles. Being magnetically attractive, the developer is drawn to the outer surface of sleeve 12 by the internal magnetic core and, as the internal core rotates counterclockwise, the developer is advanced in a clockwise direction as indicated by arrow 18. The thickness of the developer layer 19 on sleeve 12 is controlled by the position of a skive bar 20 which is adjustable relative to the sleeve's outer surface.
As core 14 rotates, developer is advanced to a development zone 22 where it contacts the electrostatic image on recording element R. Because the developer is advanced at a rate faster than that which can pass between the nip formed between the brush and the recording element, a roll back region 24 is soon established. It is in this region where the developer first contacts and effects development of the electrostatic image. As the developed electrostatic image passes a point directly opposite the recording element (i.e., top-dead-center, TDC) and beyond, there is a tendency for the developer within the image area to be displaced therefrom by the rapidly changing magnetic field produced by the rotating magnets. This movement of the developer results in the aforementioned "trailing edge" defect in image quality. Desirably, once the toner is applied to the image, it should remain unaltered by the brush applicator as it leaves the development zone.
Now in accordance with the present invention, shunt means 30 are provided for selectively reducing the magnetic field from a position just downstream of the leading edge of the development zone through a position in which the developed image is non-affected by the alternating magnetic field produced by the rotating magnets. Magnetic shunt means 30 preferably comprises a strip of magnetically-permeable material, for example, mu-metal (a trademark for an alloy comprising approximately Ni 74, Fe 20, Cu 5.3, Cr 2, Mn 0.7%), which is positioned within the sleeve, adjacent the inner surface 12a thereof, from an angle φ, measured upstream of top-dead-center, through an angle θ measured downstream from top-dead-center. Preferably, φ is between 15 degrees and 40 degrees. It has been experimentally shown that when φ exceeds 40 degrees, the results are similar to those produced by a magnetic brush of lower magnetic pole strength, and when φ is less than 15 degrees, undesirable "banding" of the image can occur. The effect of the magnetic shunt 30 is to short circuit magnetic lines of force or flux which, but for the shunt, would penetrate the non-magnetic shell 12 and cause the undesired movement of the developer after image development has taken place. The angle φ is not critical, so long as it is sufficiently large to prevent magnetic flux from the core from altering the position of the developer after the developer image pass TDC. However, since the shunt does increase the torque requirements of the brush, θ should be no greater than that required to achieve the above-stated function. It is highly preferred that the shunt length, that is the sum of angles φ and θ, be sufficient to substantially completely span the outer peripheral portions of at least two adjacent permanent magnets of core 14. Otherwise, some of the lines of force between adjacent pole pieces may still adversely affect the developed image.
Shunts made of mu-metal and steel shim stock were found to perform well. However, any other ferromagnetic material could be used as the shunt material. The thickness of the shunt, of course, depends upon its magnetic permeability and upon the pole strength of the brush magnets. The optimum value is such that the maximum field strength in the development zone at TDC is approximately 150-250 gauss. Shunts thinner than optimum will reduce trailing edge defects but to a lesser extent. Shunts thicker than optimum can result in failure of the developer to flow properly over the brush sleeve's surface. A typical shunt thickness for mu-metal is approximately 0.025 cm.
The invention will be better understood from the following example:
EXAMPLE
A strip of magnetically-permeable mu-metal was bonded to the periphery of a stainless steel brush sleeve having a diameter of 3.2 cm. The dimensions of the mu-metal strip were 0.025 cm. in thickness, 3.2 cm. in width, and 5.0 cm. in length. The leading edge of the strip was positioned at a point on the sleeve approximately 30 degrees before top-dead-center. The trailing edge of the strip was approximately 75 degrees beyond TDC. The recording element/sleeve spacing was set to 0.025 cm. The magnetic field strength of the brush magnets was 1000 gauss. An eight pole magnetic core was rotated at 2000 rpm and the transport speed of the recording element was 25 cm. per second in the direction co-current to the direction of developer transport by the brush.
Images made using this configuration were essentially free of the trailing edge developer defect. Sensitometric tests for this configuration exhibited unexpected results in that instead of the expected increase in contrast and reduced development threshold voltage due to the lower magnetic field strength in the development zone, contrast values were comparable to those attained without the magnetic shunt.
As an alternative to using a separate magnetic shunt element, the entire brush sleeve could be made of a suitable shunt material, the wall thickness being varied to achieve a desired magnetic field external to the sleeve. In FIG. 2, for example, the brush sleeve 40 is made of a thin mu-metal material which, in the vicinity 42 at which the magnetic field outside the sleeve is to be reduced, the wall thickness is selectively increased. The increased wall thickness, of course, will shunt magnetic flux to a greater extent than the nominal wall thickness, the result being a reduction in magnetic field strength outside the sleeve opposite the thicker wall portion
While the invention has been described with particular reference to preferred embodiments, it will be apparent to those skilled in the art that various modifications and changes may be made without departing from the spirit and scope of the invention. For example, the brush applicators described above are of the stationary shell rotating core variety. Obviously, the shell may be allowed to rotate as well, providing the shunt is independently supported in the position described. Other variations, too, will be self-evident to skilled artisans. | A magnetic brush apparatus for use in electrographic copiers and the like for applying magnetic developer to electrostatic images at a development zone to effect development of such images. Such apparatus includes a non-magnetic sleeve having a rotatably driven magnetic roller therein, and magnetic shunt means for selectively reducing the magnetic field produced by the magnetic roller outside the sleeve. By reducing the magnetic field shortly after the developer first contacts the image and maintaining the reduced field until the developed image is advanced beyond the influence of the magnetic roller, a trailing edge development artifact is avoided. | 6 |
RELATED ART
[0001] 1. Field of the Invention
[0002] The present invention is directed to repositionable barriers that are adapted to span across openings of various widths and, more specifically, repositionable barriers with repositionable doors to provide selective egress through an opening.
[0003] 2. Brief Discussion of Related Art
[0004] Various types of adjustable-width pressure-fit gates are known in the art. These gates are adapted to be wedged between the boundaries of an opening to inhibit egress through the opening. Pressure gates have been utilized for applications such as maintaining a child within a particular area or maintaining a pet within a particular area. In each instance, the gates are removable when the functionality of the gate is not longer needed.
SUMMARY
[0005] The present invention is directed to barriers across an opening and, more specifically, repositionable barriers to inhibit travel through an opening.
[0006] The invention includes a pressure gate comprising: (a) a frame assembly adapted to be wedged between corresponding boundaries of an opening, the frame assembly including repositionable frame members to change a widthwise dimension of the frame assembly; (b) a repositionable door mounted to the frame assembly; and (c) a repositionable stop mounted to the frame assembly, the repositionable stop comprising a clutch mounted to a bumper, the clutch engaged by a wheel so that rotational movement of the wheel is operative to reposition the bumper coaxially with respect to the wheel, where a predetermined resistance against the bumper is operative to cause the clutch to slip when engaged by the wheel to inhibit further coaxial movement of the bumper.
[0007] The present invention also includes various aspects of a repositionable gate such as, without limitation, reconfigurable gates that are widthwise adjustable, reconfigurable gates that include a swinging door that is widthwise adjustable, reconfigurable gates that include a swinging door with a repositionable latch mechanism, reconfigurable gates that include a swinging door with hanging hinges that face opposite one another, reconfigurable gates that include a swinging door that locks to the surrounding frame assembly, reconfigurable gates that include an extendable bumper with integrated clutch assembly, and reconfigurable gates that are extendable by adding fixed dimension extensions.
[0008] The aforementioned aspects of the present invention should not be considered completely inclusive of the present invention. Reference is had to the Detailed Description for a more accurate and inclusive understanding of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an elevated perspective view of a first exemplary embodiment of the present invention;
[0010] FIG. 2 is a bottom perspective view of the first exemplary embodiment of FIG. 1 , shown in a contracted position;
[0011] FIG. 3 is a bottom perspective view of the first exemplary embodiment of FIG. 1 , shown in an extended position;
[0012] FIG. 4 is a bottom view of the first exemplary embodiment of FIG. 1 ;
[0013] FIG. 5 is an elevated perspective view of a first exemplary embodiment of the present invention, with the door open;
[0014] FIG. 6 is an elevated perspective view of a first exemplary embodiment of the present invention, with the door omitted;
[0015] FIG. 7 is a close-up perspective view of an exemplary lower hinge bracket mounted to a vertical support for use with the present invention;
[0016] FIG. 8 is a close-up perspective view of an exemplary upper hinge bracket mounted to a vertical support for use with the present invention;
[0017] FIG. 9 is a perspective view of an exemplary adjustable bumper for use with the present invention;
[0018] FIG. 10 is a partially exploded and cut-away frontal view of the exemplary adjustable bumper of FIG. 9 ;
[0019] FIG. 11 is a partially exploded and cut-away rear view of the exemplary adjustable bumper of FIG. 9 ;
[0020] FIG. 12 is a cross-sectional view of the exemplary adjustable bumper of FIG. 9 ;
[0021] FIG. 13 is a cross-sectional, exploded view of the exemplary adjustable bumper of FIG. 9 ;
[0022] FIG. 14 is a close-up, elevated perspective view of an exemplary adjustable track for a door in accordance with the present invention;
[0023] FIG. 15 is an elevated perspective and cut-away view of the exemplary adjustable member to adjust the width of a door in accordance with the present invention;
[0024] FIG. 16 is a cut-away view of an exemplary handle structure for use with the present invention;
[0025] FIG. 17 is a cut-away view of an exemplary handle structure of FIG. 16 , with the trigger in the operative position; and
[0026] FIG. 18 is a cut-away view of an exemplary handle structure of FIG. 16 , with the latch retracted.
DETAILED DESCRIPTION
[0027] The exemplary embodiments of the present invention are described and illustrated below to encompass barriers for openings and associated techniques for installing, operating, and removing the barriers from such openings. Of course, it will be apparent to those of ordinary skill in the art that the preferred embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present invention.
[0028] Referencing FIGS. 1-6 , a first exemplary pressure gate 10 includes a frame assembly 12 that supports a swinging door 14 , where the frame assembly 12 is adapted to be wedged within an opening (not shown) to selectively inhibit egress through the opening. A frame extension member 16 , which is frictionally mounted to one end of a primary frame assembly 18 , includes a vertical support 20 mounted to opposing horizontal supports 22 , 24 that are separated by a reinforcing member 26 . The vertical support 20 and horizontal supports 22 , 24 are fabricated from hollow rectangular bar stock and are welded together to vertically align the ends of the horizontal supports 22 , 24 with the vertical face 28 of the vertical support 20 . Hollow rectangular bar stock adapters (not shown) are welded to corresponding ends 32 , 34 of the horizontal supports 22 , 24 to provide a rectangular cross-section adapted to fit within openings (not shown) at the ends of the horizontal supports 40 , 42 of the primary frame assembly 18 . Opposing ends 44 , 46 of the horizontal supports 22 , 24 include plastic inserts (not shown) to facilitate a friction fit between end openings of the horizontal supports 22 , 24 and respective adjustment bumpers 54 .
[0029] In an alternate exemplary embodiment, the frame assembly 12 is amendable to be indefinitely extended by sequentially adding frame extension members 16 to one another. In such an exemplary embodiment, the end openings of corresponding horizontal supports 22 , 24 of a first frame extension member 16 are adapted to receive corresponding hollow rectangular bar stock adapters of a second frame extension member. This assembly procedure may be repeated indefinitely to accommodate openings of various widths, with the outermost frame extension member 16 receiving adjustment bumpers 54 within the pair of end openings.
[0030] The primary frame assembly 18 includes a first horizontal support 40 vertically separated from a second horizontal support 42 by a pair of vertical supports 56 , 58 . The vertical supports 56 , 58 are fabricated from hollow rectangular bar stock and are welded to the horizontal supports 40 , 42 , which are likewise fabricated from hollow rectangular bar stock. A lower hinge bracket 60 and an upper hinge bracket 62 are anchored to the innermost vertical support 58 .
[0031] Referring to FIGS. 7 and 8 , the lower hinge bracket 60 and the upper hinge bracket 62 each include two holes 64 , 66 therethrough, as well as male adapters (not shown) adapted to be wedged within corresponding openings (not shown) in the innermost vertical support 58 and an end of the first horizontal supports 40 . The holes 64 , 66 through the brackets 60 , 62 receive screws to further attach the brackets to the first horizontal support 40 and innermost vertical support 58 . Both the upper hinge bracket 62 and the lower hinge bracket 60 include a cylindrical projection 78 , 80 that is respectively circumscribed by an eye of an eyebolt 82 , 84 . The cylindrical projections 78 , 80 face away from one another so that the north facing projection 80 pierces the eye of the top eyebolt 84 , whereas the south facing projection 78 pierces the eye of the bottom eyebolt 82 . The eyebolts 82 , 84 are mounted to respective top and bottom bars 304 , 306 of the swinging door 14 (see FIG. 1 ) in order to mount the door to the primary frame assembly 18 . Unlike prior art hinges, the present hinge structure utilizes the upper hinge bracket 62 to bear the majority of the weight of the swinging door 14 , whereas the lower hinge bracket 60 is utilized moreso as a guide. As will be explained in more detail below, the eyebolts 82 , 84 provide widthwise adjustability for the swinging door 14 to precisely accommodate the internal width of the primary frame assembly 18 .
[0032] Referencing FIGS. 1-6 , the hollow rectangular bar stock comprising the second horizontal support 42 extends outward beyond the innermost vertical support 58 and receives a coaxial horizontal support 100 . The coaxial horizontal support 100 has a longitudinal cross-section that fits within the rectangular longitudinal cross-section of the second horizontal support 42 to allow a sliding action between the supports 42 , 100 . A bottom surface 102 of the horizontal support 42 includes a series of spaced apart holes 104 , where at least one of the holes receives a spring-biased dowel 106 mounted to the coaxial horizontal support 100 . The spring-biased dowel 106 when inserted within one of the holes 104 maintains the relative position of the second horizontal support 42 with respect to the coaxial horizontal support 100 , thereby maintaining the overall width of the primary frame assembly 18 . To manipulate the width of the primary frame assembly 18 , the dowel 106 is pushed inward beyond the line of travel of the support 100 , thereby allowing a sliding action to occur between the supports 42 , 100 . When the sliding action is relatively slow, the bias will force the dowel 106 outward and into the next corresponding hole 104 coming into alignment therewith to incrementally adjust the width of the primary frame assembly 18 . In contrast, when the sliding action is relatively quick, the dowel 106 may pass beyond several holes 104 before the spring bias forces the dowel into one of the holes. The process of pushing the dowel 106 inward and beyond the line of travel of the coaxial horizontal support 100 may be repeated numerous times until the appropriate width of the primary frame assembly 18 is established.
[0033] The coaxial horizontal support 100 is welded to a hollow rectangular bar stock horizontal member 110 . Two vertical members 112 , 114 are welded to the horizontal member 110 at one end, and are concurrently welded to a second horizontal member 118 and a second, opposing end. Hollow rectangular bar stock is utilized for the two vertical members 112 , 114 and the second horizontal member 118 . An open end of the second horizontal member 118 includes a latch catch insert 122 having two semicircular projections 124 that extend perpendicularly from opposing faces 128 of the second horizontal member 118 . The semicircular projections 124 are adapted to contact a spring biased, reciprocating latch 132 of the swinging door 14 so that when the latch contacts either projection, the latch slides against the arcuate contour of the projection and overcomes the bias to push the latch inward. The latch catch insert 122 also includes an opening (not shown) that is adapted to receive the reciprocating latch 132 of the swinging door 14 after the latch passes beyond one of the projections to generally maintain the orientation of the swinging door 14 with respect to the primary frame assembly 18 .
[0034] Corresponding ends of each horizontal member 110 , 118 are open and may include a plastic insert (not shown) to decrease the cross sectional areas of the openings. In this exemplary embodiment, a corresponding adjustment bumper 54 occupies each opening, however, it is also within the scope of the invention that a pair of hollow rectangular bar stock adapters of a frame extension member 16 occupy these openings. In this manner, frame extension members may be utilized to increase the widthwise dimension of the frame assembly 12 .
[0035] Referring to FIGS. 9-13 , the exemplary adjustment bumpers 54 are operative to reposition an abutment plug 160 inward and outward from a main housing 162 in order to appropriately wedge the pressure gate 10 within an opening. Each adjustment bumper includes a pair of injection molded convex outer housings 164 , 166 that house a plug guide 168 and a clutch 170 . The plug guide 168 includes two openings 172 , 174 that are adapted to be pierced by a first set of corresponding columns 176 , 178 mounted to the first outer housing 164 . Two columns (not shown) of the second outer housing 166 abut the first set of columns 176 , 178 and a plate 180 of the plug guide 168 that surrounds the openings 172 , 174 to effectively sandwich the plug guide between the columns upon assembly. The plug guide 168 includes a longitudinal channel 182 adapted to receive a bolt 184 of the abutment plug 160 . A distal end 186 of the bolt 184 is crimped to provide two pair of linear guides 188 , 190 , where each pair of linear guides are 180 degrees from one another. The linear guides 188 , 190 are received within corresponding grooves 192 of the longitudinal channel 182 and inhibit the bolt 184 from rotating.
[0036] A proximal section 194 of the bolt 184 is threaded and adapted to interface with a threaded nut 196 mounted to the clutch 170 . The threaded nut 196 also includes two linear grooves 198 adapted to allow throughput of the linear guides 188 , 190 of the bolt 184 . The clutch 170 is injection molded over the threaded nut 196 to inhibit rotation of the nut independent of the clutch. A circumferential disc 200 of the clutch 170 includes a series of U-shaped cutouts defining a plurality of biased prongs 202 with leading edges 204 interfacing with pockets 206 circumferentially distributed about a backside 208 of a wheel 210 .
[0037] The wheel 210 includes a circular opening 212 through the front face 214 enabling throughput of a majority of the abutment plug 160 . A cylindrical covering 216 is mounted to the proximal tip of the bolt 184 . The front of the covering 216 includes an injection molded elastomeric layer 218 adapted to abut a boundary of an opening, such as a doorframe. This elastomeric layer 218 circumferentially extends beyond a cylindrical covering 216 of the plug 160 . In other words, the diameter of the cylindrical covering 216 is fabricated from a more rigid polymer is less than the diameter of the elastomeric layer 218 at the front of the plug 160 . The frontal opening 212 includes a diameter that accommodates the diameter of the cylindrical covering 216 , but is not large enough to accommodate throughput of the elastomeric layer 218 . Thus, all of the abutment plug 160 but for the elastomeric layer 218 can pass through the frontal opening 212 of the wheel 210 .
[0038] The front face 214 of the wheel 210 includes a series of cylindrical cavities 222 distributed in a circular manner approximate a top arcuate surface 224 of the wheel. A series of depressions 226 are distributed about the arcuate surface 224 to facilitate gripping by a user to reposition the abutment plug 160 as will be discussed in more detail below. A circular ring 228 protrudes from the rear of the wheel 210 and includes a circular flange 230 extending in a perpendicular manner. The orientation of the rear surface of the wheel 210 , ring 228 , and flange 230 cooperate to define a circumferential channel 232 . The backside 208 of the wheel 210 includes an inner cylindrical wall 236 that extends to abut the pockets 206 . The pockets 206 are bounded by the cylindrical wall 236 , an inner circular wall 238 , and a series of pyramidal fins 240 . The fins 240 include a generally perpendicular face 242 and an acute angled face 244 . The perpendicular face 242 of the fins is oriented to contact a perpendicular face 246 of each leading edge 204 , whereas the acute angled face 244 of the fins 240 is oriented to contact an acute angled face 248 of each leading edge 204 . In this manner, counterclockwise rotation of the wheel 210 is operative to direct the perpendicular faces 246 of the leading edges 204 against a corresponding perpendicular face 242 of the fins 240 to rotate the clutch 170 in a counterclockwise direction. In contrast, clockwise rotation of the wheel 210 is operative to direct the acute angled faces 248 of the leading edges 204 against a corresponding acute angled face 244 of the fins 240 to rotate the clutch 170 in a clockwise direction.
[0039] To assembly an exemplary adjustment bumper 54 , the clutch 170 is positioned within the inner cylindrical wall 236 so that the leading edges 204 are operative to interface with the pockets 206 of the wheel 210 . The plug guide 168 is oriented so that the two openings 172 , 174 are pierced by the columns 176 , 178 of the first outer housing 164 . The wheel 210 , with the clutch 170 therein, is positioned to abut the front of the plug guide so that a semicircular plateau 250 of the first outer housing 164 is seated within the circumferential channel 232 . Thereafter, the second outer housing 166 is aligned with the first outer housing 164 so that the two columns (not shown) abut the first set of columns 176 , 178 and the plate 180 of the plug guide 168 that surrounds the openings 172 , 174 to effectively sandwich the plug guide between the columns. The alignment of the housings 164 , 166 is also operative to seat the semicircular plateau 250 of the second outer housing 166 within the circumferential channel 232 . Two screws (not shown) are installed to couple the columns to mount the housings 164 , 166 to one another. In addition, a third screw is inserted through corresponding aspects 254 , 256 of a mounting bracket to mount the housings 164 , 166 to one another. After the housings 164 , 166 are mounted to one another, the rear of the adjustment bumper 54 is open to allow the rectangular aspect 258 of the plug guide 168 to be mounted within a rectangular opening in one of horizontal supports 22 , 24 or the first or second horizontal member 110 , 118 . The abutment plug 160 is inserted after the housings 164 , 166 have been mounted to one another. The wheel 210 is rotated to rotate the clutch 170 to align the two linear grooves 198 with the grooves 192 of the longitudinal channel 182 , thereby enabling insertion of the linear guides 188 , 190 of the bolt 184 . After the bolt 184 has been inserted to a depth where the threads of the bolt interface with the threads of the nut 196 , the wheel is rotated in a counterclockwise direction to draw the bolt inward and bring the elastomeric layer 218 toward the front face 214 . Continued counterclockwise rotation will eventually draw the bolt inward to a point where the elastomeric layer 218 almost abuts the front face 214 .
[0040] In operation, adjustment bumper 54 is mounted to a rectangular opening in one of horizontal supports 22 , 24 or the first or second horizontal member 110 , 118 . To secure the frame assembly 12 within an opening, the bolt 184 is repositioned inward toward the wheel 210 to decrease the width of the frame assembly or the bolt is repositioned outward away from the wheel 210 to increase the width of the frame assembly. Clockwise rotation of the wheel 210 is operative to engage the acute angled faces of the leading
[0041] Referring to FIGS. 1-5 , the swinging door 14 includes two sections 300 , 302 that are slidably mounted to one another to increase or decrease the width of the door. The first section 300 includes a top bar 304 mounted to a bottom bar 306 via a plurality of vertical dividers 308 . The top bar 304 and bottom bar 306 are fabricated from hollow rectangular bar stock and are welded to the plurality of circular solid bars comprising the vertical dividers 308 . Corresponding ends 310 , 312 of the top bar 304 and the bottom bar 306 are each enclosed with a welded metal plate that includes a hole tapped to provided a threaded interface (not shown). Each threaded interface receives one of the threaded ends of the eyebolts 82 , 84 to mount the swinging door 14 to the frame assembly 12 . As discussed previously, the eyebolts 82 , 84 can be screwed inward toward or screwed outward from the each threaded interface to adjust the width of the swinging door 14 .
[0042] The second section 302 also includes a top bar 320 mounted to a bottom bar 322 via a plurality of vertical dividers 324 . A vertical bar 326 is also welded to the ends of the top bar 320 and bottom bar 322 , where the vertical bar 326 sits squarely on top of the bottom bar 322 . The welded junction between the vertical bar 326 and the top bar 320 only occurs between two corners such that the vertical bar 326 is outset from the top bar 320 to leave a rectangular opening (not shown) within the top of the vertical bar. This vertical opening receives a rectangular insert from a handle assembly 330 that, along with two screws, mounts the handle assembly to the second section 302 . Corresponding ends of the top bar 320 and the bottom bar 322 each include inserts having widthwise adjusters 332 . Two slides each having a C-shaped channel are respectively mounted to the backside of the top bar 320 and the bottom bar 322 . The C-shaped channels of each slide are adapted to receive an I-shaped track 338 , 340 respectively mounted to the top bar 304 and bottom bar 306 of the first section 300 .
[0043] Referencing FIGS. 1-3 , 14 , and 15 , the widthwise adjusters 332 are operative to fix the relative orientation of the sections 300 , 302 with respect to one another, but may be actuated to change the overall width of the swinging door 14 . Each I-shaped track includes a series of evenly spaced teeth 350 providing gaps 352 therebetween. Each widthwise adjuster 332 includes a set pin 354 that is biased by a spring 356 into one of the gaps 352 to inhibit sliding of the sections 300 , 302 with respect to one another. When one desires to increase or decrease the width of the swinging door 14 by sliding the sections 300 , 302 with respect to one another, one actuator 358 of each adjuster 332 is depressed to overcome the bias exerted upon the set pin 354 and reposition the pin from the gap it previously occupied. While both actuators 358 are depressed, and while the each pin is not within a gap 352 , the sections may be repositioned with respect to one another by sliding the second section 302 along the I-channel until the desired width has been reached. Thereafter, the actuators 358 are no longer depressed to allow the bias of the springs 356 to force each pin 354 upward and into one of the gaps 352 between the teeth 350 . This process may be repeated at any time to amend the widthwise dimension of the swinging door 14 . For example, FIG. 2 shows a relatively narrow swinging door 14 , in comparison to the relatively wide swinging door 14 of FIG. 3 .
[0044] Referring to FIGS. 16-18 , the handle assembly 330 includes two injection molded housings 360 that are operative to contain the internal mechanisms that providing for repositioning of the reciprocating latch 132 . As discussed previously, the reciprocating latch 132 interfaces with the latch catch insert 122 (see FIG. 1 ) to mount the swinging door 14 to the second horizontal member 118 of the primary frame assembly 18 . The internal mechanisms includes a safety 360 that comprises a trigger 362 , a spring 364 to bias the trigger in the safe position as shown in FIG. 16 , and a set of alignment pins 366 that ride within corresponding oblong holes 368 that extend through the trigger 362 . The trigger 362 is vertically repositionable by a user lifting up with, for example, an index finger to overcome the bias of the spring 364 and move the trigger 362 to the operative position shown in FIG. 17 . In the operative position, a lower aspect 370 of the trigger 362 no longer blocks the line of travel of a moment arm 372 that pivots about point 374 . The arrow of FIG. 18 shows depression of the moment arm 372 , for example by a thumb of a user. This depressive force is operative to overcome a bias of a spring 376 and pivot the moment arm 372 about point 374 . A cut-out 378 is provided through the side of the reciprocating latch 132 that a contact rod 380 of the moment arm 372 protrudes through. In this manner, pivoting action of the moment arm 372 resulting from depression as represented by the arrow of FIG. 18 is operative to push the contact rod 380 against the border of the cut-out 378 , thereby for moving the reciprocating latch 132 rearward (compare FIGS. 17 and 18 ). Rearward movement of the reciprocating latch 132 to the position shown in FIG. 18 is operative to no longer continue the engagement between the primary frame assembly 18 and the swinging door 14 , thereby allowing the door to swing freely.
[0045] Referring to FIGS. 1, 16 and 17 , the reciprocating latch 132 can also be moved rearward as a result of contact with one of the two semicircular projections 124 that extend perpendicularly from opposing faces of the second horizontal member 118 . When the latch 132 contacts one of the projections 124 while the swinging door 14 is coming into alignment with the primary frame assembly 18 , the latch 132 is operative to independently slide rearward with respect to the moment arm 372 . Interaction between the latch 132 and one of the projections 124 is operative to overcome a bias of a spring 382 interposing the latch and the moment arm to force the latch 132 rearward. If the trigger 362 is engaged in the operative position as shown in FIG. 17 , the interaction between the latch 132 and one of the projections 124 is operative to overcome the bias of at least one of the springs 376 , 382 to allow a combination of rearward movement of the latch and pivoting of the moment arm 372 . When no, or an insufficient force is action upon the latch 132 , the biased nature of the trigger 362 , the moment arm 372 , and the latch itself are operative to return the components in a stand-by position as shown in FIG. 16 .
[0046] It is to be understood that the pressure gate 10 described above is exemplary in nature and modifications to the gate may be made without departing from the scope of the present invention. For example, the hollow rectangular bar stock may be replaced with polymer hollow rectangular bar stock or other components of various materials that provide at least similar functionality. Moreover, this example extends to any of the components and pieces discussed above, as materials, design elements, and shapes may be reconfigured or replaced by other materials, design elements, and shapes providing at least similar functionality. It is further within the scope of the invention that the mounting techniques recited herein are exemplary in nature and may be replaced or supplemented by other mounting techniques. For instance, the exemplary welds between the metallic components may be replaced by other fastening devices and techniques for mounting metallic components together, where as different materials may also lend to different mounting techniques. For example, if the vertical supports and horizontal supports were fabricated from polymer materials, a snap fit between the polymer supports may be preferable over polymer welding.
[0047] It is also within the scope of the invention to exchange complementary components. For example, the horizontal support 42 may include a spring-biased dowel, and the coaxial horizontal support 100 may include a series of spaced apart holes. Likewise, the handle assembly may be mounted to the primary frame assembly and the latch may engage a latch catch insert mounted to the swinging door 14 . These are simply exemplary instances where the mounting structure of the complementary components can be switched or reconfigured, each of which shall fall within the scope of the present invention.
[0048] Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention contained herein is not limited to this precise embodiment and that changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein. | A pressure gate comprising: (a) a frame assembly adapted to be wedged between corresponding boundaries of an opening, the frame assembly including repositionable frame members to change a widthwise dimension of the frame assembly; (b) a repositionable door mounted to the frame assembly; and (c) a repositionable stop mounted to the frame assembly, the repositionable stop comprising a clutch mounted to a bumper, the clutch engaged by a wheel so that rotational movement of the wheel is operative to reposition the bumper coaxially with respect to the wheel, where a predetermined resistance against the bumper is operative to cause the clutch to slip when engaged by the wheel to inhibit further coaxial movement of the bumper. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit under 35 USC §119(e) of U.S. provisional patent application Ser. No. 60/996,509 to Fayçal Djeridane, filed on Nov. 20, 2007, hereby Incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the processing of biological images and, more particularly, to the processing of multiple series of biological images obtained from a patient affected by an ischemic stroke.
BACKGROUND
[0003] Stroke is one of the leading causes of morbidity and mortality in developed countries. A stroke occurs when blood vessels in the brain are compromised. It has been defined as a “sudden neurological shortage presumed to be of vascular origin” (translated from Bousser M G: Classification et orientation générales du diagnostic. In “Accidents vasculaires cérébraux”: Bogousslaysky J, Bousser M G, Mas J L, 1993, 95-103, Doin éditeurs.)
[0004] There are two main types of stroke, namely hemorrhagic stoke and ischemic stroke. Hemorrhagic stroke is relatively infrequent, and occurs when a blood vessel ruptures, flooding a portion of the brain with blood. On the other hand, ischemic, (or nonhemorrhagic) stroke is much more common and occurs when a blood vessel is blocked (e.g., due to a clot), causing cerebral nervous tissue to be deprived of oxygen, ultimately leading to necrosis if left untreated.
[0005] Ischemic stroke is typically treated by administration of a thrombolytic, namely, a drug that aims to dissolve the clot that caused obstruction of the vessel in question. This technique restores blood flow to hypoperfused areas, potentially salvaging those portions of the affected cerebral tissue that have not yet been irreversibly damaged because they have been receiving blood flow from collateral arteries anastomosing with branches of the occluded vascular tree. These portions are known as the “ischemic penumbra”, while portions of the cerebral tissue that have been irreversibly damaged due to oxygen deprivation are known as the “core ischemic zone”. Further information can be found on the Internet by visiting the Internet Stroke Center at Washington University in St. Louis (http://www.strokecenter.org/education/ais_pathogenesis/22_ischemic_penumbra.htm).
[0006] The success of thrombolysis (i.e., treatment with a thrombolytic) therefore relies on rapid administration of the drug to a patient having undergone an ischemic stroke. With cerebral tissue being depleted at a rate of several (approximately 4) million neurons per minute, clinicians find themselves operating within a narrow time window (typically considered to be only a few hours) from occurrence of a stroke if there is to be any hope of success. If a thrombolytic is administered to a patient within this time window, then it may be possible to salvage the ischemic penumbra. However, reperfusion of severely hypoperfused areas can result in hemorrhage with its associated complications. If it turns out that the patient had insignificant salvageable cerebral tissue to begin with (i.e., with dim prospects for a positive outcome from the outset), then administering the thrombolytic will unnecessarily raise the risk of harming the patient.
[0007] For these reasons, the decision to administer a thrombolytic is not automatic. Rather, it is made as a function of whether the ischemic penumbra is large enough so as to justify pharmacological treatment and its attendant risk of hemorrhage. Accurate and rapid assessment of this risk/benefit scenario, among other factors, is therefore crucial in the early minutes of treating a patient with stroke symptoms.
[0008] As part of the decision making process, clinicians must typically assess the size of the ischemic penumbra and core ischemic zone by viewing and considering numerous images obtained from radiological instruments such as magnetic resonance imaging (MRI) machines. Due to the disparity in image type and presentation, it is only the most highly experienced clinicians who are able to extract useful diagnostic information from these images towards the decision to administer a thrombolytic. However, the number of clinicians having the requisite level of experience is expected to become inadequate to meet the needs of a growing and aging population that naturally brings about an increase in ischemic stroke cases.
[0009] As a result, improved image display and processing tools are needed to facilitate the diagnostic process, allowing a broader range of clinicians to assess the costs and benefits of administering a thrombolytic to a patient affected by an ischemic stroke.
SUMMARY OF THE INVENTION
[0010] A first broad aspect of the present invention seeks to provide a computer-readable storage medium comprising computer-readable program code stored thereon which, when interpreted by a computing apparatus, causes the computing apparatus to implement an image processing tool for processing a plurality of biological images arranged in a plurality of image series wherein certain biological images across different image series have a predefined correspondence with one another. The computer-readable program code comprises computer-readable program code for causing the computing apparatus to be attentive to receipt of an indication of a selected biological image from the plurality of biological images and belonging to a first one of the image series; computer-readable program code for causing the computing apparatus to be attentive to receipt of an indication of a segmentation mask created based on the selected biological image; computer-readable program code for causing the computing apparatus to apply the segmentation mask to a second biological image from the plurality of biological images, the second biological image belonging to a second one of the image series that is different from the first one of the image series, the second biological image having a predefined correspondence with the selected biological image; and computer-readable program code for causing the computing apparatus to display the second biological image after application of the segmentation mask.
[0011] A second broad aspect of the present invention seeks to provide a method, which comprises obtaining a plurality of series of biological images including a first series and a second series, wherein certain ones of the images in the first series and certain ones of the images in the second series are corresponding; creating a respective segmentation mask for each of at least one selected image in the first series; applying each respective segmentation mask to the corresponding image in the second series; and selecting a set of the images in the second series on which to effect a volumetric computation, the selected set of images in the second series including at least one image to which a respective segmentation mask has been applied.
[0012] A third broad aspect of the present invention seeks to provide a system, which comprises means for obtaining a plurality of series of biological images including a first series and a second series, wherein certain ones of the images in the first series and certain ones of the images in the second series are corresponding; means for creating a respective segmentation mask for each of at least one selected image in the first series; means for applying each respective segmentation mask to the corresponding image in the second series; and means for selecting a set of the images in the second series on which to effect a volumetric computation, the selected set of images in the second series including at least one image to which a respective segmentation mask has been applied.
[0013] A fourth broad aspect of the present invention seeks to provide an image processing system for processing a plurality of biological images arranged in a plurality of image series wherein certain biological images across different image series have a predefined correspondence with one another. The image processing system comprises an input configured to receive an indication of a selected biological image from the plurality of biological images and belonging to a first one of the image series and receive an indication of a segmentation mask created based on the selected biological image; a processing entity configured to apply the segmentation mask to a second biological image from the plurality of biological images, the second biological image belonging to a second one of the image series that is different from the first one of the image series, the second biological image having a predefined correspondence with the selected biological image; and a display entity configured to cause display of the second biological image.
[0014] A fifth broad aspect of the present invention seeks to provide a method of processing images that are arranged in a first series of biological images and a second series of biological images, each image being associated with a respective axial slice height. The method comprises:
a) initializing a threshold slice height difference; b) attempting to identify one or more pairs of corresponding images such that (i) each pair of corresponding images includes one image from each of the first and second series and (ii) the images in each pair are associated with respective slice heights differing by no more than the threshold slice height difference; c) increasing the threshold slice height difference; d) repeating steps b) and c) until the threshold slice height difference reaches a maximum threshold slice height difference; and e) for particular images in the first and second series that have been paired further to execution of step b), displaying each particular image in the first series in graphical correspondence with the particular image in the second series to which it is paired.
[0020] These and other aspects and features of the present invention will now become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the accompanying drawings:
[0022] FIG. 1 is a block diagram of a computer that can be configured to implement an image processing method in accordance with a non-limiting embodiment of the present invention.
[0023] FIG. 2 is a flowchart illustrating steps in an image processing method in accordance with an embodiment of the present invention.
[0024] FIG. 3 shows a series of MRI images taken at different axial slice heights.
[0025] FIG. 4 is a screen shot illustrating a plurality of image series, each series having a plurality of images, where images in the same column are corresponding.
[0026] FIG. 5 is a flowchart illustrating steps in establishing correspondence between images in different series as a function of their axial slice heights.
[0027] FIGS. 6A through 6C show creation of segmentation masks from respective source images.
[0028] FIG. 7 shows steps in the transformation of an original image into a set of pixels that is ready to be rendered, in accordance with a non-limiting embodiment of the present invention.
[0029] It is to be expressly understood that the description and drawings are only for the purpose of illustration of certain embodiments of the invention and are an aid for understanding. They are not intended to be a definition of the limits of the invention.
DETAILED DESCRIPTION
[0030] Non-limiting embodiments of the present invention provide an image processing tool that implements methods of processing biological images. These methods may be performed, at least in part, by a computing apparatus such as a computer shown in FIG. 1 as 100 . The computer 100 has a processing entity 102 communicatively coupled to a first memory 104 , a second memory 106 , an input 108 and an output 110 . The processing entity 102 may include one or more processors for processing computer-executable instructions and data. It will be understood by those of ordinary skill in the art that the computer 100 may also include other components not shown in FIG. 1 . Also, it should be appreciated that the computer 100 may communicate with other apparatuses and systems (not shown) over a network (not shown). For example, such other apparatuses and systems may include a PACS (picture archiving and communications system) commonly used to store radiological and other biological images of patients in a healthcare setting.
[0031] The first memory 104 can be an electronic storage comprising a computer-readable medium storing computer-executable instructions and/or data. The first memory 104 is readily accessible by the processing entity 102 at runtime and may include a volatile memory (e.g., random access memory—RAM) for storing computer-executable instructions and/or data. The second memory 106 can be an electronic storage comprising a computer-readable medium storing computer-executable instructions and/or data. The second memory 106 may include a non-volatile memory (e.g., flash EEPROM) for storing computer-executable instructions and data in a persistent manner. For example, the second memory 106 may store electronic files 116 . The files 116 may encode images such as radiological images (specifically, MRI images) and/or other types of biological images of a patient. In some embodiments, the biological images can be two-dimensional and each may comprise a plurality of picture elements (pixels) having respective values. In other embodiments, the biological images can be three-dimensional and each may comprise a plurality of volume elements (voxels) having respective values.
[0032] The input 108 may be used to receive commands and other input from a user 114 such as a clinician who is attempting to determine whether to administer a thrombolytic to a patient in real time, or a student who is participating in a simulation exercise. The input 108 may include one or more input devices, examples of which include but are not limited to a keyboard, a mouse, a microphone, a touch screen and an image acquisition apparatus (e.g., a scanner, a camera, an x-ray machine, MRI machine, etc.). The one or more input devices may also include a computer-readable medium such as a removable memory 112 as well as any requisite device for accessing such medium. The one or more input devices may be locally or remotely connected to the processing entity 102 , either physically or by way of a communication connection.
[0033] The output 110 may include one or more output devices, which may include a display device, such as a screen/monitor. Other examples of output devices include, without limitation, a printer, a speaker, as well as a computer-writable medium and any requisite device for writing to such medium. The one or more output devices may be locally or remotely connected to processing entity 102 , either physically or by way of a communication connection.
[0034] When the processing entity 102 executes computer-executable instructions stored by one or more of the memories 104 , 106 , 112 , the computer 100 can be caused to carry out one or more of the methods described herein. As can be appreciated, the methods described herein may also be carried out using a hardware device having circuits for performing one or more of the calculations or functions described herein. Other configurations for a computing apparatus are also within the scope of the present invention.
[0035] Certain non-limiting embodiments of the present invention have application to diagnosis and treatment of ischemic stroke. In this context, certain classes of biological images are of particular significance. Biological images in a first class are obtained by diffusion-weighted magnetic resonance imaging and are hereinafter referred to as DWI images. DWI images can bring to light a variety of parameters, which include, without limitation;
B0; B500; B1000; ADC (apparent diffusion coefficient); FLAIR (fluid-attenuated inversion recovery); T1 (spin-lattice relaxation time); T2 (spin-spin relaxation time); Etc.
[0044] Biological images in a second class are obtained by perfusion-weighted magnetic resonance imaging and are hereinafter referred to as PWI images. Perfusion is the steady state delivery of blood to tissue parenchyma through the capillaries, representing the microscopic coherent motion of water and cellular material, PWI images can bring to light a variety of hemodynamic parameters, which include, without limitation:
CBV (cerebral blood volume); CBF (cerebral blood flow); MTT (mean transit time); TTP (time to peak); Etc.
[0050] A popular way to perform perfusion MRI is to inject a contrast agent and observe its passage through the brain. Thus, it will be appreciated that PWI images can be obtained by performing computations on a time series of raw images. For information on various non-limiting examples of such computations, and on perfusion MRI generally, reference can be made to the following publications, hereby incorporated by reference herein:
Gregory Sorensen, Peter Reimer: Cerebral MR Perfusion Imaging, Principles and Current Applications , Eds. Thieme, 2000; and Wu O, Ostergaard L, Weisskoff R M, Benner T, Rosen B R, Sorensen A G: Tracer arrival timing - insensitive technique for estimating flow in MR - perfusion - weighted imaging using singular value decomposition with a block - circulant deconvolution matrix, Magn Reson Med. 2003 July; 50(1):164-74.
[0053] Another hemodynamic parameter that can be brought to light using PWI images is the time to peak of the residue function (sometimes abbreviated “Tmax”), which involves deconvolution of the “tissue concentration over time” curve using an arterial input function from the contralateral middle cerebral artery.
[0054] The following references provide additional information regarding the measurement of cerebral blood flow and other parameters.
Ostergaard L, Weisskoff R M, Chesler D A, et al. High resolution measurement of cerebral blood flow using intravascular tracer bolus passages , part I: mathematical approach and statistical analysis. Magn Reson Med 1996; 36:715-725 Ostergaard L, Sorensen A G, Kwong K K, et al. High resolution measurement of cerebral blood flow using intravascular tracer bolus passages , part II: experimental comparison and preliminary results. Magn Reson Med 1996; 36:726-736
[0057] For the purposes of the description to follow, biological images (including DWI and PWI images) that evidence at least some of the above parameters are assumed to be available to the computer 100 for processing and/or display. Such availability can arise by virtue of the biological images being stored as files 116 in the memory 106 or by the PACS, etc. The set of images that evidences a particular parameter are hereinafter referred to as forming a “series” of images. Thus, there may be plural series of images available for processing and/or display by the computer 100 . One or more of the series may include DWI images, while another one or more of the series may include PWI images.
[0058] For the purposes of the description to follow, and with reference to FIG. 3 , each biological image 304 1 , 304 2 , 304 3 , 304 4 in a given series 306 is a two-dimensional axial image of a patient's brain 302 at a particular axial slice height H 1 , H 2 , H 3 , H 4 . The axial slice height of an image may be indicated in a header portion of a file that encodes the image, such as one of the files 116 . A common format for such a file is DICOM (abbreviation of “Digital Imaging and Communications in Medicine”), which includes a DICOM header that specifies the height of the axial slice at which the accompanying image was taken. It should be appreciated that in other embodiments, file formats other than DICOM may be used, including proprietary file formats that may not include a header, whereby the height of an axial slice is recorded in a different fashion. It should also be appreciated that in other applications, views other than axial (e.g., sagittal or coronal) may be of interest.
[0059] A non-limiting description of an example method that may be performed by the computer 100 when executing computer-readable instructions stored in one or more of the memories 104 , 106 , 112 is now provided with reference to the flowchart in FIG. 2 . Specifically, the method includes the steps of registration 202 , image correspondence 204 , display 206 , filtering 208 and volumetric computation 210 . It should be appreciated that not all of these steps are essential in all embodiments. In the description to follow, reference will be made to pixels for reasons of simplicity, with the understanding that reference could also have been made to voxels.
Step 202 : Registration
[0060] The step of registration 202 generally includes ensuring that all images in all of the series have the same pixel spacing, origin and orientation. This can be achieved using operations of zoom, translation and rotation. Specifically:
a) To achieve the same pixel spacing: consider the non-limiting scenario where each image is associated with a header that indicates the pixel spacing for that image in terms of units of distance. A reference pixel spacing is selected, either automatically by the computer 100 (e.g., as being the median pixel spacing among the various images of the various series) or manually by the user 114 via the input 108 . Then, for all images whose pixel spacing is not equal to the reference pixel spacing, an interpolation function (such as, without limitation, the nearest neighbor interpolation function) is applied to those images in order to achieve the reference pixel spacing. Of course, other forms of interpolation and, generally, other methodologies are possible in order to achieve a common pixel spacing without departing from the scope of the present invention. b) To achieve the same origin: the origin of each image can be a point (e.g., a pixel) that refers to the same physiological structure in each image of each series. The origin can be selected manually by the user 114 via the input 108 , although an automatic mechanism can be used without departing from the scope of the present invention. Once the origin has been identified for each image, an absolute origin is selected (namely, the coordinates where the origin will appear for all images once processing is complete), and then it suffices to effect a translation of each image whose origin does not correspond to the absolute origin until such correspondence is achieved. c) To achieve the same orientation: with all images having the common origin (see b) above), a second reference point (e.g., a pixel) that refers to a second common physiological structure in each image of each series is identified. The second reference point can be selected manually by the user 114 via the input 108 , although an automatic mechanism can be used without departing from the scope of the present invention. Once the second reference point has been identified for each image, an absolute reference point is selected (namely, the coordinates where the second reference point will appear for all images once processing is complete), and then it suffices to effect a rotation of each image whose second reference point does not correspond to the absolute reference point until such correspondence is achieved.
Step 204 : Image Correspondence
[0064] Consider the non-limiting scenario where the images in a particular series are all axial slices taken at different axial slice heights. Consider also that there are multiple series. Then, the step of image correspondence 204 generally includes attempting to identify a group of images, one from each series, that have comparable axial slice heights. The information regarding the axial slice height of a particular image may be available in a header that accompanies the image. An ideal example of two axial slice heights that are comparable includes two axial slice heights that are identical. Thus, an image in series A with a particular axial slice height H, and an image in series B also with an axial slice height H can be said to exhibit image correspondence. However, it is more common to find that images in different series have axial slice heights that are different for each series. In fact, the number of images in each series may itself be different.
[0065] With reference to FIG. 5 , one non-limiting methodology for executing the step of image correspondence 204 between pairs of images in two series A and B is as follows (assuming that the various images have already been registered in accordance with the registration step 202 ). At sub-step 502 , select all pairs of images in series A and series B having exactly the same axial slice height (i.e., for which the difference in axial slice height is zero). At sub-step 504 , the tolerable axial slice height difference ΔH is increased (e.g., to one unit of height) and step 502 is repeated. That is to say, from the remaining images in series A and series B, select all pairs of images having an axial slice height that differs only by one unit of height. The tolerable axial slice height difference is increased again at step 504 and the process continues until a maximum tolerable height difference ΔH max is reached (step 506 ). The maximum tolerable height difference ΔH max represents a height difference beyond which two images are simply too distant in the Z-direction (i.e., axially) that they cannot be said to correspond to one another.
[0066] At sub-step 508 , for any image in series A that was not paired with an image in series B by virtue of step 502 , create a blank corresponding B-series image, and for any image in series B that was not paired with an image in series A by virtue of step 502 , create a blank corresponding A-series image. At sub-step 510 , the images in each series (now potentially including blank images) are ordered in accordance with their axial slice height (or in the case of a blank image, the axial slice height of the corresponding image in the other series). At sub-step 512 , an index (e.g., “j”) is given to corresponding images in each series. In this way, images denoted A(j) will correspond to images denoted B(j), for any value of j, recalling that the “image” in question may be blank.
Step 206 : Display
[0067] The step of display 206 generally includes providing a scrolling functionality to view several images in a single series, and/or corresponding images in two or more series simultaneously (such as images A(j) and B(j) for one or more values of j). It is recalled that corresponding images are those images that were found to have a comparable axial slice height.
[0068] In a general sense, as shown in FIG. 4 , a table 402 of M rows and N columns can be presented. It should be appreciated that M (i.e., the number of rows, that is, series) and N (i.e., the number of columns, that is, images per series) are variable, and can be varied by the user 114 by way of the input 108 . In this case, M=2 and, specifically, images from series A and B are displayed. Also in this case, N=4 and, specifically, images having indexes 1, 2, 7 and 8 are displayed.
[0069] Also, scrolling functionality can be provided by, for example, a horizontal navigation bar 404 , allowing the user 114 to manipulate which N indexes to display (the N indexes can be contiguous or individually selected). Similarly, scrolling functionality can be provided by, for example, a vertical navigation bar 406 , allowing the user 114 to indicate from which M series the images for display will be taken from.
[0070] It should be appreciated that a key consideration is how to display the images in the table 402 . Clearly, one option is to display the raw image content of the files 116 , which may provide grayscale pixel values having an 8- or 16-bit dynamic range. However, it may be more beneficial to a clinician (who needs to view many images over a short period of time) to utilize a color scheme. When a color scheme is utilized, the value of a pixel is mapped to a color. Several standard color schemes can be provided, including rainbow, gray, etc., as well as customized color schemes. The same or different color schemes can be used for different image series. A touch-up panel 408 A, 408 B can be provided for each series whereby the color scheme can be selected for the particular image series. The touch-up panel 408 A, 408 B can also be used to manually apply other image processing features such as contrast and brightness.
[0071] It is also within the scope of the present invention to automatically optimize the color scheme selected for a particular series. Specifically, the color scheme has a range of colors that are mapped to pixel values. Without optimization, certain highly perceptible colors may not actually be rendered on the display device because they are mapped to pixel values that do not appear in the images in the particular series. In order to optimize the selected color scheme, an autolevel graphical element (such as a button) 410 A, 410 B allows the user 114 to select an “autolevel” function. The autolevel function adjusts the contrast and brightness for the images of the particular series, by constraining the values of the pixels in the images of the particular series to within m−s and m+s, where m is the average pixel value and s is the standard deviation of pixel values either (i) within each individual image or (ii) among all images of the series. Under the latter option, if the particular series is A, then a “red” pixel in image A(p) will correspond a value that is the same as the pixel value of a “red” pixel in image A(q) for any p and any q (provided of course that there are “red” pixels in images A(p) and A(q)).
[0072] It should be appreciated that activation of the touch-up panel 408 A, 408 B and/or the autolevel button 410 A, 410 B causes the computer 100 to vary the appearance of the images in the series as rendered on the display device without altering the original files 116 . This can be achieved as follows. With reference to FIG. 7 , an image of interest (e.g., a DICOM image) has pixel values that are stored in one of the files 116 in memory, say file 702 . These pixel values are processed as per the registration step 202 , thereby to yield a new set of pixel values that are stored in a second file 704 in memory. The contents of the second file 704 are copied into a third file 706 . If applicable, the contents of the second file 704 are also used to generate a “segmentation mask” by the filtering step 208 (see below). The segmentation mask is then applied to the contents of the second file 704 , thereby to yield a new set of pixel values which are stored in a third file 706 in memory. The contents of the third file 706 are used to calculate the optimized color scheme when the autolevel button 410 A, 410 B is activated. Then, the selected color scheme (whether optimized or not) as well as other functions (such as brightness and contrast, if applicable) are applied to the contents of the third file 706 , which yields a new set of pixel values (which are high-resolution since they contain color information) that are stored in a fourth file 708 in memory. The fourth file 708 thus contains the actual color values that are rendered by the display device.
Step 208 : Filtering
[0073] The step of filtering 208 is performed based on segmentation masks that can be created via the input 108 . A segmentation mask defines a set of pixels to be eliminated from an image by bringing the value of those pixels captured by the segmentation mask to a baseline value (such as zero). A segmentation mask can be created according to various techniques, including but not limited to:
a) using a source image, whose pixels are subjected to a validity interval [x,y], whereby pixels whose values fall outside the validity window are considered to form part of the segmentation mask; b) explicitly identifying a geometric figure, e.g., in free form or using a polygonal drawing tool, whereby pixels within the geometric figure are considered to form part of the segmentation mask; and c) based on a segmentation mask that has left isolated regions of pixels untouched, absorbing those regions into the segmentation mask.
[0077] Once created, the segmentation mask is applied to an image. Application of the segmentation mask brings the value of pixels captured by the segmentation mask to the baseline value, leaving the value of the other pixels intact. The result is the creation of a filtered image.
[0078] A segmentation mask can be applied to the image from which it was created, but also to images appearing in other series but corresponding to the image from which it was created (where correspondence is established in accordance with step 204 described above). Since corresponding images have the same pixel spacing, origin and orientation, the segmentation mask geometrically “fits” over all images corresponding to the image from which the segmentation mask was created. In some cases, the same segmentation mask can be used for images appearing at different axial slice heights, but it may be preferable to create different segmentation masks for different axial slice heights due to physiological dimensionality variations between adjacent axial slices.
[0079] Non-limiting examples of segmentation masks that can be created, along with some possible applications, are provided below:
a) With reference to FIG. 6A , a segmentation mask 604 can be created using a source image 602 obtained from B1000-type DWI images, whose pixels are subjected to a validity interval. Application of the segmentation mask 604 can serve to isolate pixels representing the skull; b) With reference to FIG. 6B , a segmentation mask 614 can be created using a source image 612 obtained from CBV-type PWI images, whose pixels are subjected to a validity interval. Application of the segmentation mask 614 can serve to isolate pixels representing the patient's large vessels; c) With reference to FIG. 6C , a segmentation mask 624 can be created using a source image 622 obtained from ADC-type DWI images, whose pixels are subjected to a validity interval. Application of the segmentation mask 624 can serve to isolate pixels representing the cerebrospinal fluid (CSF). For more information, reference can be made to Imagerie de diffusion et de perfusion par résonance magnétique de l′encéphale, G. Cosnard et al., LOUVAIN MED, 118; 129-140, 1999; d) a segmentation mask created using a source image obtained from TTP-type PWI images or MTT-type perfusion-weighted images, whose pixels are subjected to a validity interval, can serve to isolate pixels representing areas affected by ischemic stroke; and e) a segmentation mask created using a source image obtained from CBF-type PWI images, whose pixels are subjected to a validity interval, can serve to isolate pixels whose values are aberrant.
[0085] Other applications of a segmentation mask are of course within the scope of the present invention.
[0086] It should be appreciated that some of the segmentation masks described above can be applied one after the other on the same image (or series of images), resulting in application of a “compound” segmentation mask, which has the features of removing noise, skull tissue, cerebrospinal fluid and large vessels, thus providing improved visibility of key features of interest in the cerebral tissue. Thus, multiple segmentation masks derived from multiple series can be applied to the same series. Similarly, the same original segmentation mask can be applied to images in multiple series, including the series containing the image from which the segmentation mask was derived.
[0087] Thus, for example, in the context of identifying the core ischemic zone, namely the tissue that has been irreversibly damaged due to oxygen deprivation, segmentation masks can be created to remove the skull and cerebrospinal fluid. Thereafter, the B1000 or ADC series can be displayed. From there, it may be possible to identify a region representing the core ischemic zone by creating and applying one or more further segmentation masks. A first such further segmentation mask can be used to remove pixels whose values fall below a threshold. A second such further segmentation mask can be created by absorbing remaining isolated pixels. Finally, the pixels that have not been captured by the compound segmentation mask represent areas of the cerebral tissue in the core ischendc zone.
[0088] A next step is therefore to perform a volumetric computation.
Step 210 : Volumetric Computation
[0089] The step of volumetric computation 210 is performed on a plurality of images of a given series. One specific volumetric computation of interest seeks to estimate the volume of the core ischemic zone. Specifically, having identified the core ischemic zone in each axial slice by a method such as that described above, the computer 100 can estimate the total volume of the core ischemic zone. This is basically a computation of the area of the identified region times inter-slice axial distance, but interpolated (e.g., in linear fashion) to account for variability in the area of the region of interest between neighbouring axial slices. In some embodiments, the computer 100 automatically performs this calculation for those images in the selected series (e.g., B1000 or ADC) where the region of interest appears. In other embodiments, the user 114 can select via the input 108 a specific set of images on which the volumetric computation will be performed, which can possibly reduce artifacts at the extreme axial slices. The output is thus a volume in an appropriate unit (e.g., CC).
[0090] Another volumetric computation can be effected for the ischemic penumbra in a similar fashion. In this case, the images under consideration can be PWI images that can allow isolation of a poorly irrigated area of the brain that is nevertheless salvageable/viable. Suitable image series are the TTP or MTT or Tmax series, for example, which can be filtered using a compound segmentation mask to arrive at a region on each image in the chosen series which represents the ischemic penumbra. The computer 100 can then effect a computation of the surface area of the region times inter-slice axial distance, but interpolated (e.g., in linear fashion) to account for variability in the area of the region of interest between axial slices. In some embodiments, the computer 100 automatically performs this calculation for those images in the selected series (e.g., TTP or MTT or Tmax) where the region of interest appears, whereas in other embodiments, the user 114 can select via the input 108 the images on which the volumetric computation will be performed, which can possibly reduce artifacts at the extreme axial slices. The output is thus a volume in an appropriate unit (e.g., CC).
[0091] It follows that the user 114 can have access to two important volumetric computations, namely that of the core ischemic zone and that of the ischemic penumbra. Then, based on the absolute and/or relative volumes of each, as well as other factors, the user 114 can be in a position to perform a more informed cost/benefit analysis regarding the option of administering a thrombolytic. This can be useful in both real-life and simulated environments. Further information on the clinical value of this approach can be found in Optimal Definition for PWI/DWI Mismatch in Acute Ischemic Stroke Patients , W Kakuda et al., Journal of Cerebral Blood Flow & Metabolism (2008), 1-5.
[0092] Of course, it should be appreciated that other ways of effecting a volumetric computation are within the scope of the present invention, and it should also be appreciated that computations can be performed to estimate the volume of other regions of interest of the imaged physiological structure.
[0093] In the above non-limiting embodiments of the present invention, particular emphasis has been placed on diagnosis and treatment of ischemic stroke, but it should be appreciated that embodiments of the present invention are applicable to other areas of neuromedicine (such as diagnosis and/or treatment of epilepsy, tumors, Alzheimer's, etc.) as well as potentially other areas of medicine in general. In each of these contexts, the biological images of particular significance may be different, but the principles set forth herein are clearly applicable thereto.
[0094] Those skilled in the art will also appreciate that inputs received from the user 114 can be recorded (and restored) by the computer 100 so as to serve for traceability and training purposes. More specifically, the computer 100 can record the values of the pixels that were displayed (based on user selections of contrast, brightness, color scheme, etc.), the validity intervals [x,y] used in the creation segmentation masks, the various parameters of other segmentation masks used for isolating the core ischemic zone and the ischemic penumbra, the parameters used to calculate the perfusion images, and so on.
[0095] While specific embodiments of the present invention have been described and illustrated, it will be apparent to those skilled in the art that numerous modifications and variations can be made without departing from the scope of the invention as defined in the appended claims. | A computer-readable storage medium comprising computer-readable program code stored thereon which, when interpreted by a computing apparatus, causes the computing apparatus to implement an image processing tool for processing a plurality of biological images arranged in a plurality of image series wherein certain biological images across different image series have a predefined correspondence with one another. The computer-readable program code comprises computer-readable program code for causing the computing apparatus to: be attentive to receipt of an indication of a selected biological image from the plurality of biological images and belonging to a first one of the image series; be attentive to receipt of an indication of a segmentation mask created based on the selected biological image; apply the segmentation mask to a second biological image from the plurality of biological images, the second biological image belonging to a second one of the image series that is different from the first one of the image series, the second biological image having a predefined correspondence with the selected biological image; and display the second biological image after application of the segmentation mask. | 6 |
FIELD OF THE INVENTION
The invention relates to a rotary positive displacement machine, and more particularly to a rotary internal combustion engine.
The basic design and method of operation of the internal combustion engine is well established, particularly in piston engine form where many reciprocating parts are used. Attempts have been made to design a viable alternative to the piston engine in which the main motion is rotational, or substantially rotational, thereby avoiding or reducing vibration and power losses caused by reciprocation. Other advantages such as weight reduction and simplification of valve operation have also been sought, but ideally not at the expense of certain well established features of the piston engine such as efficient sealing of the combustion chamber, proven reliability and acceptable combinations of torque output and fuel economy. By utilising a method of combustion which involves continuously burning combustion chambers, this invention constitutes an attempt to provide an engine combining pure rotational motion with a simple design and method of operation, thereby gaining the above advantages with the minimum of disadvantages.
SUMMARY OF THE INVENTION
The invention as claimed is intended to provide a means of compression and expansion, applied more particularly to an internal combustion engine, in which all reciprocating motion or eccentric rotation is replaced by pure rotation about fixed axes. In perhaps the simplest of its many forms the rotary engine consists of four similar rotors, each mounted on parallel axles in a symmetrical `square` formation. Each rotor resembles a cogged or lobed wheel symmetrically mounted on an axle about which it can rotate in the opposite sense to each of two neighbouring rotors and, during rotation, the lobes of such neighbouring rotors mesh, or interlocate, with no contact occuring between lobes, but with each lobe closely approaching or possibly contacting the surface between lobes on the other rotor. The rotation, phasing and consistency of meshing of the rotors is controlled by gearing on the axles and these axles are supported by bearings in the housing which surrounds the rotors on all sides, or substantially so, with close proximity to the swept volume of the rotor lobes. Suitably positioned inlet and outlet ports are set into the housing together with suitably positioned ignition and/or injection devices so that, during rotation, working fluid is caused to be drawn into one of two expanding regions defined between rotors and housing, thence to be carried around to a compression region, subsequently to pass between two rotors and become ignited, thereafter to join an expanding combustion region before being conveyed to one of the outlet regions.
A crucial factor in such a design is that the compression ratio, at the point of maximum compression of the fluid, is not fixed but varies and tends to converge to a value dictated mainly by the shape of the rotors. The advantages offered by the invention are manifold. Firstly, as the motion is rotational and unfluctuating for a given engine speed, the power losses due to reciprocation are eliminated. Also the motion is perfectly balanced, and the rotational motion, coupled with a total absence of valve gear, should provide for smooth operation. Ignition may be simplified to glow plugs so situated that each compressed charge is ignited, as it passes the glow plug, either by the plug itself or by a remnant of burning gas from a previous such ignition. Also, when in operation, each combustion chamber burns continuously with frequent replenishment on one side and separation to exhaust on another. This method of combustion, analogous to a steadily burning and well tended coal fire, should provide greater efficiency as well as offering interesting possibilities concerned with exhaust emission control and the employment of lean mixtures for combustion. A wide usable range of revolution speeds is expected due to the smooth operation, the large number of power strokes per revolution and the fact that each cycle is completed in one revolution, not two as in the piston engine. Also the dimensions of such an engine prove to be very compact in relation to the swept capacity, and high power output is expected due to the many gains in efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
One way of carrying out the invention is described in detail below with reference to drawings which illustrate one specific embodiment, as well as certain possible variations, in which:
FIG. 1 is a diagrammatic sectional view of a rotary internal combustion engine in accordance with the invention in a direction parallel to the rotor axles, as seen with one side wall of the housing removed,
FIG. 2 is a sectional view of the internal combustion engine of FIG. 1 on the plane indicated by the line I--I,
FIGS. 3 to 7 are diagrammatic views of part of the internal combustion engine of FIGS. 1 and 2 showing part of the sequence of rotation of the rotors,
FIGS. 8 to 10 indicate some other possible configurations and variations of the design within the scope of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 2 of the drawings, an internal combustion engine in accordance with the invention comprises a housing consisting of an outer casing 1, an inner wall 6 and two side walls 7 and 8, in which are mounted four rotors 2,3,4 and 5 each resembling a cogged or lobed wheel, rotatable on parallel axles 2a, 3a,4a and 5a which are supported by bearings in the side walls 7 and 8 of the housing. In this preferred embodiment of the design the points at the centres of the axles in FIG. 1 form a square, and the rotors are of similar, or substantially similar, size and shape, their faces perpendicular to the axles being coplanar, and the lobes being uniformly spaced around each rotor, there being six lobes on each rotor in this example. During operation adjacent rotors are constrained to rotate in opposite senses but with the same angular speed so that lobes of adjacent rotors mesh or interlocate with no contact, or minimal contact, occuring between lobes, and in such a way that a lobe of one rotor fits symmetrically in the gap between two lobes of a neighbouring rotor at the central position of the meshing region, with close proximity or near to rolling contact in this region, the motion being maintained by suitable gearing 18 which may be external to, or in another compartment of, the housing. This same gearing may be used to allow for power output from the engine, either by using one or more of the axles directly, or by an output shaft suitably geared to these axles.
Cooling fluid compartments or channels such as 15,16,17,27 and 28 are provided within the walls of the housing to enable cooling where it may be required, and also inlet ports 9 and 10 and outlet ports 11 and 12 are situated in suitable positions in the housing adjacent to the appropriate regions, these ports being continually open with no need for any valve gear. Sparking plugs or glow plugs or other suitable ignition devices may be positioned at approximately the points 13 and 14 in either or both of the side walls, or in the case of a compression ignition version of the engine these may be replaced by injection devices. Also, in the case of a fuel injection version of the engine, both injection and ignition devices may be present with injection possibly occuring slightly before ignition.
When the rotors rotate with, in FIG. 1, rotors 3 and 5 rotating clockwise and rotors 2 and 4 rotating anticlockwise, the combustible mixture, or air in the designs where subsequent injection is involved, is drawn in through the inlet ports 9 and 10 to be carried around with the rotors before becoming compressed in either of the two regions of varying shape 21 and 22. Subsequently, at approximately positions 23 and 24, a section of the compressed gas becomes separated from the compression region and is ignited, and the expansion of burning gases, due to a sequence of such ignitions, continues in regions 25 and 26 before the gases are exhausted through the outlet ports 11 and 12.
FIGS. 3 to 7 show part of the working cycle of the internal combustion engine of FIGS. 1 and 2, concentrating on the compression, ignition and expansion sequence, with rotor 2 rotating anticlockwise and rotor 5 rotating clockwise. In the position shown in FIG. 3 the gases in regions 31 and 32 have just been effectively separated and the gases in regions 34 and 31 are about to be combined into a single region by the opening of the gap at 35 during subsequent rotation. Just before this combination occurs it would normally be expected that the pressure of the gas in chamber 34 would be near to atmospheric pressure, and the pressure and corresponding density of the gas in chamber 31 would be higher, and it will be shown that as rotation continues the pressure and density in chamber 31, at the position as shown in FIG. 3, will tend to converge to certain values, these values being predictable and calculable to a high degree of accuracy, with some variation being possible depending on existing conditions and other factors.
In FIG. 4 the two gases of chambers 34 and 31 of FIG. 3 have combined and compression of this combined volume of gas 40 has commenced. Subsequently, as shown in FIG. 5, the compressed gas of region 40 of FIG. 4 has been further compressed into a region 50 and is on the point of being effectively separated into two regions 51 and 52 by close proximity or contact between rotors, and also in FIG. 5 the regions 54 and 51 are about to be combined into a single region in a similar manner to that described in reference to FIG. 3. The gas in chamber 52 is now near the point of maximum compression and at about this point ignition takes place and the gas expands due to combustion as rotation continues. In FIG. 6 the burning gas in region 60 is on the point of combining with already burning gases in region 61, this combustion region having been created by one or more previous ignitions. The combined volume of burning gas now continues to expand, doing work on the rotors and thence providing the motive force as it does so, until the situation as shown in FIG. 7 is reached where the gas is on the point of being effectively separated into regions 70 and 71, the volume in region 71 being subsequently exhausted through port 12, and the volume in region 70 being about to combine with a newly ignited charge in a manner similar to that described in reference to FIG. 6.
The cycle continues in this fashion as described above with compression repeatedly occuring in regions 21 and 22 of FIG. 1 and combustion repeatedly or continuously taking place in regions 25 and 26, and a similar cycle occurs for all rotors.
Although the engine described above operates on the familiar principle of compression, ignition and expansion, it is the way in which the compression and expansion of the gas is achieved which differs from the method used in the piston engine, and it can be justified mathematically by methods as outlined below, in which, of course, certain assumptions about consistent or ideal conditions have to be made.
Let the density of the gas in its uncompressed or input form as held, for example, in chamber 34 of FIG. 3 be d , measured in some suitable units, and let the density of the two chambers 31 and 32 of FIG. 3 which are at about the point of separation be d n where the subscript n corresponds to the situation after the n'th ignition, for this rotor pair, since the engine was started. Let the volumes of these two chambers 31 and 32 at this instant of separation be v 2 and v 3 respectively, and let the volume in chamber 34 be v 1 .
The mass of gas in chamber 31 is v 2 ·d n and the mass of gas in chamber 34 is v 1 ·d, and when subsequently these volumes combine as the gap 35 opens during rotation of the rotors the total mass of gas will be v 1 ·d+v 2 ·d n .
Subsequently the position shown in FIG. 5 will be reached when this same mass of gas will be compressed into a volume of v 2 +v 3 at the point where separation occurs between chambers 51 and 52, and the density at this point is d n+1 .
Hence the mass of the gas in chambers 51 and 52 is given by (v 2 +v 3 )·d n+1 , and it follows that
(v.sub.2 +v.sub.3)·d.sub.n+1 =v.sub.1 ·d+v.sub.2 ·d.sub.n (1).
It can be seen that if d n and d n+1 are ever equal, as may be expected to a high level of accuracy when the engine has been running for an appreciable time and n is large, then equation (1) becomes
(v.sub.2 +v.sub.3)·d.sub.n =v.sub.1 ·d+v.sub.2 ·d.sub.n
v.sub.2 ·d.sub.n +v.sub.3 ·d.sub.n =v.sub.1 ·d+v.sub.2 ·d.sub.n
v.sub.3 ·d.sub.n =v.sub.1 ·d
d.sub.n =d·(v.sub.1 /v.sub.3)
In general let the actual value of d n be given by d n =d·(v 1 /v 3 )-e n , where e n may be regarded as an error term. Hence equation (1) becomes ##EQU1##
The quantity v 2 /(v 2 +v 3 ) has a value in the region of 0.8 for the configuration of the engine suggested in the example, and it can be seen that as n increases the error term e n tends towards zero.
If d 0 is the density in chamber 31 of FIG. 3 when the first ignition is about to occur, and e 0 is the corresponding error term, then after n such ignitions for this pair of rotors, ##EQU2##
When n is large the term ##EQU3## is negligible and d n ≈(v 1 /v 3 )·d, the accuracy being very good as n increases.
In practice v 1 /v 3 may be regarded as the compression ratio of the engine at the point shown in FIG. 3, but the volume of the compressed gas in chamber 32 will be further compressed by a small amount to give the true compression ratio of the engine. Also, when starting, the compression ratio may need to be `pumped up` before ignition will occur, but the same mathematical argument will apply.
Similarly on the expansion side, when a substantially steady state has been reached, each compressed and ignited charge of volume v 3 combines with a burning and partly expanded volune of gas v 2 , and this combined volume mixes and expands into a volume: v 1 +v 2 in a similar state. The expansion of rhe compressed charge to this position therefore has an expansion ratio of v 1 /v 3 , the same as the compression ratio, and it can be seen that each section of gas achieves the same expansion in combustion as in a piston engine of similar compression ratio. Equally it can be shown that the work done by the expansion of each compressed charge corresponds to the value for a piston engine cylinder of similar compression ratio and capacity, despite the fact that in this design successive charges merge during combustion. Also the work done in compression has a value which corresponds to that of a piston engine cylinder of similar capacity and compression ratio.
The above mathematics indicates the general behaviour of the engine whilst running, assuming perfect conditions, and of course in practice there will be variations caused by various factors such as temperature change, seepage between chambers and density variation at input, but nevertheless the general tendency will be for the engine to operate in a substantially steady state with a compression ratio which remains substantially constant.
It is of course possible for various modifications to be made to the above described embodiment without departing from the scope of the invention. For example, the rotary internal combustion engine so described could be made to operate on the compression ignition cycle with air being input and injection occuring at approximately the positions 13 and 14 of FIG. 1. In this case the compression ratio would need to be higher than that shown in the example, and it may be necessary to pre-compress the air before input or to so shape the lobes of the rotors so that the higher compression ratio is achieved without clashing occuring between rotor lobes, as shown in a possible configuration in FIG. 9.
Another possibility is to use fuel injection in conjunction with ignition by glow plugs or other suitable means. This would require injection occuring at some point adjacent to an induction or compression region with ignition occuring at approximately the positions 13 and 14 of FIG. 1. Also a machine consisting of at least two rotors, such as rotors 2 and 3 with a suitable housing around them, could operate as a pump or a compressor.
Whether the rotary machine of the invention is used as an engine or as a pump there are also many possible variations in the design which do not detract from the general mode of operation of the machine or from the scope of the invention. There could, for example, be a different number of rotors other than four, or the rotors could rotate in the opposite directions to the way in which they rotate in the example with inlet and outlet ports switching roles, or the number of lobes on each rotor may be varied from the six shown in the example. Also the shape of the rotors, their lobes and the housing around them may take many forms, with possible variations in the number, style and positioning of such items as the inlet and outlet ports, ignition devices, injection devices, cooling chambers and bearings. It may, for example, be thought advantageous to position the inlet and outlet ports in opposite walls of the housing, possibly with a slight overlap to allow for scavenging of the exhaust gases. Equally, there may be justification in using a plurality of ports for any input or output region, possibly using ports set into walls 1 and 6 near appropriate regions. It is also possible to design a configuration of the rotary machine of the invention in which the axles are more generally positioned relative to each other than in the symmetrical form of the example, or in which the axles are not parallel, or in which rotors of different shapes and sizes are used in the same design.
FIG. 8 shows an alternative configuration of an internal combustion engine in accordance with the invention in which six rotors are used, there being five lobes on each rotor, and in this Figure there are three inlet ports 81,82 and 83 and three outlet ports 84,85 and 86, ignition taking place at approximately the positions 87,88 and 89, and the general mode of operation being similar to the example described.
Many other features of the machine can take different forms, and much will depend upon development. Cooling may be achieved by pumping water or other suitable fluid through chambers in the housing, but alternatively air cooling may be employed, perhaps using the action of the rotors to pass air around or through the engine, using gaps in the housing and/or the rotors.
The pure rotational motion of the design will permit precision engineering, with a very narrow gap being possible between rotors and housing, particularly near the compression and expansion regions, and similarly the rotors could have a near to rolling contact at their point of nearest approach. If the rotors, gears and housing are made of similar material, expansion due to heat generation should be largely uniform, again permitting close tolerances to be held over a range of operating temperatures. As such, the use of seals may not be necessary, but if desired they may be incorporated in various positions in the housing and/or the rotors so as to assist in separation of regions. FIG. 10 illustrates one way of achieving this with seals such as 19 and 29. Such seals may be spring loaded or flexible and, if the rotor lobes are shaped to resemble sections of a torus, it may be possible to use piston ring technology.
Lubrication may be achieved in many ways, possibly using oil spread and distributed by the rotating action of the rotors and gears, or alternatively oil could be input with the fuel. Ihe presence of a film of oil or other lubricant on the rotors and walls of the housing may also assist with segregation of the gas regions, further reducing the need for seals.
When in the form of an internal combustion engine many ancillary devices may be necessary or desirable, depending on particular requirements. The design readily lends itself to supercharging or turbocharging, particularly as the flow of gases in and out of the engine is substantially steady, and naturally the input of air or combustible mixture at higher than atmospheric pressure would merely increase the effective compression ratio of the engine without departing from the basic concept of the design. As mentioned before, carburation or fuel injection may be used, possibly allowing for simplified designs in each case due to the continuous flow of gases. Injection, for example, could be occuring continuously into the compression regions 21 and 22 of FIG. 1, thereby obviating the need for timing of an intermittently operating injector. Also the ignition system may be simplified to a constantly lit glow plug with no timing being required. Other ancillary devices such as altenator, starter motor, cooling fan, battery and general electrical system would be incorporated as required.
In one of its many possible forms, a rotary engine in accordance with the invention would have many advantages over a piston engine. In the example previously described there would be 24 power strokes per revolution of the rotors, these occuring in 12 virtually simultaneous pairs, and hence there would be a firing rate similar to that of a 24 cylinder piston engine. The main motion, that of the rotors, would be purely rotational about fixed axes, and the rotation of each rotor would be at constant angular speed for a given rotational speed of the output shaft. Also inlet and exhaust gases would flow at substantially steady rates for a given speed of rotation. There would be no reciprocating parts nor any valve gear to operate, and these factors combined with those given above should provide an engine of high reliability, smooth operation and a very wide usable range of revolution speeds.
Ignition, when utilising a glow plug system, should be greatly simplified. A remnant of burning gas would remain, after each ignition, within a cavity in which the glow plug could be set, and this would ignite the following compressed charge. Such ignition by contact with a burning gas should virtually eliminate the delay period of ignition which causes complications in a piston engine. Also the nature of the motion, combustion and expansion would allow for continuously burning combustion regions, with no timing being necessary, the action being self perpetuating.
Finally such an engine would be considerably smaller and lighter than a piston engine of similar swept capacity. | A rotary positive displacement machine, and more particularly an internal combustion engine in one of its simplest of many forms, has a housing 1 with inner walls closely surrounding four similar rotors 2,3,4 and 5 arranged in a symmetrical `square` formation on axles supported by bearings in the housing. Each rotor has evenly spaced lobes and, during rotation, the lobes of neighboring rotors are caused to interlocate, with gearing on the axles maintaining the opposite sense of rotation of such rotors. Chambers are defined between rotors, lobes and housing and, during rotation, working fluid enters through inlet ports 9 and 10 to be carried around to compression regions 21 and 22 from which sections of fluid become transferred between rotors and ignited, thereafter to join expansion regions 25 and 26 before becoming exhausted through outlet ports 11 and 12. The compression ratio so achieved varies and converges to a predictable value. | 5 |
BACKGROUND OF THE INVENTION
This invention generally relates to slicing of meat products, more particularly to meat product slicing which eliminates slices formed from more than one meat muscle cut or piece. Prior to slicing, the whole meat muscle cut or piece is somewhat reshaped, particularly its longitudinal end portions, by engaging same with a spacer when the meat and spacer are within a casing which is then longitudinally tensioned.
Casings are of course well known for their usefulness in producing meat products of various types. It is also generally appreciated that casings are useful in shaping meats. Included in this regard are shaping smaller meat pieces, including ground meat, within casings in order to form products which are traditionally recognized as sausages, luncheon meats, restructured meat products, and the like. Patents such as U.S. Pat. No. 3,480,449 and U.S. Pat. No. 5,003,666 incorporate the use of discs at the longitudinal ends of casings otherwise filled with ground meat, multiple meat pieces and meat batters. Discs of this type are said to provide flattened sausage ends. In some channels of trade, such flattened ends can be considered to be aesthetically more pleasing than a dome-shaped end.
Also generally known is the use of casings in preparing so-called chunk sectioned and formed meat products. Illustrative in this regard is U.S. Pat. No. 4,534,084. In some instances, casings are used in procedures for joining together two or more larger muscle pieces or chunks. In such approaches, the casing surrounding the meat is stretched and clipped to close same around the meat, thereby compressing the meat and adhering the meat pieces together at the interfaces between them.
In approaches such as these, it is also known to cook the meat when thus stuffed into the casings, and allow the meat to cool and set. The result is the formation of a relatively solid assembled meat product which remains assembled and which generally retains the shape imparted to it as a result of the casing stretching and cooking. Such approaches also include traditional treatments which are known to those skilled in the art, such as chilling and the like. It is also heretofore known that the thus-assembled shaped meat product can be sliced as desired. Often, this slicing is carried out after the casing is removed and typically discarded. These types of approaches are often geared toward providing stacks of sliced meat products. These meat product slices may be of uniform slice thickness, with each slice having a target weight. Alternatively, slicing technology is available for forming slices of uniform weight.
In certain applications, sliced meat products which have a restructured constitution are perceived as being of lower quality and thus less desirable, when compared with slices made from whole muscle cuts or large pieces of meat. Meats which have been restructured or assembled can be perceived as less desirable when, by casual observation, it is evident that the meat piece or slice had been made from more than a single muscle piece. These types of observations are especially easily made when the meat is a beef product. Meat cuts such as those traditionally identified as roast beef vary considerably from piece to piece in terms of color, texture, grain orientation and overall appearance. Accordingly, when a slice of roast beef is cut from an assembled meat product, that slice can vary in appearance from slices made from other roast beef products. In general, this is expected and usually therefore easily accepted (if not welcomed) by the consumer. However, this divergence in appearance is often viewed negatively by the consumer when this variety in appearance occurs in the same slice. For example, such a slice could have a significant portion which is of a reddish color and another significant portion which is of a grayish color, thereby strongly indicating a line of demarcation which evidences a product which is restructured and had been assembled from more than one muscle piece.
An important reason for reshaping products such as large cuts of meat muscle is to enhance the efficiency of slicing and of slice distribution. Most naturally occurring or traditionally butchered meat cuts are not of a uniform shape. Although some such cuts can be considered to be generally longitudinal in shape, and thus often more conveniently sliced, even these types of cuts of muscle have longitudinal end portions which are not uniformly shaped or sized. Virtually every naturally occurring or traditionally butchered meat muscle piece does not have a uniform size and shape throughout its longitudinal extent. Without reshaping, certain slices (often those at the longitudinal ends) will be difficult to slice, thereby leaving low-value butt ends. Alternatively, if slicing of these portions of meat pieces is carried out, the resulting slices are often less than satisfactory, such as being significantly underweight or of too small a perimeter in order to satisfy demanding expectations and tastes of consumers. Accordingly, there is often a desire to proceed with some reshaping so as to substantially increase slicing yield for a given cut or piece of meat muscle, such as one traditionally used in preparing whole roast beef slices.
It would accordingly be desirable to achieve the slicing yield benefits and handling efficiency benefits which can be realized by proceeding with some type of reshaping procedure. At the same time, it would be desirable to achieve this important commercial result without encountering the perceived disadvantageous result of providing slices which have a structure originating from more than a single meat muscle cut or piece. It would also be advantageous if these important results could be obtained without requiring specially designed and manufactured equipment.
SUMMARY OF THE INVENTION
In accordance with the present invention, whole meat muscles are manipulated by the operation, upon a meat muscle, of a casing and one or more spacers. Often, multiple meat muscles are so manipulated, and this is accomplished without joining the meat muscles together. Each resulting reshaped muscle cut is of enhanced value in that it is more readily sliced into slices of more uniform size and weight. The spacer is substantially rigid and has generally flat faces for engaging meat muscle. When the thus organized meat muscle and spacer are subjected to longitudinal tensioning by a casing positioned thereover, the desired reshaping is carried out without joining one muscle cut to another.
It is accordingly a general object of the present invention to provide an improved process for reshaping and slicing meat muscle chunks.
Another object of the present invention is to provide an improved process for reshaping a plurality of whole muscle pieces in one assembly without assembling any of the muscle pieces together.
Another object of this invention is to provide an improved shaping and slicing process and slices produced thereby, each of which is from a single, unassembled whole muscle piece, while the slices are substantially more uniform in perimeter size than if slices were cut from the same meat muscle piece which had not been reshaped in accordance with the invention.
Another object of the present invention is to provide enhanced slicing yield without negatively impacting the perceived quality of each slice.
These and other objects, features and advantages of the present invention will be apparent from and clearly understood through a consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of this description, reference will be made to the attached drawings, wherein:
FIG. 1 is an exploded perspective view of a preferred embodiment of the present invention, shown with the casing component partially broken away;
FIG. 2 is a perspective, cut-away view of the embodiment of FIG. 1 shown after assembly and tensioning;
FIG. 3 is a longitudinal cross-sectional view of the embodiment as shown in FIG. 2;
FIG. 4 is a cross-sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is a cross-sectional view taken along the line 5--5 of FIG. 3;
FIG. 6 is longitudinal sectional view illustrating a prior art approach which is improved upon by the present invention;
FIG. 7 is a cross-sectional view taken along the line 7--7 of FIG. 6;
FIG. 8 is an exploded perspective view of an alternate embodiment, shown with the casing component cut away;
FIG. 9 is a perspective, cut-away view of the embodiment as shown in FIG. 8 in its assembled and tensioned condition; and
FIG. 10 is a longitudinal cross-sectional view of the embodiment illustrated in FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates components according to the invention during the process of their assembly according to the invention. A spacer 21 is shown in the process of being positioned into a casing 22. Already shown positioned within the casing is a whole meat muscle cut 23. A second whole meat muscle cut 24 is shown oriented for positioning within the casing. Each meat muscle cut includes a leading end 25 and a trailing end 26.
With more particular reference to each whole meat muscle cut, this term encompasses a unitary piece of meat muscle. A preferred unitary meat muscle cut is a unitary piece of meat which is of a traditionally butchered type and/or may be considered as a naturally delineated and available cut or piece. In those instances where the meat muscle cut might be less than what is traditionally considered to be a full-sized muscle piece, the term meat muscle cut can encompass severed portions of traditional cuts. In any event, the meat muscle cut 23, 24 is a unitary piece of meat muscle.
The important aspects of the present invention are more advantageously applied to meat muscle cuts which are of the bovine variety. So-called roast beef cuts are the preferred meat muscle cuts. Porcine meat sources can also be the focus of the present invention. Generally, pork and ham products are not as diverse in coloration, texture, grain orientation and overall appearance as are beef cuts. Accordingly, they are less in need of the present invention. Poultry sources are typically even less in need of practices in accordance with the present invention, although poultry muscle cuts are also susceptible to being processed according to the present invention.
It will be noted that each illustrated spacer 21 has opposing faces which are generally flat. Illustrative in this regard is spacer face 27. Most casings are circular or generally circular in cross-section, such as casing 22 illustrated in the drawings. Each spacer 21 will typically have a profile or perimeter in transverse cross-section which is likewise circular or generally circular so as to substantially conform in shape to the cross-sectional profile of the particular casing being used. Preferably, each spacer is a right cylinder. Typically, the perimeter size of each spacer 21 will be noticeably less than that of the casing 22. This smaller size is to reduce the chance that the spacer will interfere with the longitudinal tensioning and compressing described elsewhere herein, which action is best accomplished when the spacer does not interfere with diameter reduction of the casing which occurs when it is stretched.
Preferred spacers used for making products such as sliced roast beef have a diameter on the order of about 4 inches (about 18 to 19 cm). It can be important for facilitating the assembly procedure practiced according to the invention that the spacer have a substantial length. A spacer which is relatively short in the longitudinal or axial direction has a tendency to be difficult to align when it is being properly positioned within the casing. Spacers which are too thin in this regard, such as to be more in the nature of a lid or button, easily become misaligned so that their axes are not substantially coincident with the longitudinal axis of the casing. They often will fall over or become skewed, especially when encountering meat muscle cuts having a leading or trailing end which is particularly lacking in natural flatness, such as the illustrated, somewhat conical ends 25 and 26 which are illustrated in FIG. 1, for example. For spacers having a diameter on the order of about 4 inches, the axial or longitudinal length of the spacer should be at least 1.5 inches (about 4 cm), preferably at least 2 inches (about 5 cm), and more preferably at least about 2.5 inches (about 6.5 cm). A particularly preferred spacer has a diameter of 4.125 inches (about 10.5 cm) and an axial length of about 3 inches (about 7.6 cm).
Spacer 21 should be made of a material that is inert, easily cleaned and thus sanitary, relatively light in weight, rugged, and able to withstand the cooking temperatures and conditions practiced according to the invention, as well as the harsh cleaning conditions to which food-contacting equipment must be subjected. Usually polymers are more suitable than metals, primarily due to the relatively heavier weight of metals which satisfy the other criteria for the spacer. Exemplary polymers include acetyl copolymers such as CELCON®, acetyl homopolymers such as DELRYN® and polyolefins, particularly the tougher or higher density ones. Acetyl copolymers have been found to be particularly suitable.
With more particular reference to the embodiment illustrated in FIG. 1, each unitary muscle cut 23 is typically subjected to known treatment approaches in order to enhance the flexibility and reduce the elasticity of the unitary muscle cut. Typical practices in this regard include maceration, injection with brines, pickles and the like, and tumbling. An initial unitary muscle cut 23 is inserted toward one end of the casing, the leading end of the cut being oriented generally to the left as shown in FIG. 1. In this instance, one end of the casing is already clipped or tied by suitable known means at gathered end 31. Next, a spacer 21 is inserted into the casing such that its leading face is positioned for contacting the trailing end of the unitary muscle cut 23. Next, another meat muscle cut 24 is inserted into the casing such that its leading end 25 is positioned for engagement with the trailing spacer face 27. Additional spacers and meat muscle cuts can be added as desired, although no more spacers or muscle cuts need be added into the casing.
In the illustrated embodiment as shown in FIG. 2 and FIG. 3, a second spacer 21 is shown for engagement with the trailing end 26 of the unitary meat muscle cut 24. A third meat muscle cut is then positioned for engagement with the trailing face of this additional spacer. Generally, the number of muscle cuts will be determined by the needs of the meat processor and the casing stuffing and stretching equipment which is available, especially the casing lengths which are accommodated by the equipment.
Whatever the number of unitary meat muscle cuts and spacers which are incorporated, the assembly can be facilitated by the use of a commercial stuffing machine. Suitable machines in this regard include those available from AFECO, of Algona, Iowa. The stuffed casing is then stretched and tied off or clipped. It is suitable to use commercial equipment to accomplish these functions, such as equipment available from Tipper Tie, of Apex, North Carolina. With this type of equipment, the casing is stretched tightly so as to impart inwardly directed, longitudinally aligned forces, as well as generally inwardly directed radial forces, in order to thereby tension the casing and cause longitudinal compression and radial compression of the muscle cuts. Once the proper tensioning has been applied, clip 32 is secured in place (as is a clip at gathered end 31, if such had not already been secured in place). The result is the formation of reshaped unitary meat muscle cuts such as those illustrated at 23a, 24a, 28a. Such reshaped meat muscle cuts are formed by compression, especially as applied between the closed casing ends and the opposing faces of the spacer or spacers 21.
This assembly of casing, reshaped meat muscle cuts and spacer(s) is then subjected to typical processing conditions. For example, beef products are typically subjected to cooking in accordance with conditions generally known in the art. A typical assembly may be about 40 inches (about one meter) long. Such cooking of the meat when in the reshaped condition, in conjunction with typical pre-stuffing treatments as discussed herein, renders the reshaped unitary meat muscle cut more solid and more readily sliceable. After any subsequent treatment procedures which may be desired, such as chilling, spraying, and the like, the casing 22 is removed in accordance with generally known approaches. The spacers are cleaned and recycled for future use, while the reshaped unitary meat muscle cuts are transported to a slicing operation.
Slicing is carried out on generally known equipment. With the present invention, relatively unsophisticated slicing of each slice to a chosen thickness is typically all that is required. Slices of uniform thickness are as generally depicted in FIG. 4, with the casing having been previously removed. Although each slice does not necessarily have a true circular perimeter, and although slicer perimeter shapes can vary somewhat due to natural non-uniform shapes (see FIG. 4), most slices thus prepared from the reshaped muscle cuts will be of about the same perimeter size. Perimeter sizes will be somewhat smaller at the extreme ends of the assembly when the assembly does not incorporate a spacer at the far end, which is the situation illustrated in FIG. 2 and FIG. 3. It will be appreciated that each such slice will be from a single meat muscle cut, even those at the extreme longitudinal edges of each and every reshaped muscle product.
In comparison, prior art approaches such as those illustrated in FIG. 6 and FIG. 7 do not always produce slices originating from a single meat muscle cut. With this prior art approach, no spacers are included. Instead, each unitary meat muscle cut 43, 44, 45, 46 has been adhered to one or more adjoining such unitary meat muscle cuts. Due to the naturally uneven and non-flat shape of the muscle cuts, adherence interfaces are formed between the cuts during stuffing, stretching and clipping operations generally along the lines of those generally discussed herein in accordance with the invention. After the casing 42 is removed, the composite meat product as shown in FIG. 6 is ready for slicing.
When the center portion of any of the unitary meat muscle cuts 43, 44, 45, 46 is sliced, a unitary slice is formed. When the slicing is through any portion of the interfaces 47, 48, 49, the slice will consist of parts from two different muscle cuts. In the illustration of FIG. 7, the generally illustrated slice includes portions from meat muscle cut 44 and meat muscle cut 45. Most notably, the adherence interface 48 is readily apparent. The ease with which the adherence interface can be discerned is magnified by the difference in texture and coloration between muscle cut 44 and muscle cut 45 in this illustration.
In addition, with such a prior art approach, these slices originating from two or more different muscle cuts have a tendency to separate. More specifically, because the forces adhering the muscles together are relatively weak, such slices may separate along the adherence interface as they are individually removed from a stack of slices, especially when those slices have been vacuum packaged. This is another undesirable attribute of slices formed from multiple muscle cuts.
With reference to the alternate embodiment illustrated in FIG. 8, FIG. 9 and FIG. 10, a primary difference between this embodiment and the embodiment of FIG. 1 through FIG. 5 is the inclusion of end spacers 71. A step in the assembly according to this embodiment includes inserting end spacer 71 into the casing 52, as generally shown in FIG. 8. Unitary meat muscle cut 53 is positioned at the trailing or inside end face of the end spacer 71. The rest of the assembly is as previously described. A spacer 51 is positioned between cut 53 and unitary meat muscle cut 54, with its face 57 being oriented for engagement with the leading end 55 of the cut 54. Another spacer 51 is shown for engagement with the trailing end 56 of the cut 54. Another end spacer 71 is positioned into place, and the casing is stretched and clipped as previously discussed. The resulting reshaped unitary meat muscle cuts 53a, 54a, 58a each have two flattened ends, as is particularly evident from FIG. 10. This approach will result in minimizing slices which have a periphery noticeably smaller than that of the remainder of the slices, including center slices, from any given reshaped unitary meat muscle cut.
A typical meat muscle cut processed according to the invention will have a weight of between approximately 10 pounds and 20 pounds (between approximately 4.5 kg and 9 kg). A typical slice weight is between about 0.5 ounce and about 1 ounce (between about 14 grams and about 28 grams), such as about 2/3 ounce (about 19 grams). A typical slice thickness is between about 0.04 inch and about 0.05 inch (between about 1.0 mm and about 1.3 mm). With the generally uniform slice preparation in accordance with the invention, excellent portion control and weight control objectives are readily achievable.
It will be understood that the embodiments of the present invention which have been described are illustrative of some of the applications of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention. | Whole muscle slicing is accomplished in order to provide a plurality of meat slices, each of which is a single piece of meat, despite the fact that the muscle from which the slices originate had been reshaped prior to slicing in order to enhance slicing yield from each such muscle. The invention is particularly useful in forming roast beef slices which are used in preparing weight-controlled food products such as sandwiches. | 0 |
BACKGROUND OF THE INVENTION
Corning Incorporated, Corning, N.Y., has marketed glass lenses which polarize radiation in the red to near infrared portion of the radiation spectrum for a number of years under the trademark POLARCOR®. Those lenses are prepared in accordance with the method described in U.S. Pat. No. 4,479,819 (Borrelli et al.). As is explained in that patent, the method involves four fundamental steps:
(a) a glass article of a desired configuration is fashioned from a composition containing silver and at least one halide from the group of chloride, bromide, and iodide;
(b) that glass article is heated to a temperature above the strain point, but not higher than about 50° C. above the softening point of the glass, for a sufficient period of time to generate crystals therein of AgCl, AgBr, and/or AgI;
(c) that crystal-containing article is elongated under stress at a temperature above the annealing point, but below that at which the glass exhibits a viscosity of about 10 8 poises, such that the crystals are elongated to an aspect ratio of at least 5:1, and thereafter;
(d) that article is exposed to a reducing environment at a temperature above about 250° C., but no higher than about 25° C. above the annealing point of the glass, for a sufficient length of time to develop a chemically reduced surface layer on the article wherein at least a portion of the elongated silver halide particles is reduced to elemental silver.
Three different general base types of silver halide-containing glass compositions are disclosed therein: (1) glasses containing copper which exhibit photochromic behavior; (2) glasses having similar base compositions, but wherein copper is absent so that the glasses do not exhibit photochromic behavior; and (3) glasses having compositions in the alkali metal oxide borosilicate system containing high levels of B 2 O 3 which do not display photochromic behavior. Readily-reducible metal oxides, such as PbO and Bi 2 O 3 will be avoided.
In the preferred embodiment of the first two types of glasses, each had a base composition consisting essentially, expressed in terms of weight percent on the oxide basis, of 6-20% R 2 O, wherein R 2 O consists of 0-2.5% Li 2 O, 0-9% Na 2 O, 0-17% K 2 O, and 0-6% Cs 2 O, 14-23% B 2 O 3 , 5-25% Al 2 O 3 , 0-25% P 2 O 5 , 20-65% SiO 2 , 0.004-0.02% CuO, 0.15-0.3% Ag, 0.1-0.25% Cl, and 0.1-0.2% Br, the molar ratio R 2 O:B 2 O 3 ranging between about 0.55-0.85, where the composition is essentially free from divalent metal oxides other than CuO, and the weight ratio Ag:(Cl+Br) ranging about 0.65-0.95. In the second type of glass, CuO is omitted from the composition such that the glass does not demonstrate photochromism.
The third type of glass containing silver halide crystals may contain copper and consists essentially, expressed in terms of weight percent on the oxide basis, of 5-12 alkali metal oxides, 1-15% Al 2 O 3 , 27-35% B 2 O 3 , and the remainder SiO 2 , the molar ratio (R 2 O--Al 2 O 3 ):B 2 O 3 preferably being less than 0.25.
The elongated metallic silver particles can polarize light in the visible and/or near infrared regions of the radiation spectrum depending upon the size and aspect ratio of the elongated silver halide crystals. Nevertheless, inasmuch as the preferred reducing treatment penetrates the glass only to a depth of about 20 microns, a large population of photochromic silver halide crystals will be left in the glass matrix of the first type of glass described above. (The depth to which the reducing heat treatment penetrates is controlled by the time and temperature of the treatment.) The phenomenon of photochromic behavior is of no consequence when the polarizing effect takes place in the infrared regime of the radiation spectrum. Photochromism becomes a problem, however, where polarization in the visible portion of the radiation spectrum is desired.
As was discussed above, copper-free, silver halide-containing glasses which display no photochromic behavior have been prepared. Unfortunately, whereas photochromism was not displayed by the glasses, the silver was reduced to the metallic state during melting of the glass batch or during the subsequent heat treatment to generate silver halide crystals. That action is evidenced in the formation of a red colored glass. This premature reduction of the silver precludes the formation of silver halide crystals in the subsequent heat treatment. As indicated in U.S. Pat. No. 4,479,819, supra, the elongated silver halide crystals, wherein at least a portion thereof is reduced to elemental silver, imparts the polarizing capability to the glass.
The mechanism via which the inclusion of copper inhibits the reduction of Ag + ions to Ag° metal has been explained as follows. The presence of Cu +2 ions in the glass composition provides protection against the reduction of Ag + ions to Ag° by the reaction Cu +2 →Cu + . Hence, the elimination of copper from the glass removes this protection, thereby allowing the reaction Ag + →Ag° to take place.
Therefore, the primary objective of the present invention was to develop glass compositions containing silver halides which, when heat treated to generate silver halide crystals that can be elongated to impart polarizing properties to the glasses, would not exhibit photochromism when exposed to radiation in the ultraviolet/visible portions of the radiation spectrum, and wherein silver ions present in the glasses would not be reduced to metallic silver during the melting process or the heat treatment step.
SUMMARY OF THE INVENTION
Our invention is based upon our discovery of means to retain this silver in the glass in the oxidized state during melting of the glass and during the silver halide crystal growth phase of the process, while assuring that the glass will not exhibit photochromism. In broadest terms our invention contemplates a silver halide-containing base glass which is essentially free of monovalent copper to eliminate the development of photochromic behavior, and which contains a quantity of cerium, expressed in terms of CeO 2 , effective to retain the silver in the oxidized state during melting of the glass and as the glass is heat treated to generate silver halide crystals therein. (As employed here, silver halide crystals denote AgCl, AgBr, and AgI.) Because these cerium additions effectively replace the trace amount of copper that functions both in the photochromic process and as an oxidizer of silver, only very small concentrations of CeO 2 are necessary. The minimum amount of cerium required to maintain the silver in the oxidized state is dependent upon the overall oxidation state of the glass which, in turn, is impacted both by glass composition and by the conditions present during melting of the batch materials. Therefore, the minimum operable level of CeO 2 has not been determined with ultimate certainty. Nevertheless, our laboratory investigations have demonstrated that concentrations at least as low as 0.01% by weight CeO 2 are effective under certain conditions. Much greater amounts, e.g., up to 1.5% by weight CeO 2 and higher, are likewise effective, but provide no substantive advantages over lesser amounts. And because CeO 2 is a relatively expensive material, 1.5% has been deemed to constitute a practical maximum, with levels between about 0.075-0.75% by weight being preferred.
In the preferred embodiments of the invention, the base glass composition will be selected from the following three groups, expressed in terms of weight percent on the oxide basis:
(1) 6-20% R 2 O, wherein R 2 O consists of 0-2.5% Li 2 O, 0-9% Na 2 O, 0-17% K 2 O, and 0-6% Cs 2 O, 14-23% B 2 O 3 , 5-25% Al 2 O 3 , 0-25% P 2 O 5 , 20-65% SiO 2 , 0-2.5% TiO 2 , 0-5% ZrO 2 , 0.15-0.35% Ag, 0.1-0.36% Cl, and 0.1-0.2% Br, the molar ratio R 2 O:B 2 O 3 ranging between about 0.55-0.85, and the weight ratio Ag:(Cl+Br) ranging about 0.5-0.95; or
(2) 2-2.5% Li 2 O, 3-5% Na 2 O, 6-7% K 2 O, 9-10% Al 2 O 3 , 19-20.5% B 2 O 3 , 0-0.25% PbO, 0.1-0.3% Ag, 0.2-0.5% Cl, 0.05-0.15% Br, and 55-60% SiO 2 , or
(3) 3.75-4.5% Li 2 O , 0-1% Na 2 O, 5.5-7.5% K 2 O, 7-8% Al 2 O 3 , 18-22% B 2 O 3 , 0-2% TiO 2 , 0-5% ZrO 2 , 54-58% SiO 2 , 0-0.08% PbO, 0-0.2% Sb 2 O 3 , 0.2-0.33% Ag, 0.3-0.5% Cl, and 0.04-0.12% Br.
DESCRIPTION OF PREFERRED EMBODIMENTS
Table I records a number of glass compositions, expressed in terms of parts by weight on the oxide basis, illustrating the parameters of the present invention. Inasmuch as it is not known with which cation(s) the halides are combined and the levels thereof are so small, they are simply reported as the halide. In like manner because the amounts are so small, the silver concentrations are recited as silver metal. Furthermore, in view of the fact that the sum of the individual components closely approximates 100, for all practical purposes the value listed for each component may be deemed to represent weight percent. Finally, the actual batch ingredients used in preparing the glasses can comprise any materials, either oxides or other compounds, which, when melted together, will be converted into the desired oxides in the proper proportions. For example, Li 2 CO 3 , Na 2 CO 3 , and K 2 CO 3 can comprise the batch materials of Li 2 O, Na 2 O, an K 2 O, respectively. Table IA presents the glass compositions of Table I (except for the halide constituents) expressed in terms of approximate cation percent.
The batch ingredients were compounded, ballmilled together to assist in obtaining a homogeneous melt, and charged into platinum crucibles. After placing lids thereon, the crucibles were moved into an electrically heated furnace operating at 1450° C. and, with occasional stirring, retained therewithin for four hours. The melts were then poured into metal molds to form glass slabs having dimensions of 4"×7"×0.5" (˜10.2×17.8×1.3 cm), and those slabs were immediately transferred to an annealer operating at 480° C. Samples were cut from the slabs for use in various tests. The samples exhibited no red color, thereby indicating the absence of silver metal.
It will be appreciated that the above description reflects laboratory melting and forming only, and that large scale melts thereof can be carried out in commercial melting units with the resultant molten glass being shaped employing conventional glass forming techniques and equipment. It is only necessary that the batch ingredients be melted at a temperature and for a time sufficient to produce a homogeneous melt.
TABLE I__________________________________________________________________________1 2 3 4 5 6 7 8 9 10__________________________________________________________________________SiO.sub.2 56.3 55.9 56.3 55.6 57.2 58.8 58.8 58.4 58.0 58.7B.sub.2 O.sub.3 18.1 17.9 18.1 17.8 18.4 19.5 19.5 19.4 19.2 19.4Al.sub.2 O.sub.3 6.2 6.1 6.2 6.1 6.3 9.6 9.6 9.5 9.4 9.5Li.sub.2 O 1.8 1.8 1.8 1.8 1.8 2.2 2.2 2.2 2.2 2.2Na.sub.2 O 4.1 4.0 4.1 4.0 4.1 3.0 3.0 3.0 3.0 3.0K.sub.2 O 5.7 5.7 5.7 5.6 5.8 6.3 6.3 6.2 6.2 6.3TiO.sub.2 2.3 2.2 2.3 2.2 --ZrO.sub.2 5.0 4.9 5.0 4.9 5.1Ag 0.22 0.22 0.22 0.22 0.23 0.22 0.22 0.22 0.22 0.22CuO 0.006 0.006 -- -- -- 0.008 -- -- -- --CeO.sub.2 -- 0.594 -- 1.18 0.607 -- -- 0.61 1.2 0.18Cl 0.24 0.24 0.24 0.24 0.24 0.40 0.40 0.40 0.40 0.40Br 0.20 0.20 0.20 0.20 0.20 0.08 0.08 0.08 0.08 0.08__________________________________________________________________________
TABLE IA______________________________________(Cation %)1 2 3 4 5______________________________________SiO.sub.2 46.4 46.4 46.4 46.4 46.4B.sub.2 O.sub.3 25.7 25.7 25.7 25.7 25.7Al.sub.2 O.sub.3 6.0 6.0 6.0 6.0 6.0Li.sub.2 O 6.0 6.0 6.0 6.0 6.0Na.sub.2 O 6.5 6.5 6.5 6.5 6.5K.sub.2 O 6.0 6.0 6.0 6.0 6.0TiO.sub.2 1.4 1.4 1.4 1.4 --ZrO.sub.2 2.0 2.0 2.0 2.0 2.0Ag 0.10 0.10 0.10 0.10 0.10CuO 0.004 0.004 -- -- --CeO.sub.2 -- 0.172 -- 0.344 0.172______________________________________(Concl.)6 7 8 9 10______________________________________SiO.sub.2 47.0 47.0 47.0 47.0 47.0B.sub.2 O.sub.3 26.9 26.9 26.9 26.9 26.9Al.sub.2 O.sub.3 9.0 9.0 9.0 9.0 9.0Li.sub.2 O 7.0 7.0 7.0 7.0 7.0Na.sub.2 O 4.7 4.7 4.7 4.7 4.7K.sub.2 O 6.4 6.4 6.4 6.4 6.4Ag 0.10 0.10 0.10 0.10 0.10CuO 0.005 -- -- -- --CeO.sub.2 -- -- 0.17 0.34 0.05______________________________________
Example 1 is a laboratory melt of Corning Code 8112, a photochromic glass marketed by Corning Incorporated, Corning, N.Y. Example 6 is a laboratory melt of Corning Code 8124, another photochromic glass marketed by Corning Incorporated. Each of those glasses relies upon the presence of silver halide crystals to impart photochromism thereto, and each was utilized as a baseline to investigate the actions of copper and CeO 2 in developing non-photochromic polarizing glasses.
Each of the Examples in the form of a 2.0 mm thick plate sample with polished surfaces was heat treated for 30 minutes at 660° C. to test for photochromic performance. In Table II below, T o is the transmittance of the glass prior to darkening; T D15 is the transmittance of the glass after an exposure of 15 minutes to a "black light blue" ultraviolet radiation emitting lamp, and T F5 is the transmittance of the glass five minutes after removal from exposure to ultraviolet radiation. A heat treatment for 30 minutes at 660° C. is utilized in the commercial production of Corning Code 8112 glass to develop photochromism therein.
The previously heat treated samples were thereafter heated to 720° C. and held at that temperature for two hours to determine their suitability for polarizing visible radiation. The 720° C. heat treatment is currently employed in the fabrication of POLARCOR® products.
Table II records the visual appearance of the initially heat treated samples to generate silver halide crystals in the glass, along with a description of the appearance of the subsequently heat treated samples to determine their potential for polarizing visible radiation. In Table II, "Ext." denotes extremely hazy and "V.sl." denotes very slightly hazy.
TABLE II__________________________________________________________________________ 1 2 3 4 5__________________________________________________________________________Heat Treated 660° C. For 30 MinutesT.sub.o 89.1 88.1 84.3 54.2 90.5T.sub.D15 43.4 80.4 81.8 55.0 90.26T.sub.F5 75.5 81.9 82.2 54.2 90.22Appearance Slightly Yellow Amber Amber Slightly Hazy Hazy YellowHeat Treated 720° C. For 2 HoursAppearance Very Hazy Very Hazy Very Hazy Ext. Hazy V.sl.Hazy Blue-Gray Slightly Red Gray Slightly Yellow YellowHeat Treated 660° C. For 30 MinutesT.sub.o 91.2 81.8 90.4 87.6 89.2T.sub.D15 50.1 73.3 87.2 85.0 86.3T.sub.F5 83.5 74.1 87.4 85.1 86.4Appearance Clear Amber Clear Amber ClearHeat Treated 720° C. For 2 HoursAppearance V.sl.Hazy V.sl.Hazy V.sl.Hazy V.sl.Hazy V.sl.Haze Blue Red White Slightly Pink Yellow__________________________________________________________________________
As can be seen through an examination of Tables I and II, Examples 1 and 6 exhibit substantial photochromic behavior when subjected to a conventional heat treatment to develop photochromic properties. Example 2 is, in essence, Example 1 with 0.172 cation % CeO 2 added. It can be seen that this addition of CeO 2 effectively interrupts the photochromic mechanism, as is evidenced by the fact that the glass darkens only 8 percentage points. Example 3 is, in essence, Example 1 with the copper removed and, as would be expected, Example 3 is essentially non-photochromic. When heat treated at 720° C. for two hours, a conventional heat treatment to produce silver halide crystals which are stretched to impart polarizing properties to the glass, Example 3 takes on a red coloration, thereby indicating that the silver ions in the glass have been reduced to metallic silver. Example 4 has twice the concentration of CeO 2 of Example 2 with all of the copper oxide removed. Again, the glass was not photochromic and, upon heating to 720° C. for two hours, developed a gray haze, thereby indicating that copper can be completely eliminated from the composition without having the silver ions being reduced to metallic silver. Electron micrographs of Examples 1-4 heat treated for two hours at 720° C. identified the presence of rutile crystals therein. It was reasoned that their presence was the source of the observed haze in the Examples. It was speculated that the extreme haze and low value of T o exhibited by Example 4 may be due to a nucleating effect of the CeO 2 in relatively large amounts. To examine the effect of TiO 2 , Example 5 was prepared which comprises Example 2 with all of the copper and titania removed. As can be seen, Example 5 does not demonstrate photochromism and, after heat treatment at 720° C., displays a very light haze with a slightly yellow appearance, thereby indicating (1) the action of TiO 2 crystals in fostering haze in the glass, and (2) that the silver ions were not reduced to metallic silver.
Based upon that experience regarding the effect of TiO 2 , glass compositions 6-10 were prepared and tested, Example 6 being a laboratory melt of Corning Code 8124 glass which contains no intentionally included TiO 2 . Example 6 manifests photochromic behavior and, after heat treatment at 720° C., exhibits very light haze and a blue coloration, the latter coloration indicating that the silver ions were not reduced to silver metal. Example 7, constituting in essence Example 6 with the CuO removed, was substantially non-photochromic and, after the 720° C. heat treatment, displayed a red appearance, thereby denoting the reduction of silver ions to metallic silver. Examples 8-10 utilize essentially the same base glass composition with various levels of CeO 2 added. Each glass is non-photochromic and the silver ions are not reduced in Examples 8 and 9. The pink tint exhibited in Example 10 is believed to evidence some reduction of silver ions to metallic silver. Accordingly, at least 0.25% by weight CeO 2 is most preferably included to assure retention of silver in the oxidized state in this glass.
Whereas the total removal of TiO 2 from the glass composition assures a minimum level of haze in the final product, its practical inclusion to adjust refractive index is quite useful. Further experimentation has demonstrated that concentrations up to about 1% by weight can be tolerated, particularly where the content of CeO 2 is maintained below about 0.75% by weight. | This invention is directed to a glass containing elongated silver halide crystals selected from the group consisting of AgCl, AgBr, AgI, and mixtures thereof which is capable of polarizing radiation in the visible portion of the radiation spectrum and which does not exhibit photochromism when exposed to radiation in the ultraviolet/visible portions of the radiation spectrum, wherein the composition of the glass is essentially free of copper and includes an amount of CeO 2 effective to retain the silver in the glass composition in the oxidized state. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a cosmetic or pharmaceutical preparation of the kind typically used in crèmes, skin lotions, lipsticks and other cosmetic end products or in pharmacy salves. In particular, the invention relates to a preparation manufactured on a purely vegetable basis intended as a replacement or substitute for the known Vaseline (petrolatum).
Vaseline is a petroleum-based product used frequently in cosmetics and pharmacies that has been generally known for some time. It is precisely in the area of cosmetics that petroleum-based constituents are often the focus of criticism due to potentially adverse properties. In particular the grooming characteristics of petroleum derivatives are much worse than those exhibited by substances especially of vegetable origin, because the molecular size of certain components in the Vaseline exceeds the pore size of human skin.
In response to this criticism, attempts have already been made to provide a vegetable-based replacement for Vaseline. German Utility Models DE 20 2005 019 453 U1 and DE 20 2005 019 454 U1 each describe vegetable-based cosmetics consisting of vegetable oils, vegetable fats, vegetable waxes and possibly beeswax, Vitamin E and fragrances, in particular ether oils. In the two aforementioned utility model specifications, in particular the following vegetable oils or fats are used for manufacturing so-called vegan Biomelk fat: canola oil, palm oil, olive oil, castor oil, jojoba oil, palm sterin, shea butter and coconut oil.
The disadvantage to the known preparation lies in the difficulty of setting the desired viscosity given the use of natural products with a typically fluctuating composition. In addition, the typical rheological properties of the Vaseline cannot be achieved to the desired extent. In particular, the shelf life of the previously known preparation is unsatisfactory; after a certain storage period, in particular at high temperatures, specific components in the previously known preparation can become rancid.
The object of the invention is to provide a vegetable-based cosmetic or pharmaceutical preparation that imitates the properties of Vaseline as effectively as possible, in particular its rheological properties, skin protection characteristics and long shelf life.
SUMMARY OF THE INVENTION
The aforementioned object is achieved according to the invention by means of a cosmetic or pharmaceutical preparation containing
60% to 98% of a mixture of medium-chain triglycerides (MCT)
2% to 40% of a mixture of long-chain triglycerides (LCT)
The content of MCT mixture preferably ranges between 70% and 95%, and the content of LCT mixture between 5% and 30%. Other components can consist in particular of oils, fats and waxes, in particular those of vegetable origin. All percentage indications in this application relate to percentage by weight (% w/w).
The MCT and LCT used according to the invention should be obtained entirely from vegetable raw materials. By definition, the medium-chain triglyceride mixture should exhibit fatty acids with chain lengths of 8 to 10 carbon atoms (C8 to C10). By contrast, the long-chain triglyceride mixture should preferably consist of fatty acids with chain lengths of C18 to C24.
In a particularly advantageous manner, the LCT mixture should exhibit a greater than 10% content of fatty acids with a chain length of carbon atoms greater than or equal to 20, more preferably greater than 40%, and even more preferably greater than 50%.
To achieve as long a shelf life as possible for the preparation according to the invention, the fatty acids in both the MCT mixture and LCT mixture must be saturated fatty acids. In the case of unsaturated fatty acids of the kind often encountered in natural oils and fats, partial or complete hydrogenation (hardening) can take place, if needed. This eliminates the danger of the preparation according to the invention becoming rancid.
The iodine number of the used oils or fats should range between 0 and 30, preferably between 0 and 2, and most preferably between 0 and 1.
It makes sense in particular that the parent material for the long-chain triglyceride mixture consist of a canola oil with a high content of erucic acid, a simple unsaturated fatty acid with 22 carbon atoms. It is here preferred to use the so-called behenic acid, which is the hardened form of erucic acid. The behenic acid glycerides lead to very advantageous hardening properties for the preparation. The behenic acid already acts as frame generator for a very good crystalline structure at very low percentages in the preparation as a whole measuring between 1% and 2.5%, preferably between approx. 2.5% and 15%.
It is here especially preferred that the behenic acid in the preparation be present in the so-called β′-form of the crystalline structure. This crystalline structure is distinguished by very fine crystals, and a resultant very high oil binding capacity. In this way, the content of LCT mixture in the preparation can be kept low. In addition, this yields the rheological property typical for Vaseline in the preparation according to the invention of the viscosity being high in the mechanically unloaded state, while it drops under a mechanical load, i.e., in particular during exposure to shear stress, making it possible to rub the preparation on the affected parts of the skin like a crème. After application, the preparation then exhibits a sufficient resistance once again, i.e., it does not run even at body temperature, which is important with respect to a plurality of cosmetic or pharmaceutical applications.
Transesterified mixtures of vegetable fats can be used for the LCT mixture within the framework of the invention, especially when a low melting point is desired. In this case, hardened or unhardened coconut oils are used. By increasing the melting point, hydrogenation results in a strong increase in viscosity.
Even if behenic acid-based triglycerides are preferred for the LCT mixtures, other vegetable oils are basically also conceivable, in particular in completely hydrated form. These also include completely hydrogenated canola oils, completely sunflower oils or completely hydrated soybean oil. The oils in question should contain high or predominant percentages of stearic acid (C18) and/or arachinic acid (C20). While the β-form of the crystalline structure is basically not as desirable as the β′-form mentioned in the above C22 fatty acids due to the coarser crystals, it can be achieved by targeted transesterification.
It is especially preferred that the MCT mixture be manufactured with coconut oil, which has a comparatively high content of caprylic acid (C8) and caprinic acid (C10). These MCT mixtures have a very high oxidation stability, since they consist exclusively of the fractionated, saturated fatty acids.
At room temperature, the content of crystallized fats (solid-fat content SCF)) of the preparation ranges between roughly 1% and 40%, preferably between 5% and 30%.
Other components can consist of waxes (in particular vegetable waxes, but also beeswax) and other oils with active properties, including ether oils, so that the use-related properties of the preparation according to the invention can be set as desired.
The preparation according to the invention is typically anhydrous. However, it can certainly also serve as the lipid phase of an emulsion, which then forms the finished cosmetic or pharmaceutical product or is used for its manufacture. Therefore, the preparation can be both an end product and semi-finished article, i.e., raw material, for further use in the cosmetics or pharmacy branch.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will be described in greater detail below using examples of preparations in the form of a vegetable-based Vaseline:
Example 1
The preparation consists of a mixture of 88% of an MCT mixture, which serves as the carrier oil, and 6% of an LCT mixture, which at room temperature is present in the preparation in a β′-crystalline form with fine crystals and high oil-binding capacity. In addition, the preparation contains 6% beeswax, which forms a mechanically stabile, water-insoluble layer on the skin, and hence acts as a barrier, just like classical petroleum-based Vaseline.
The MCT mixture in the exemplary preparation consists of approx. 60% C8 and 40% C10 fatty acids, and the iodine number of the MCT mixture is less than 1.
In the present case, the LCT mixture contains approx. 50% behenic acid made of hardened erucic acid-rich canola oil. The LCT mixture also contains approx. 40% stearic acid (C18), and low percentages totaling approx. 10% of other fatty acids. The crystals of the behenic acid glycerides serve as the frame for fabricating a crystalline structure for the preparation according to the invention that is very pleasant from a physiological standpoint.
The solid fat content in the anhydrous exemplary preparation measures 10% at 20° C.
Example 2
The preparation consists of a mixture of 90% of an MCT mixture, which serves as the carrier oil, and 10% of an LCT mixture, which at room temperature is present in the preparation in a β′-crystalline form with fine crystals and high oil-binding capacity.
The MCT mixture in the exemplary preparation consists of approx. 60% C8 and 40% C10 fatty acids, and the iodine number is less than 1.
In the present case, the LCT mixture contains approx. 50% behenic acid made of hardened erucic acid-rich canola oil. The LCT mixture also contains approx. 40% stearic acid (C18), and low percentages totaling approx. 10% of other fatty acids. The crystals of the behenic acid glycerides serve as the frame for fabricating a crystalline structure for the preparation according to the invention that is very pleasant form a physiological standpoint.
The solid fat content in the anhydrous exemplary preparation measures 9% at 20° C. This example reflects a commercially available Vaseline from a visual and rheological standpoint.
Alternative Recipe:
In the case of a recipe not according to the invention, the preparation consists of a mixture of 99% of an MCT mixture, which serves as the carrier oil, and 1% of an LCT mixture, which at room temperature is present in the preparation as a β′-crystalline form with fine crystals and high oil-binding capacity. The MCT mixture of the exemplary preparation consists of approx. 60% C8 and 40% C10 fatty acid, and the iodine number is less than 1.
In the present case, the LCT mixture contains approx. 50% behenic acid made of hardened erucic acid-rich canola oil. The LCT mixture also contains approx. 40% steric acid (C18), and low percentages totaling approx. 10% of other fatty acids. The crystals of the behenic acid glycerides serve as the frame for fabricating a crystalline structure.
The solid fat content in the anhydrous exemplary preparation was found to be <1% at 20° C. This sample is turbid and does not solidify, since the values fell outside the scope according to the invention.
The rheological properties were checked in all three aforementioned cases using a commercially available rheometer. The storage module G′ in [Pa] was determined at 37° C. The samples were first subjected to oscillation for 5 minutes, after which the structural makeup was measured after 10 minutes (Table 1). The recipe according to the invention is characterized by rheological properties lying within the range of commercially available Vaselines. A deviation from the recipe of the preparation according to the invention results in products that are either too soft or too hard.
During storage at room temperature, the preparations described in Examples 1 and 2 were completely oxidation stable over a period of 12 months, i.e., exhibited no tendency to become rancid.
TABLE 1
Sample
Composition
G′ in [Pa] at 37° C.
Commercial sample 1
100% paraffins
670
(supermarket)
Commercial sample 2
100% paraffins
1250
(OTC drugstore)
Commercial sample 3
100% paraffins
2800
(prescription pharmacy)
Example 1
88% MCT, 6% LCT,
2200
6% beeswax
Example 2
90% MCT, 10% LCT
2000
Recipe not according to
99% MCT, 1% LCT
<10
invention
While the invention has been illustrated and described as embodied in a cosmetic or pharmaceutical preparation, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and their equivalents. | The invention proposes a cosmetic or pharmaceutical preparation containing a mixture of medium-chain, preferably saturated triglycerides with a fatty acid chain length of between C8 and C10 of between 60% and 98% and a content of saturated, long-chain, preferably saturated triglycerides with a fatty acid chain length of between C18 and C24 of between 2% and 40% as a vegetable replacement for Vaseline. | 0 |
RELATED APPLICATION
[0001] The instant application hereby claims priority to the U.S. provisional patent application Ser. No. 60/519,969 for a “Wrap Motor Housing” filed on Nov. 13, 2003, which is also incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates generally to motor housings, more particularly, to an apparatus and a method of creating the apparatus for housing a motor.
BACKGROUND OF THE INVENTION
[0003] Electric motors are manufactured in a variety of types and configurations. Typically, a motor includes a stator, a rotor, a shaft, and bearings. These assembled parts create a motor assembly around which a motor housing is used to provide structure and support. Motor housings often require a high level of precision to tightly fit and contain the enclosed motor assembly. Current methods for creating motor housings are expensive. For example, the housing could be machined to the exact specifications of the motor housing. This method, however, requires high precision machining capabilities and involves an extremely low tolerance for error in the manufacturing process.
[0004] Alternately, motor housings are often created through a two step process. The first step involves creating a cylinder slightly smaller than the motor assembly's final diameter. The second step involves, a process of fine-sizing the motor housing. Several methods of fine-sizing are known in the art. The motor assembly is then inserted into the motor housing, after the housing has been fine-sized.
[0005] FIGS. 1A-1D show one method of fine-sizing a motor assembly. It involves drawing a solid metal block through a pre-sized cylindrical tube. In FIG. 1A , a motor housing 100 is shown as a cylindrical tube having a hollow interior. The hollow interior 105 in FIG. 1A , acts to enclose and protect a motor assembly (not shown).
[0006] First, a coarse-form cylindrical metal tube is created. Next, a secondary fine-sizing operation is performed. For example, either a cylindrical or spherical metal block 110 is drawn through the motor housing 100 , to expand the housing 100 to the specified tolerances and thereby accommodate the motor assembly. FIG. 1A illustrates a cylindrical metal block 110 that is chosen with a circumference equal to or slightly greater than that of the motor assembly. Once the corresponding metal block 110 is chosen, it is drawn through the motor housing 100 along a co-axial line A-A in steps as shown in FIGS. 1A-1D . This same expansion process can be completed with a spherical metal form drawn through the motor housing.
[0007] FIG. 1B illustrates the first step in the fine-sizing process, wherein the leading edge 115 of the metal block 110 , deforms the proximal end 120 of the motor housing 100 . In some embodiments the metal block's leading edge 115 is beveled to ease the drawing process. FIG. 1C illustrates an intermediate stage of the drawing process. FIG. 1D illustrates the step wherein the metal block 110 has been completely drawn through the motor assembly 100 . At this point, the size of the motor housing 100 corresponds to the diameter of the motor assembly.
[0008] This type of fine-sizing involves additional manufacturing machinery that leads to higher production costs and increased complexity associated with the housing manufacturing process. Fine-sizing also requires extremely accurate tolerances associated with matching the stator's outer diameter to the fine-sized tube's inner circumference. Furthermore, these expansion based fine-sizing methods make it impossible to easily correct an oversize error. Once the block is drawn through the pre-sized tube or the expansion device deforms the inner circumference of the tube, the pre-sized tube's circumference can only be further expanded. Accordingly, it is difficult to correct an accidental or erroneous over-expansion.
SUMMARY OF THE INVENTION
[0009] The present invention provides an efficient alternative to the drawn metal fine-sizing process described with regard to FIGS. 1A-1D . The elements of the invention described herein provide a more efficient, less costly method of producing a motor housing.
[0010] An object of the invention relates to an efficient method of producing a motor housing by stamping or cutting a flat sheet or strip of metal. The sheet is then rolled into a semi-cylindrical hollow tube wherein the ends are almost touching. A motor assembly is inserted into the housing. Advantageously, because the housing is not a continuous cylindrical tube at this point in the process, the housing may be easily shaped to accommodate any necessary fine-sizing adjustments. This allows for a greater acceptable margin of error for the initial manufacturing process and consequently, reduces the complexity and the cost associated with manufacturing both the housing, as well as the stator core.
[0011] After any such fine-sizing adjustments are made, the housing is then joined with the motor assembly. Depending on the actual implementation, the lateral ends of the housing are fused together, and thereby act to crimp the motor assembly in place. In an alternate embodiment the lateral ends are welded to each other and the motor assembly. In another embodiment, the housing is formed from stacks of lamination which are secured in place by a slot liner and/or a motor winding. In the embodiments the motor assembly is secured in place. Furthermore, the process creates a very strong bond between the elements providing a great deal of structural support to the motor assembly. Moreover, welding the lateral ends of the housing accomplishes the fine-sizing process, to accurately fit the motor assembly and the housing.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIGS. 1A-1D illustrate a conventional process of drawn metal expansion of a motor housing.
[0013] FIG. 2 is a flow-diagram disclosing a method for producing a motor housing in accordance with an embodiment of the present invention.
[0014] FIG. 3 illustrates the elements in a motor housing formed according to an advantageous embodiment of the present invention.
[0015] FIGS. 4A-4D illustrate different stages associated with forming the motor housing according to an embodiment of the present invention.
[0016] FIGS. 5A-5B illustrate the process of inserting the motor assembly into the motor housing according to an embodiment of the present invention.
[0017] FIG. 6 illustrates the final step of securing the motor housing to the motor assembly according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0018] In the following description of the various embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration various embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.
[0019] FIG. 2 is a high level flow diagram of the various stages associated with forming a motor housing according to an advantageous embodiment of the present invention. The process of producing a motor housing according to the present invention can be broken down into six stages. The first stage 200 is obtaining sizing characteristics from the motor assembly and will be discussed in greater detail with regard to FIG. 3 . The second and third stages 205 , 210 shape a piece of metal into the motor housing. The final three stages 215 , 220 , 225 are inserting, size-adjusting if necessary, and securing a motor assembly in the housing.
[0020] First, the sizing constraints of a motor assembly are identified. As shown in FIG. 3 , the relevant measurements of the motor assembly 300 are its circumference 320 and length/height 310 . These measurements can come from design specifications or from measuring actual motor assemblies. The critical dimension for fitting the motor within the housing is the motor assembly's circumference. However, at this point in the process, it is only necessary to obtain a rough estimate of the circumference. The actual fine-sizing of the motor housing if necessary will be achieved in step 220 prior to securing the motor housing to the motor assembly.
[0021] FIGS. 4A-4D illustrate stages 205 and 210 of creating the metal strip and forming a split annulus. The annulus 400 is formed by two ends rolled toward each other to form a hollow tube and is generally shaped like a cylindrical tube with a slit 430 along a longitudinal axis. It is to be understood that the annulus may be formed by any metal shaping device that performs metal shaping, such as a steel roller in combination with at least one rubber coated roller or a plurality of steel rollers that shape the metal sheet, such an apparatus may be seen at www.roundo.com. As shown in FIG. 4D , the width of the longitudinal slit 430 is exaggerated for illustrative purposes. Both ends have a spring-like action that provides for elastic deformation of the ends while the motor assembly is inserted, after which the ends spring back into the rolled position.
[0022] Two exemplary methods of producing the annulus 400 from a metal strip may include stamping or cutting the features of the housing in a flat sheet or strip of metal. The metal used for the annulus may include any suitable metals, such as steel or aluminum. Furthermore, it is to be understood that any the features of the housing, such as went holds, bolt holes, slots and other housing features may be formed in the flat sheet of metal prior to forming the split annulus.
[0023] It is also to be understood that the process of forming the annulus is not limited to the embodiment illustrated herein. In an alternate embodiment, instead of starting with a flat sheet of metal that is pre-cut or stamped in accordance with a specified length and height, stock metal cylinders may be utilized. A stock cylindrical tube can be longitudinally slit to form an annulus.
[0024] In an alternate embodiment, long sheets of stock metal may be pre-rolled into split annuli with various standardized circumferences. The stock split annuli may be selected that correspond to the circumference of a given motor assembly and cut to match the height of the motor assembly. The stock split annuli are also fine-sized if necessary in accordance with the deformation/welding process described in greater detail below.
[0025] FIG. 4A illustrates the initial stage in the annulus 400 rolling process (step 210 in FIG. 2 ). From this initial position, the ends of the flat metal sheet are incrementally deformed, so as to gradually curl each end toward the other to form a split annulus shape in accordance with an estimated outer circumference of the motor assembly. The process of deforming the ends into the split annulus may be accomplished by any deformation technique that is known in the art associated with metal shaping. FIGS. 4B and 4C illustrate intermediate stages of the rolling process 210 , wherein the ends 410 , 420 of sheet 400 are initially curved inward. From these intermediate stages, the rolling process continues as the ends get progressively closer, as shown in FIG. 4B and FIG. 4C . The deformation process of the ends 410 , 420 continues until the inner circumference is formed in accordance with the estimated annulus. FIG. 4D illustrates the formed motor housing produced by the rolling process 210 .
[0026] The inner circumference of the formed motor housing illustrated in FIG. 4D differs from the outer circumference of the motor assembly, by a user-defined tolerance. This tolerance, may be a product of several factors, such as specific motor applications and tolerances, the type of machining implemented to shape the metal sheet into the split annulus, and/or the type of weld used in any necessary fine-sizing and securing the motor assembly to the annulus.
[0027] FIGS. 5A and 5B illustrate the stages of inserting the motor assembly into the motor housing ( 215 , 220 ) according to an exemplary embodiment of the invention. Specifically, in FIG. 5A , the motor assembly 510 is inserted into a split annulus 400 . The assembly 510 is inserted in the axial direction indicated by arrows 505 . Ends 410 and 420 of the metal sheet are free floating and may be manipulated, as shown by arrows 525 . The spring action of the annulus 400 facilitates inserting the motor assembly 510 axially into the annulus 400 . The ends of the metal sheet may be elastically deformed to increase the inner circumference of the annulus 400 as the assembly 510 is inserted. After insertion, the ends may be deformed back to their pre-insertion position. FIG. 5B illustrates the motor assembly 510 inserted into the annulus 400 before securing of the housing to the motor assembly.
[0028] As shown in FIG. 6 , the motor assembly is inserted into the motor housing and ready for the final stage of securing the housing to the motor assembly 510 . If necessary, the split annulus 400 is fine-sized with respect to the assembly 510 by pulling the edges of the annulus 400 toward each other and achieving a tight wrap. It is to be understood that the housing should be formed in accordance with tolerances that do not require additional machining. The welding process described herein may account for typical variations in the manufacturing process. Once the elements are positioned, the ends 410 , 420 may be welded together along weld-line 600 , so as to secure the lateral ends of the housing. This process might also involve welding the motor housing to the motor assembly 510 . The fine-sizing process may include adjustments associated with the edges 410 , 420 . For example, edges 410 and 420 as in FIG. 5B may be pushed outward or spaced farther apart to increase the inner circumference of the housing. Alternately, the edges 410 , 420 may be deformed inward or moved closer together to decrease the inner circumference of the annulus 400 . In another embodiment, the housing may be formed from stacks of lamination secured by a slot liner and/or a motor winding.
[0029] Moreover, the weld itself may act to eliminate extraneous space between the assembly 510 and the annulus 400 . The annulus 400 does not necessarily have to be secured to a finished motor assembly. Annulus 400 can be secured to the elements of the assembly ranging from laminations to finished stators. Furthermore, depending on the manufacturing considerations related to the motor, the process of joining the ends of the annulus 400 , may involve simply welding one end to the other, or alternately welding both edges to each other and the motor assembly.
[0030] The weld on the annulus provides several benefits with regard to the motor assembly housing. Specifically, after any necessary fine-sizing is completed and the assembly is inserted, the weld acts to complement the fine-sizing and account for any remaining variations in dimensions. This leads to a reduction in machining from the outset and simplifies the manufacturing process. It is to be understood that depending on the embodiment, only the ends of the annulus may be welded, which in turn act crimp the motor assembly in place or the weld may be applied to the ends of the annulus and the motor stator, itself. Further, it is to be understood that the weld may be applied to other aspects of the motor assembly, including but not limited to stators comprising a stack of laminations or to a wound and varnished stator.
[0031] The joining of the annulus ends accomplished by the welding process creates a tension which holds the motor assembly, i.e., a crimping action that clamps around the stator's outer contour. Also, if the weld fuses the motor assembly to the motor housing, it creates a very strong structural support and bond between the housing and the stator. Advantageously, the stator as part of the motor assembly does not need to be welded before insertion, because once inserted the housing provides a sufficient support to the assembly. Furthermore, it is to be understood that exemplary welding methods may include Metal Inactive/Active Gas (MIG/MAG) welding or Manual Metal Arc (MMA welding), but are not limited to such welding methods.
[0032] It should be understood that the above description is only representative of illustrative embodiments. For the convenience of the reader, the above descriptions have focused on a representative sample of possible embodiments, a sample that teaches the principles of the invention. The description has not attempted to exhaustively enumerate all possible variations. That alternate embodiments may not have been presented for a specific portion of the invention or that further undescribed alternate embodiments may be available for a portion is not to be considered a disclaimer of those alternate embodiments. It will be appreciated that many of those undescribed embodiments incorporate the same principles of the invention and others are equivalent. Thus, it is to be understood that the embodiments and variations shown and described herein are merely illustrative of the principles of this invention and that various modifications may be implemented without departing from the scope and spirit of the invention. | The invention is directed to an efficient cost-effective method for creating a housing. One application of the method creates a motor housing to secure and protect a motor assembly. A flat metal sheet is shaped, so that deformable ends of the sheet are incrementally rolled to form a split annulus approximating the outer circumference of a motor assembly. Once the split annulus is formed, the ends are elastically deformed to facilitate inserting the motor into a hollow portion of the split annulus. After the motor is inserted, the ends may be joined by welding one to the other. This type of housing secures the motor assembly through a crimping force applied by the housing. Alternately, the ends may be welded together and to the motor assembly itself, thereby forming a strong support structure between the housing and the motor assembly. | 7 |
BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates, generally, to anti-theft devices. More particularly, it relates to a device that locks an extended hydraulic cylinder so that it cannot move.
2. Description of the Prior Art
Heavy machinery such as such as loaders, backhoes, skid steer loaders, crawlers, graders, articulated loaders, trenchers, dozers, and the like are typically parked on the job site throughout the course of a construction project because the effort to transport the equipment to a secure site is expensive and time-consuming. The machinery is susceptible to theft and vandalism.
Equipment theft from construction sites is a significant problem. The machinery is expensive to replace if stolen.
Devices that lock steering wheels offer little protection because such devices are easily cut off with a hacksaw or other suitable cutting tool. Other locking devices can be burned or pried off.
What is needed, then, is a locking device that is highly resistant to sawing, burning, or prying.
Buckets, blades and other attachments of heavy machinery commonly include hydraulic cylinder and piston rod assemblies. Hydraulic pressure is harnessed to retract and extend a piston rod from a hydraulic cylinder.
A steel sleeve is commonly interposed between the connection point, or bearing, at the distal end of the piston rod and the cylinder. The steel sleeve prevents retraction of the piston rod in the event of loss of hydraulic pressure, thereby preventing unintended movement of the attachment.
A steel sleeve can also be used as a locking device by placing it over the exposed piston rod. A padlock is typically employed to lock the sleeve. This prevents the sleeve from being removed and thus secures the piston rod in an extended condition.
With the rod in an extended position the attachments are secured in either a lowered or raised position, thereby hindering unauthorized movement of the heavy machinery.
Prior art hydraulic locking devices include U.S. Pat. No. 4,373,851 to Confoey that discloses a split cylindrical sleeve that encloses around the piston rod and includes extended tabs that are locked together using a padlock to prevent removal. The Confoey configuration is susceptible to having the padlock cut off using bolt cutters or broken off using extreme force.
An improved locking device that is easy to install and remove, which is durable, and which protects against theft and vandalism is needed.
However, in view of the prior art considered as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified needs could be fulfilled.
SUMMARY OF INVENTION
The long-standing but heretofore unfulfilled need for a locking device for heavy machinery that can be used at unsecured construction sites or storage areas, which can be installed and removed easily, and which is durable, is now provided in the form of a new, useful and non-obvious device.
The novel structure includes a substantially rigid, hollow sleeve made of two generally symmetrical, elongate parts that are hingedly connected to one another.
Each sleeve part is channel-shaped in transverse cross-section and has a proximal end, a distal end, a top wall, a side wall, and a bottom wall. The bottom wall of each sleeve part has a breadth less than the breadth of the top wall. Accordingly, when a first sleeve part is disposed in confronting relation to a second sleeve part, the top walls of said first and second sleeve parts abut one another and the bottom walls are spaced apart from one another.
The post of an elongate hinge member is positioned in the elongate space between said bottom walls and substantially occupies said space.
The elongate hinge is of conventional construction but is discontinuous mid-length of the hollow sleeve. Thus a first and a second part of the hinge are in axial alignment with one another but are longitudinally spaced apart from one another. The space between the first and second hinge parts is provided to accommodate a second or auxiliary sleeve-locking means that backs up a primary sleeve-locking means.
Each part of the hinge includes a first plurality of equidistantly and longitudinally spaced apart cylindrical inboard parts that slidingly, rotatingly, and collectively receive a hinge post. A first flat plate outboard part formed integrally with said inboard parts is fixedly secured to a bottom wall of the first sleeve part in overlying relation thereto.
Each part of the hinge includes a second plurality of equidistantly and longitudinally spaced apart cylindrical inboard parts that are interleaved with and in axial alignment with the first plurality of cylindrical inboard parts and which also collectively receive said hinge post. A second flat plate outboard part formed integrally with said second plurality of cylindrical inboard parts is fixedly secured to a bottom wall of the second sleeve part in overlying relation thereto.
The second part of the hinge has the same construction.
The first and second sleeve parts are thus hingedly connected to one another along their respective bottom walls. When the hinge is fully closed, the respective edges of the top walls of the first and second sleeve parts abut one another and the assembly is adapted to form an enclosure about an extended hydraulic piston rod.
A half flange is formed at the proximal end of each sleeve part so that when the hinge is fully closed, a full flange is formed at said proximal end. The flange abuts the distal end of a hydraulic cylinder.
A first reinforcing band is fixedly secured to the distal end of the first sleeve part. The distal edge of said first reinforcing band is flush with the distal end of said first sleeve part.
A second reinforcing band is fixedly secured to the distal end of the second sleeve part. The distal edge of said second reinforcing band is flush with the distal end of said second sleeve part.
The first and second reinforcing bands perform the function of dissipating stress loads concentrated at the respective distal ends of said first and second sleeve parts.
A first centrally apertured lock lug is secured to or formed integrally with the first sleeve part, mid-length thereof, in upstanding relation relative to said top wall of said first sleeve part. Said first lock lug is positioned on the inboard edge of said first sleeve part top wall.
A second centrally apertured lock lug is secured to or formed integrally with the second sleeve part, mid-length thereof, in upstanding relation relative to said top wall of said second sleeve part. Said second lock lug is positioned on the inboard edge of said second sleeve part top wall, in confronting relation to said first lock lug. The respective apertures formed in said first and second lock lugs are therefore in alignment with one another.
A first semicircular wall of uniform height is mounted to said first top wall, mid-length thereof and in upstanding relation thereto, in half-encircling relation to said first lock lug.
A second semicircular wall of non-uniform height is mounted to said second top wall, mid-length thereof and in upstanding relation thereto, in half-encircling relation to said second lock lug. A semicircular cut-away is formed in an outboard end of said second semicircular wall. The cut-away is formed in the bight region of said second semicircular wall and provides a clearance space.
The first lock lug integral with the first sleeve part and the second lock lug integral with the second sleeve part are secured to one another by a commercially available shackleless locking means with a hidden pin assembly or other suitable locking means.
A second locking means is formed in the novel apparatus on the opposite, bottom side thereof. A first transversely disposed, centrally apertured lock lug is secured to or formed integrally with the bottom wall of the first sleeve part, mid-length thereof. A plane that longitudinally bisects the apparatus into the first sleeve part and the second sleeve part bisects the first bottom wall lock lug.
Similarly, a second transversely disposed, centrally apertured lock lug is secured to or formed integrally with the bottom wall of the second sleeve part, mid-length thereof. Said plane also bisects said second bottom wall lock lug.
A first transversely extending slot is formed in the second sleeve part to accommodate the first bottom lock lug when the hollow sleeve is swung open about its hinge, and a second transversely extending slot is formed in the first sleeve part to accommodate the second bottom lock lug when said hollow sleeve is swung open about said hinge.
A shackleless locking means with a hidden pin assembly or other suitable locking means is employed to join the first and second bottom lock lugs together by extending the pin of a shackleless locking means through the confronting central apertures formed in said first and second bottom lock lugs. The bottom lock may also be secured by extending the shackles of a conventional lock having shackles through said confronting apertures.
In this way, the hollow sleeve is locked with two opposed locking means, both of which must be defeated before the hollow sleeve may be swung open about said elongate hinge.
An important object of the present invention is to provide an improved locking device for use with heavy machinery that prevents the movement of a hydraulic piston rod and thus prevents the theft of the machinery.
Another object is to provide a means for attaching the locking device in a proper, functional location without undue effort so that the locking device may be easily installed and removed as needed.
Another object is to provide a locking device suitable for several different heavy machines without modification.
Another object is to provide a durable locking device that and can withstand multiple unauthorized removal attempts.
These and other important objects, advantages, and features of the invention will become clear as this description proceeds.
It is to be understood that both the foregoing general description and the following detailed description are explanatory and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute part of the specification, illustrate embodiments of the present invention and together with the general description, serve to explain principles of the present invention.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of the novel locking device in its fully closed and locked configuration position;
FIG. 2 is a top plan view thereof;
FIG. 3 is top view thereof when in an unlocked and open configuration;
FIG. 4 is a detailed side elevational view thereof;
FIG. 5 is a side elevational view of the novel locking apparatus when in its fully closed and locked configuration;
FIG. 6 is a rear elevational view thereof when in its fully closed and locked configuration;
FIG. 7 is a sectional view taken along line 7 — 7 in FIG. 6 ;
FIG. 8 is a view like FIG. 7 but depicting the novel locking apparatus in an open configuration;
FIG. 9 is a side elevational view depicting the novel locking apparatus when positioned in operative relation to a backhoe equipped tractor; and
FIG. 10 is front view of the novel locking apparatus when positioned in operative relation to a bulldozer.
DETAILED DESCRIPTION
Referring now to FIGS. 1 and 2 , it will there be seen that the reference numeral 10 denotes the novel locking device as a whole. Device 10 will be known commercially as the SleevLock™ theft-deterrent apparatus or locking device.
Locking device 10 includes first sleeve part 12 and second sleeve part 14 . Each of said sleeve parts is channel shaped so that when said parts are positioned in confronting relation to one another, they collectively form a hollow sleeve. Although both sleeve parts are depicted as having a generally square “U” shape in transverse cross-section so that they collectively form an elongate square sleeve when disposed in confronting relation to one another, each of said sleeve parts could also have a semi-circular shape in transverse cross-section so that they collectively form a cylinder when so disposed. Nor is the invention limited to hollow sleeves of square or cylindrical cross-section; a machine designer of ordinary skill may select numerous other operable shapes and all such other shapes are within the scope of this invention.
As best understood in connection with FIGS. 3 and 6 , longitudinally extending hinge members 16 a and 16 b hingedly interconnect first sleeve part 12 and second sleeve part 14 to one another. Said hinge members are in axial alignment with one another but are discontinuous relative to one another as best depicted in FIG. 6 .
Hinges 16 a and 16 b have a common, conventional construction including a first and a second plurality of equidistantly and longitudinally spaced apart, axially aligned, interleaved cylindrical inboard parts that slidingly, rotatingly, and collectively receive a common hinge post in a well-known way.
More particularly, hinge 16 a includes a first flat outboard plate 17 a formed integrally with said first plurality of cylindrical inboard parts. Flat plate 17 a is fixedly secured to an interior surface of bottom wall 12 b of first sleeve 12 part in overlying relation thereto as perhaps best depicted in FIGS. 7 and 8 .
Hinge 16 a further includes a second flat outboard plate 17 b formed integrally with said second plurality of cylindrical inboard parts. Flat plate 17 b is fixedly secured to an interior surface of bottom wall 14 b of second sleeve part 14 in overlying relation thereto also as depicted in FIGS. 7 and 8 .
Hinge 16 b has the same construction as aforesaid.
The longitudinally extending space occupied at least in part by hinge members 16 a and 16 b is created because top wall 12 a of sleeve part 12 and top wall 14 a of sleeve part 14 have a greater transverse extent than bottom wall 12 b of sleeve part 12 and bottom wall 14 b of sleeve part 14 , as perhaps best understood in connection with FIG. 7 . When novel locking device 10 is in its fully closed configuration, the confronting edges of top walls 12 a and 14 a abut one another and the confronting edges of bottom walls 12 b , 14 b are spaced apart from one another by a space sufficient to receive said elongate hinge members 16 a and 16 b.
Half flange 18 is formed at the proximal end of sleeve part 12 and half flange 20 is formed at the proximal end of sleeve part 14 so that when the hinge is fully closed, a full flange 22 is formed at said proximal end as depicted in FIG. 1 . Flange 22 abuts the distal end of a hydraulic cylinder when the novel locking device is in use.
First reinforcing band 24 is fixedly secured to the distal end of first sleeve part 12 . The distal edge of said first reinforcing band is flush with the distal end of said first sleeve part.
Second reinforcing band 26 is fixedly secured to the distal end of second sleeve part 14 . The distal edge of said second reinforcing band is flush with the distal end of said second sleeve part.
First and second reinforcing bands 24 and 26 perform the function of dissipating stress loads concentrated at the respective distal ends of said first and second sleeve parts, i.e., the interface between locking means 10 and the load-bearing region where the hydraulic cylinder bears against the part or parts controlled thereby.
First centrally apertured lock lug 28 is secured to or formed integrally with first sleeve part 12 , mid-length thereof, in upstanding relation relative to top wall 12 a on the inboard edge of said top wall 12 a.
Second centrally apertured lock lug 30 is secured to or formed integrally with second sleeve part 14 , mid-length thereof, in upstanding relation relative to top wall 14 a on the inboard edge of said top wall 14 a , in confronting relation to first lock lug 28 when locking device 10 is in its fully closed configuration. The respective central apertures formed in said first and second lock lugs, which are depicted but unnumbered to avoid cluttering the drawings, are in cooperative alignment with one another when said locking device is in said fully closed configuration.
First semicircular wall 32 of uniform height is mounted to top wall 12 a , mid-length thereof and in upstanding relation thereto, in half-encircling relation to first lock lug 28 .
Second semicircular wall 34 of non-uniform height is mounted to second top wall 14 a , mid-length thereof and in upstanding relation thereto, in half-encircling relation to second lock lug. 30 A semicircular cut-away 36 is formed in the bight region of said second semicircular wall and provides a clearance space so that a key, not shown, may access keyhole 38 ( FIG. 4 ) to enable an authorized user to lock and unlock shackleless locking member 40 (also depicted in FIG. 4 ).
It should be understood that shackleless locking member 40 includes a hidden pin that extends through the central apertures formed in first and second lock lugs 28 , 30 when said lock lugs are in confronting relation to one another, i.e., when locking device 10 is in its fully closed configuration.
A plurality of resilient pads, collectively denoted 42 , are positioned within each sleeve part 12 , 14 , at opposite ends thereof to protect an extended hydraulic piston rod from damage and to provide a secure fit of locking device 10 around said piston rod when the locking device is in its fully closed and locked configuration.
A second locking means is formed in novel locking device 10 on the opposite, bottom side thereof.
Said second locking means includes a first centrally apertured lock lug 44 secured to or formed integrally with bottom wall 12 b of first sleeve part 12 , mid-length thereof and a second centrally apertured lock lug 46 secured to or formed integrally with bottom wall 14 b of second sleeve part 14 , mid-length thereof.
As perhaps best understood in FIG. 4 , first and second lock lugs 44 and 46 are disposed in parallel, confronting relation to one another when locking device 10 is in its fully closed configuration. Both of said lock lugs are disposed transversely to a longitudinal axis of locking device 10 .
First transversely extending slot 44 a formed in second sleeve part 14 to accommodate first bottom lock lug 44 when hollow sleeve 10 is swung open about its hinge. Second transversely extending slot 46 a is formed in first sleeve part 12 to accommodate second bottom lock lug 46 when said hollow sleeve is swung open about said hinge.
Shackleless locking means 40 a having keyhole 38 a and a hidden pin ( FIG. 5 ) is employed to join first and second bottom lock lugs 44 , 46 together by extending the pin through the confronting central apertures formed in said first and second bottom lock lugs. The bottom lock may also be secured by extending the shackles of a conventional lock having shackles through said confronting apertures.
FIG. 9 depicts locking device 10 installed on tractor 50 having backhoe attachment 52 that includes a pair of booms 54 , 56 and a bucket 58 pivotally connected to one another. Boom 56 is under the control of hydraulic piston and cylinder assembly 60 . Piston rod 62 of first boom 56 is shown in an extended position and device 10 is depicted in a closed and locked position encircling said piston rod 62 . Flange 22 is disposed in abutting relation to hydraulic cylinder 60 and has a diameter greater than said hydraulic cylinder 60 where the opposing end of locking device 10 abuts boom 54 . Thus, any hydraulic force generated by an attempt to retract piston rod 62 into cylinder 60 when locking device 10 is installed is distributed to the outer cylinder wall thereby decreasing the potential for damage to the mechanical capabilities of attachment 52 during a theft or vandalism attempt.
With locking device 10 in place, boom 54 and bucket 58 cannot be raised from the ground and tractor 10 cannot be moved.
A second locking device may be installed on hydraulic piston and cylinder assembly 70 if desired for additional security protection. However, placing locking device 10 solely on second piston rod 72 would not provide the desired security protection to prevent bucket 58 from being raised.
FIG. 10 partially depicts bulldozer 80 having blade attachment 82 . Blade 82 is pivotally attached to bulldozer 80 and is under the control of hydraulic piston and cylinder assembly 84 . Piston rod 86 of cylinder 84 is in an extended position and device 10 is depicted in its fully closed and locked position encircling rod 86 . Annular flange 22 is disposed in abutting relation to cylinder 84 and has a diameter greater than cylinder 84 where the opposing end of locking device 10 abuts blade 82 . Similar to backhoe attachment 52 depicted in FIG. 9 , any hydraulic force generated by an attempt to retract piston rod 86 into cylinder 84 is distributed to the outer cylinder wall thus decreasing the potential for damage to the mechanical capabilities of blade 82 during a theft or vandalism attempt.
Accordingly, when locking device 10 is in its functional configuration, blade 82 cannot be raised from the ground and bulldozer 80 cannot be moved.
The locking device is easily installed and is easily removed by authorized personnel. The locking device is durable and withstands multiple unauthorized removal attempts. It is suitable for use with any heavy machine having a hydraulic cylinder. Moreover, locking device can be manufactured to any desired length or diameter to fit hydraulic cylinders of differing sizes.
It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.
Now that the invention has been described. | A device for locking a piston rod of a hydraulic piston and cylinder assembly in an extended condition so that mobile construction equipment or other heavy machinery cannot be driven from a job site. The locking device is placed in ensleeving relation to an extended piston rod between a proximal hydraulic cylinder and a distal bearing point to prevent retraction of the piston rod. The device has a hollow sleeve configuration formed of confronting first and second sleeve parts that are hingedly connected to one another. A first lock secures the first and second sleeve members to one another along a longitudinally extending parting line. A second lock is opposed to the first lock and prevents hinged movement of the first and second sleeve parts relative to one another even if the first lock is defeated. The device is adaptable to a variety of hydraulic piston and cylinder assemblies. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of Ser. No. 09/737,667 filed Dec. 15, 2000, now abandoned.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
“Imperial” grade natural jadeite gems are extremely rare and highly valued with prices exceeding those of equivalently sized gem diamonds. The term “jade” as used in the gem trade refers to two minerals: jadeite (NaAlSi 2 O 6 ) and nephrite (Ca 2 (Mg,Fe) 5 Si 8 O 22 (OH) 2 ). Before the 18 th century, only nephrite had been found, mined, and carved into art objects or jewelry. During the 1700's, a new mineral, jadeite, was found in Burma. Jadeite is different in chemical composition from nephrite and can exhibit highly saturated colors and a higher degree of translucency, a higher hardness, and a glassy appearance. Because of its superior properties, jadeite quickly replaced nephrite as the “jade” of choice among art and gem collectors. Contemporary descriptions of “Imperial” jadeite cite the following qualitative attributes: a very intense and uniform green color ranging from “apple green” to “spinach green”; a high degree of uniform translucency; and an extremely smooth finish with a greasy feel and luster. The surfaces of natural gems often are treated with green waxes to improve color and translucency by filling surface defects.
Jadeite is a high-pressure polycrystalline mineral with nominal chemical composition of NaAlSi 2 O 6 and a density of 3.3 g/cc. It occurs naturally in a variety of colors ranging from colorless or white to yellowish white, green, lavender, red, and black. A specific green hue is associated with “Imperial” jade and has been highly prized since its discovery. The color of jadeite is due to the presence of impurity elements. For example, the presence of iron and/or chromium imparts a green color to the mineral. Manganese provides a lavender color.
Since the 1950's, jadeite has been synthesized in laboratory quantities in high-pressure (HP) phase equilibrium experiments to elucidate planetary evolution. Temperatures over 600° C. (for hydrothermal synthesis) and pressures over 20 Kbar were required. These numerous works produced very small laboratory samples, typically less than 2 mm in any dimension and which were of no gemological value. A much smaller number of reports describe attempts to produce jadeite in gemologically valuable size and quality. These reports reveal that larger jadeite samples can be produced with nominal mineralogical attributes of density, refractive index, hardness, and crystallographic structure. None of these reports quantitatively describes the product or claims to synthesize “Imperial” grade jadeite. In fact, the most detailed evaluations of synthetic jadeite categorically state that “Imperial” quality was not achieved.
Shigley and Nassau, (Kurt Nassau and James E. Shigley, “A Study of the General Electric Synthetic Jadeite”, Gems & Gemology , Spring 1987, pp. 27-35) provided the most complete gemological evaluation of synthetic jadeite. They report on several samples produced by high-pressure processes. The gemologists found that the synthetic materials were predominately jadeite and reproduced the chemical composition, refractive index, density, infrared spectra, x-ray patterns, fluorescence, and hardness values expected of natural jadeite. Samples up to 2.6 carats in weight were described. The authors also indicated that while this jadeite, “can be considered gem material, it does not match the highly translucent, almost transparent, quality of what is known in the trade as ‘Imperial’ jadeite',” and described the material as, “semi-translucent to opaque.” The authors attributed the opacity to the presence of a minor concentration of glassy phase. They further noted that the color was concentrated in distinct areas providing a “mottled” and “granular” appearance. Lamellar cracks, unexpected trace contaminants, non-uniform polishing, and an unusual reflective property called “adventuresence” further distinguished the synthetic product from “Imperial” gem quality jadeite. FIG. 1 , shows the lack of uniformity, cracking, and opacity of the materials evaluated by Shigley.
In two publications DeVries and Fleischer (DeVries and Fleischer, “Synthesis of Jadeite for Jewelry”, GE Technical Information Series , 84 CRD 282, 1984; and DeVries and Fleischer, Material Research Society Symp. Proc. Vol 22, pp. 203-207, 1984, Elsevier Science Pub. Inc.), who successfully synthesized jadeite minerals more than 17 years ago, noted that, while of gemologically useful size, the “quality of Imperial jade is not achieved.” The transparency of their products was limited by the presence of a residual eutectic material. Microgaphs in their reports show this second phase to be present between 5 and 10 volume percent and up to 30 microns in size. These authors further describe non-uniform coloration as “mottled” and “mixed.” Radial inhomogeneity and lateral cracking limited the size of gems that could be fabricated. While not cited by these authors as limiting transparency, the synthetic jadeite microstructures shown exhibited other defects: intergranular cracking of up to 30% of the grain boundaries; polishing pullout; and large, distinct grains averaging 30 microns in diameter and as large as 150 microns.
More recently, Zhao, et al. (Tinghe Zhao, et al., “The Physical and Chemical Properties of Synthetic and Natural Jade for Jewellery”, J. Material Science , vol 29, 1996 pp. 1514-1520; Zhao, et al., “Synthesis of the clinopyroxenes CaMgSi 2 O 6 —NaAlSi 2 O 6 for jewelry”, J. Material Science , 30, 1995, pp. 1117-1123) describe an expanded range of process parameters used to synthesize gem-sized pieces of jadeite. The mineralogical and compositional properties of natural jadeite were achieved on samples twice the size of the DeVries materials. The largest sample prepared was approximately 15 carats in weight. The gemological quality of the samples is not described. These authors characterize the products as, “green,” “emerald green,” and “translucent.” In the second reference, other colors were produced, but not in stoichiometric jadeite. In this second article, the translucency was described as “somewhat improved” but not measured. The jadeite microstructure in both Zhou references contains fibrous, elongated crystals up to 10 by 40 microns with very distinct grain boundaries.
With respect to the processes used by the foregoing authors to make synthetic Jadeite, DeVries and Fleischer used glass powders having the composition, NaAlSi 2 O 6 , and containing small amounts (0.5 to 2.0 weight-%) coloring agents, such as Cr 2 O 3 for green and manganese oxides for lavender. The glass compositions were melted and crushed to achieve homogeneity. Crushed glass powders (−60/+100 mesh size) were placed in a high-pressure cell in direct contact with the heating element. The powders were sintered and annealed in the jadeite stable region of the pressure-temperature phase diagram. The mineralogical properties of jadeite were routinely obtained in this work. The samples produced were of poor quality and there was high incidence of cracking and delamination of the samples. This is attributed to the large volume reduction during sintering of glass powder into a dense jadeite sample. The packing density of glass powder is only ˜60% of theoretical density of solid glass. Further, the jadeite glass phase itself has just 74% of the density of the crystalline jadeite phase of corresponding composition. Hence, sintering of jadeite glass powder to a jadeite crystal resulted in very large combined (60%) reduction in part volume during high-pressure processing. This large volume reduction causes distortion of the cell making the process less reliable, causing cracking, and limiting the size of samples that can be made by powder sintering. The authors attributed cracking and radial non-uniformities to the use of indirect heating. The cell used a graphite heater, which was in direct contact with the samples.
Zhao et aL's process also used a similar glass powder approach to make jadeite and jadeite-like clinopyroxenes by sintering at jadeite stable high-pressure and high temperature conditions. These investigators used a direct contact, indirect heated cell almost identical to the DeVries design. The quantitative details on the quality of the samples are not available other than that they were translucent and green in color.
These contemporary descriptions of synthetic jadeite qualitatively describe color, uniformity, translucency, and finish. None claim to have synthesized “Imperial” grade material. The most detailed reports categorically state that the “Imperial” quality level was not achieved.
Thus, despite the reported ability to synthesize jadeite under high-pressure processing conditions, no reports of Imperial jadeite have been published, regardless of size of the resulting jadeite synthesized. Thus, there exists a need in the art to manufacture jadeite of improved quality and size. There also is a need in the art to manufacture Imperial jadeite. The present invention is addressed to these needs.
BRIEF SUMMARY OF THE INVENTION
The invention is a man-made jadeite mineral that simultaneously and quantitatively achieves the color, translucency, uniformity, and finish of rare “Imperial” jadeite. Unlike prior art synthetic jadeite, which exhibits readily detectable lamellar cracking, significant opacity, mottled, and non-uniform coloration, the inventive jadeite material requires microscopic differentiation from “Imperial” grade jadeite. The invention features a microstructure that permits ready identification of the man-made product, preventing misrepresentation of the material. Additionally, the invention incorporates a repeatable, quantitative gemological specification distinguishing it from prior art.
The jadeite material has a thickness in excess of about 1.0 mm and CIELAB indices of L*>42, a*<−6, and b*>+6. The grain size of the jadeite material is less than about 30 microns, and often less than about 10 microns, and is an equiaxed grain structure. The jadeite material has an optical transmission peak between 500 and 565 nm with an I/I O optical transmission ratio of over 40%.
The first step in making the jadeite material is to wrap a glass block (jadeite material precursor glass), convertible by HP/HT into jadeite and having a nominal composition of NaAlSi 2 O 6 , with a graphite or refractive metal sheet. The wrapped jadeite material precursor glass is placed in an HP/HT apparatus, rapidly heated, and subjected therein to a pressure in excess of about 3 GPa and a temperature in excess of about 1000° C. for a time adequate to convert the glass block into jadeite. The jadeite material then is cooled and the pressure subsequently released.
This process also can be used to produce gem materials from solid blocks of silicates, germanates, borates, and phosphates (glass-forming); as well as for colored or non-colored (transparent) ceramic materials useful in manufacturing dental appliances, optical components, and electro-optical materials, e.g., for telecommunications or lasers.
BRIEF DESCRIPTION OF THE DRAWINGS
The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the Patent and Trademark Office upon request and payment of the necessary fee.
For a fuller understanding of the nature and advantages of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:
FIG. 1 shows the lack of uniformity, cracking, and opacity of the prior art materials evaluated by Shigley in the Gems & Gemology article, cited above;
FIG. 2 is a schematic cross-section of the high-pressure reaction cell that was used in the Examples to manufacture the novel jadeite;
FIG. 3 is schematic of the set-up used to characterize jadeite samples using a spectrophotometer;
FIG. 4 shows the a*, b* chromaticity diagram;
FIG. 5 is the CIELAB color gamuts for pure blue;
FIG. 6 is the CIELAB typical L-C color gamut saturation curves for yellow, orange, green, red, purple, and blue;
FIG. 7 is a photograph of natural “Imperial” grade jadeite (Sample 1);
FIGS. 8 and 9 are continuous transmission spectra of two different natural jadeite gems describe in Table 1, below;
FIG. 10 is a 500× photomicrograph of a polished section of the inventive jadeite as reported in Example 1;
FIG. 10 a is the CIELAB L-C color gamut saturation curve for “Imperial” jadeite green and comparisons of prior art, the inventive jadeite, and natural jadeite gems;
FIG. 11 is a 1000× photomicrograph of an acid-etched section of the inventive jadeite as reported in Example 1;
FIG. 12 is a photograph of the inventive jadeite as manufactured in Example 1;
FIG. 13 is a continuous transmission spectrum for the inventive jadeite sample of Example 1;
FIG. 14 is a continuous transmission spectrum for the inventive jadeite sample of Example 3;
FIGS. 15A , 15 B, and 15 C are phase diagrams for NaAlSiO 4 -NaAlSi 3 O 6 at various temperatures and pressures;
FIG. 16 is partial chemical configuration of natural jadeite with Fe +2 and Ti 4+ replacement for producing a blue jadeite material; and
FIG. 17 is an energy diagram of the jadeite material of FIG. 16 showing that light absorption causes a broadband absorbance centered at 588 nanometers, thereby coloring the crystal blue.
The Figures will be described in more detail below.
DETAILED DESCRIPTION OF THE INVENTION
Manufacture of Imperial Jadeite
“Imperial” jadeite is highly valued not only for its inherent beauty, but also because nature only rarely provides the chemical and physical environment for its formation. Gemological references provide quantitative mineralogical attributes that allow the gem trade to distinguish simulants (i.e., simulated jadeite), nephrite, and other minerals, as well as treated (enhanced) natural materials, from true jadeite. These references do not provide quantitative specifications or a rigorous grading method for “Imperial” jadeite. Quantitative color, uniformity, and finish; and translucency specifications for “Imperial” grade jadeite differentiate the present invention from prior art.
Color manipulation of oxide materials is well described. Use of metallic ions to achieve various hues of green is disclosed in the prior art. It is also known that translucent polycrystalline ceramics must have polished surfaces to avoid scattering loss, low inherent absorption, grain boundaries without major refraction losses or scattering, and other scattering features minimized in frequency or intensity. The invention comprises proper coloration, polish, controlled absorption, and reduced scattering to achieve “Imperial” grade jadeite.
This invention uses a different approach to synthesize jadeite with color and translucency similar to those of “Imperial” grade natural jadeite. Instead of glass powder, this present invention uses solid blocks of glass. These glass blocks can be shaped as spheres, ellipsoids, cubes, parallelepipeds, pyramids, cones, regular and irregular polyhedrons, and other solid geometric forms. The glass has no porosity and, hence, the only volume change during jadeite formation is due to the glass-to-crystal phase change (−33%). This relatively low volume change contrasts to the very large volume change (−60%) associated with the glass powder-to-crystal phase change of the prior art. The advantages of this solid-glass method include the production of larger jadeite polycrystalline masses with fewer inclusions and cracks, no porosity, and better jadeite colors. The solid-glass method also minimizes the cell distortion and improves the consistency and yield of the process. The solid-glass method also insures a controlled uniform composition in the finished jadeite. The powder process, in contrast, has a large powder surface area from which volatile constituents can evaporate easily during processing, thereby inadvertently changing the composition or introducing undesirable concentration gradients in the jadeite.
The consistency of the starting glass provides the desired uniform coloration. The starting glass advantageously, then, should be of high quality with no undissolved material, bubbles, devitrification, or coloration heterogeneity. Optical quality seems desirable, but may not be necessary. The glass block can be formed by melting a pre-mixed powder consisting of the components, viz., Na 2 CO 3 , Al 2 O 3 , SiO 2 , Cr 2 O 3 , etc., in the desired proportions and casting the melt in the form of an ingot. The pre-mixed powder could be made by physical blending of powder ingredients, pre-reacting some of ingredients before mixing, or by sol-gel technique. Solid blocks of glass are fabricated from the cast ingot.
Raw materials for forming the glass blocks can contain the following ingredients: 0.8-1.2 moles of a Na component, 0.8-1.2 moles of an Al component, 1.8-2.2 moles of an Si component, 5-7 moles of an oxygen component, 0-0.2 moles of an alkaline or alkaline earth element(s) (e.g., K, Li, Ca, Mg, Be), 0-0.5 moles of a transition element(s) (e.g., Fe, Cr, Mn, Ti, V, Ni, or other transition element), and 0-0.5 moles of a rare earth element (Nd, La, Ce, Pr, Sm, Eu, or other rare earth element). Preferred raw materials for forming the glass blocks include: 0.8-1.2 moles of a Na component, 0.8-1.2 moles of an Al component, 1.6-2.4 moles of an Si component, 4.8-7.2 moles of an oxygen component, 0-0.2 moles of an alkaline earth element(s) (e.g., Ca, Mg), and 0-0.5 moles of a transition element(s) (e.g., Fe, Cr, Mn).
The product jadeite, then, comprises the nominal NaAlSi 2 O 6 composition with added impurities. In mineralogy terminology, the jadeite product can be represented as follows:
(Na, Alkali or Alkaline Earth)(Al, Transition Element, Rare Earth Element)Si 2 O 6
where there is 0-0.2 mole of an alkali or alkaline earth metal element, 0-0.5 mole of a transition element, and 0-0.5 moles of a rare earth element.
The reaction cell used to produce the inventive jadeite is schematically shown in FIG. 2. A glass cylinder, 51 , is surrounded first by tantalum foil, 52 , and then by Grafoil®, 53 , (or vice versa) and placed in preformed pills, 54 a and 54 b . The pills are placed inside MgO cups, 55 a and 55 b , which then are inserted in heater assembly consisting of a graphite tube, 56 , and graphite end discs, 57 a and 57 b . The heater assembly is surrounded by a MgO tube, 58 , and by MgO discs, 59 a and 59 b , which are surrounded by pills, 60 a and 60 b , and by a cylinder, 61 , made of black salt. Graphite pins, 62 a and 62 b , are inserted in salt pills and graphite discs, 63 a and 63 b , seal the ends of the salt cylinder, 61 . Ceramic rings, 64 a and 64 b , are added to the cell to improve consistency of high-pressure runs.
This cell design overcomes many problems in prior art designs. The Ta and Grafoil® wraps prevent reaction of the glass material with surrounding cell components, viz., graphite. This improves the chemical homogeneity of the final product and avoids the radial non-uniformity of prior art. The wraps prevent attachment of the sample to the pressure transmission media reducing stress and concomitant cracking during depressurization. The reaction mass is heated by conduction and radiation through insulating masses—the cup and salt—that homogenizes the temperature gradients described in the prior art. Other refractory metal wraps include, for example, one or more of W, Nb, Mo, Zr, Ti, Hf, Va, Cr, Th, U, or alloys thereof.
Cell conditions established generally are within the high pressure/high temperature (HP/HT) range as established in the HP art. Such high pressures generally are in excess of 3 GPa with pressures of between about 3 and 6 GPa being suitable for present purposes. High temperatures are in excess of about 1000° C. with about 1000° to 1800° C. also being suitable for present purposes. Nucleation of jadeite crystals from the glass phase occurs on heating through a jadeite nucleation zone centered around 950° C. with a width of a few hundred degrees Centigrade, i.e., 850°→1050° Centigrade. Fast heating rates through this nucleation zone limit the number of jadeite crystal nuclei that form in this nucleation zone and thereby maximize the final sizes of the polycrystals in the jadeite. Slow heating rates through the nucleation zone allow many jadeite crystals to nucleate and, thus, minimize the final crystal sizes in the jadeite. Anneal times range from about 5 minutes to 72 hours and correspond with the above anneal temperatures and pressures. Slow cooling and gradual pressure release from peak values also have been determined to aid in suppressing cracking and delamination of the jadeite being produced. Cooling preferably is done at sufficiently high pressures (>2 GPa) to avoid any precipitation of albite or nepheline, which are the stable phases at low pressure. Precipitation of other phases in the pure jadeite causes both light absorption and Rayleigh scattering and, thereby, reduces the translucency of the jadeite. The appearance of other phases also may degrade the color of the jadeite. The combination of slow cooling rates and low pressures favor the appearance of these undesirable secondary phases. Such phases are most likely to nucleate at grain boundaries in the crystalline jadeite where the atomic kinetics are always the highest.
Jadeite Color and Translucency
Introduction
In the past, there has been a general bias in the gem industry against objective color measurements of gemstones. This bias stems from the view that each gemstone is considered and treated as an “object d'art” that can only be valued by its subjective beauty. However, this subjective approach is fatally flawed because of the lack of a standard observer. Moreover, objective color gratings have proven useful in many commercial settings, such as, for example, the paint, plastic, and automotive industries, and it is proving successful today for the first time in the gemstone industry. The color of a semitransparent gemstone, such as jadeite, can be specified through the use of color measuring instruments and color order systems. The most precise and intuitive system is the CIELAB color notation where the color and clarity of jadeite is specified with a series of numbers, e.g., L*=51, a*=−40 and b*=+33.
The color and translucency of a gemstone has four major variables, namely: (1) the light source; (2) the colored gemstone itself; (3) the observer; and (4) the geometry of illumination and viewing. All of these variables must be standardized so that one can arrive at an objective specification of the color appearance of the gemstone.
The Illuminant
The Commission Internationale de d'Eclairage (CIE) designated illuminant D65 as the illuminant that most closely approximates northern daylight and is the illuminant of choice for gemstones. Other illuminants can be used if adjustments are later made during color measurement for their non-standard spectra.
Illumination and Viewing Geometry
Color measurement and specification are technologically well developed and rest on a firm scientific basis. The best system, the CIE measurement system, is based on the spectral response of the human eye. The human eye has three color receptors, each of which has a different spectral response. A spectrophotometer can measure either the light reflectance or transmittance of a gemstone as a function of its wavelength in the visible spectrum from 400 to 700 nm. The resulting spectrum can be adjusted for the illuminant of choice by a software program that adjusts the spectrum to one that would have been seen in standard northern daylight.
The standardized spectrum then is analyzed according to the response spectral function of the three-color receptors of the human eye to determine what color a human eye would see from this spectrum. For example, if the spectrum has a high relative intensity in the longer wavelength part of the visible spectrum, the gemstone will appear reddish to the human eye. Similarly, if the spectrum has a high relative intensity in the shorter wavelength part of the visible spectrum, the gemstone will appear blue to the human eye. Finally, if the spectrum has the highest relative intensity in the center of the visible spectrum, the gemstone will appear green to the human eye like Imperial jadeite.
For a semitransparent object, such as a gemstone, the illuminating and viewing geometry will affect the observed color. For example, if the illumination is done from the back and viewing is from the front of the gemstone, the transmission color of the gemstone will dominate. In contrast, if the illumination and viewing are both done from the front of the gemstone, the reflection color of the gemstone will dominate. In some gemstones, these colors can be very different. So, in specifying an objective color for the gemstone, the geometry of the illumination and viewing system also must be given.
The color of jadeite, most of which is semitransparent, is derived both from reflection and transmission. However, the color of a few types of jadeite, such as black jadeite, may be principally from reflection because of the opaqueness of these specimens. Nevertheless, the reflection mode was discarded because it would be sensitive to surface finish, surface discolorations, and specula reflections from glossy surfaces like those of a jadeite cabochon. Moreover, the most highly valued types of jadeite have a high degree of transparency that would not be characterized by the reflection method. Consequently, the mode of choice to characterize Imperial jadeite and similar high grades of jadeite is the transmission mode.
To characterize jadeite in a scientific manner, a transmission method was selected where the jadeite was placed between the illuminant and the viewer as shown in FIG. 3 . The specimen, 10 , was placed on a centered platform, 12 , inside an integrating sphere, 14 , with a white matte surface, 16 . Integrating sphere 14 was illuminated by a light source, 18 , which was not in direct view of specimen 10 . Light from light source 18 was repeatedly reflected between different areas of white matte interior surface 16 of integrating sphere 14 so that the light was incident on specimen 10 from all hemispherical angles. Just beneath specimen 10 was an optical fiber, 20 , which collected light that had been transmitted through specimen 10 . The collected light was passed via optical fiber 20 to a spectrophotometer (not shown) where the specimen color was determined from its transmission spectrum. The commercial instrument used for this purpose was the SAS2000 Spectrophotometer Analysis System made by Adamas Gemological Laboratory of Brookline, Mass., USA.
The CIELAB Color Diagram
The CIELAB three-dimensional diagram was designed to be both precise and to appear logical to the human eye and brain. FIG. 4 shows the L*a*b* chromaticity diagram. One axis, L*, indicates how light-dark a specimen is. It describes the lightness of a color and varies from black=0 to white=100 in visually uniform steps of colorless gray in between. The other two axes contain, respectively, the opponent colors of red-green and yellow-blue. The idea of opponent colors derives from way the human eye and the neural networks of the brain perceive color. A human being cannot see a single hue as both red and green at the same time. Hence, red and green are opponent colors. Similarly, a human cannot see both blue and yellow as a single hue simultaneously, so blue and yellow also are opponent colors. In contrast to these opponent colors, both red and yellow can be seen as a single hue at the same time as in oranges, red and blue as in purples, etc. The CIELAB diagram takes advantage of the existence of opponent colors to make a unique diagram to specify any color. The opponent colors of red (+direction) and green (−direction) are plotted along and on opposing ends of a second orthogonal axis labeled a*. In a similar manner, the opponent colors of yellow (+direction) and blue (−direction) are plotted on opposing ends of a third orthogonal axis labeled b*. At the center of both the a* and b* axes, there is no color, just differing shades of gray as one moves up and down the L* axis. Movement towards either ends of the a* or b* axes corresponds with an increase in the intensity and saturation of the color. Because all colors can be made up of mixtures of light-dark (L*), red-green (a*), and blue-yellow (b*), any color of any hue, saturation, and brightness can be plotted on the CIELAB diagram.
The CIELAB diagram also was carefully designed so that equal distances on the diagram correspond to equal hue, saturation, and lightness changes as observed by a human eye. The lack of correspondence between distance and perceived color changes was a major flaw of previous color diagrams. The difference, ΔE, between two colors located at random points on the CIELAB diagram can be calculated by applying the Pythagorean Theorem:
Δ E (Δ a* 2 +Δb* 2 +ΔL* 2 ) 1/2 (1)
If the colors are at the same lightness level, i.e. ΔL*=0, Equation 1 reduces to
Δ C =(Δ a* 2 +Δb* 2 ) 1/2 (2)
where,
C =( a* 2 +b* 2 ) 1/2 (3)
The single dimension, C index, facilitates the balance of translucency and color saturation of a gemstone like jadeite. It is sometimes more convenient and useful to plot L* versus C in a two-dimensional diagram rather than L* versus a* and b* in a three-dimensional diagram if the color mixture or hue angle, i.e., the ratio of a*/b*, has been already fixed as it is with Imperial Green jadeite.
Accessibility in Color/Translucency Space
Because L* can vary from 0 to 100 and a* and b* can individually range from 0 to 100, one might think that the entire L*a*b* three-dimensional space of 100×100×100 would be accessible to real colors. However, L* and a* and b* are not independent variables as they might first appear. Consider a gemstone that is colorless and completely transparent with L*=100 and C=0. As color is added to the gemstone, C will increase. However, at the same time the added color will reduce the transparency of the specimen so that L* will decrease. Consequently, not all of the L*a*b* three-dimensional color space is accessible because of this dependency of L* on a* and b*. Hence, in real gemstones, or indeed in any color medium, both the maximum color saturation and the maximum transparency are limited by each other. FIG. 5 (FIG. 7.7 from Collecting and Classifying Diamond , by Stephen C. Hofer, Ashland Press (New York, 1998), ISBN 0-9659410-1-0) shows with three curves (Theoretical Limit Curve 22 , Transparent Gamut Curve 24 , and Opaque Gamut Curve 26 ) that illustrate, respectively, the dependency of L* and C on each other for a pure blue color (−b*) for an ideal, an opaque, and a transparent color medium. Only color saturations and transparencies depicted by areas to the left of the curves are achievable. For opaque gemstones such as black jadeite, the opaque curve is valid. For transparent gemstones such as blue sapphire, the transparent curve is controlling. The theoretical curve is the ideal maximum combination of L* and C that can be obtained in any medium in any form.
The Best Gemstone Colors
Because the invention is concerned primarily with jadeites, the limitations on L* and C for transparent gemstones of different colors are of the most interest, recognizing that jadeite gemstones are translucent and come in a variety of vivid colors including green, white, yellow to reddish orange, brown, gray, lavender, and reddish-purple which is sometimes referred to as blue. FIG. 6 (FIG. 7.13 from Collecting and Classifying Diamond, by Stephen C. Hofer, Ashland Press (New York, 1998), ISBN 0-9659410-1-0) shows typical L*-C saturation curves for yellow 28 , orange 30 , green 32 , red 34 , purple 36 , and blue 38 .
The most spectacular gemstones with the combined maximum vivid color and transparency occupy regions around the right-hand nose of each curve. For example, good green jadeite is in the region with C's between 60-75 and L*'s between 45-75, in the right-hand nose of the green curve. Jadeite with either greater or smaller L*'s or smaller C's will be less appealing to the human eye. Yellow jadeite will have good colors at C's between 65-73 and L*'s between 65-90. Orange jadeite will have good colors at C's between 60-84 and L*'s between 50-90. Purple jadeite will have good colors at C's between 60-75 and L*'s between 30-55. Blue jadeite will have good colors at a C's between 60-82 and L*'s between 15-50. With all the above colors, the maximum possible C compatible with the maximum possible L* in the ranges given above will give the most vivid translucent and best appearing color. For example, theoretically green jadeite will have its best color at C of 73 and L* of 60 just at the nose of the curve shown in FIG. 6 . Some jadeite colors are mixtures of the basic colors given above. For example, Imperial Green jadeite is actually a mixture of 63.3% green and 36.7% yellow with a hue angle of 150 degrees. The Imperial Green color will have good colors at C's between 60 to 73 and L*'s between 45-75. The best Imperial Green color will occur at C of 73 and L* of 62.
Table 1 below displays the range of compatible L*'s and C's for the good color range for the various basic colors discussed above for jadeite. In addition, Table 1 gives the compatible L* and C of the best color for each color, i.e., that combination of L* and C that occurs at the right-hand nose of the respective color gamut curves of FIGS. 5 and 6 .
TABLE 1 Good L* Good C Color Range Range Best L* Best C* Green 45-75 60-75 60 73 Imperial Green 45-75 60-73 65 73 Yellow 65-90 65-75 85 75 Orange 50-90 60-84 80 82 Purple 30-55 60-75 40 75 Blue 15-50 60-82 26 81 *Best L* and Best C combinations are not independent, but rather are dependent on each other.
Variation of the Color and Translucency with Gemstone Size
Both L* and C are dependent on the thickness of a gemstone, which has a uniform body color. C will increase with thickness. That is, the color will become more vivid and saturated as the thickness of the gemstone increases. This makes sense since a thicker gemstone has more total color centers than a thin gemstone of the same body color. L* decreases with thickness because the clearness or transparency of the gemstone will decrease with the increasing absorption by color centers or scattering centers in a thicker gemstone. Because light absorption increases exponentially with thickness, one might at first think that L* and C would also vary exponentially with the thickness. However, the human eye also responds in a logarithmic manner to light intensity. This logarithmic response, for example, is one reason that we can see such a wide range of stars in the night sky whose intensities vary by over a factor of one million. The CIELAB diagram was constructed so that equal distances on the diagram correspond to equal changes in visual intensity and color. In other words, the CIELAB diagram is a logarithmic diagram—equal distances correspond to equal ratios in intensities. Hence, both L* and C are logarithmic measures, respectively, of the transparency and color intensity of a gemstone. Although transparency and color intensity do vary exponentially with thickness, the logarithms of the transparency and color intensity, i.e. L* and C values, only vary linearly with thickness X, as follows:
C 1 =C 2 ( X 1 /X 2 ) (4)
L* 2 =L* 1 ( X 1 /X 2 ) (5)
where,
C 1 and C 2 are the colors, and L* 1 and L* 2 are the translucencies, respectively, of gemstones of thickness X 1 and X 2 , having a uniform body color and translucency.
Variation of Color and Translucency with Impurity Concentration.
In a perfect gemstone crystal, the body color, C 0 , and translucency, L* 0 , are linear functions of the concentration, I, of impurity color centers in the gemstone or jadeite:
C 0 =αI (6)
L 0 =β1/I (7)
where,
α and β are constants related to the specific impurity and gemstone.
For example, the color of Imperial Green jadeite comes from a small amount of Cr impurity added to the jadeite, NaAlSi 2 O 6 .
Impurity Concentration Versus Thickness for the Optimum Color Gemstones
If one produces a gemstone, or specifically a piece of jadeite, with an optimum translucency and color of L* and C for a given thickness X, how does one vary the impurity concentration, I(X) (where (X) signifies the functional dependency of impurity concentration I on the specimen thickness X), to obtain this same optimum color and translucency for a different thickness? Substitution of Equations 6 and 7 into 4 and 5 while holding C and L* constant, respectively, both give:
I ( X 1 )/ I ( X 2 )= X 1 / X 2 (8)
I ( X 1 )/ I ( X 2 )= X 1 / X 2 (9)
where,
I(X 1 ) and I(X 2 ), respectively, are the impurity concentrations necessary to maintain color and translucency constant at gemstone thicknesses X 1 and X 2 .
Fortunately, both equations give the same answer. One can see from Equations 8 and 9 that it is possible to obtain the exact same apparent color and apparent translucency in gemstones of varying sizes if one changes the intrinsic body color and transparency with size. For example, if one doubles the thickness of a jadeite gemstone, one must halve the impurity concentration to maintain the same color C and same translucency L*. Consequently, the composition of a jadeite glass used as the precursor to grow jadeite is only optimized for one gemstone size (i.e., thickness). As the desired gemstone size is changed, the impurity concentration of the precursor glass also must be changed to maintain the same color C and translucency L*. For example, to make Imperial Green jadeite for a cabochon that will be 3 mm thick requires the concentration of Cr to be 0.25 weight-%. To make the same Imperial Green jadeite color and translucency in a cabochon that is 6 mm thick, a precursor glass with only half the concentration of Cr concentration, i.e., 0.12 weight-%, is required (Equations 8 and 9).
Table 2 tabulates the approximate wholesale value (US Dollars per carat, as estimated by a recognized gemological laboratory) and L*a*b* and C indices, as well as an overall Pythagorean-weighted translucency-color L*C vector for the gemological samples. Because L* follows Lambert's relationship for thickness and transparency, these natural “Imperial” jadeite samples all had maximum thickness between 2 and 3 mm. Other color space measurement systems are recognized and can be correlated (technically equivalent) with the CIELAB measurements.
TABLE 2
Natural Jadeite Gems
L*C Vector
Sample
$/carat
L*
a*
b*
C
(L* 2 + C 2 ) (1/2)
1
7000
63.4
−55.8
33.7
65.19
90.94
2
2800
66.5
−49.6
31.9
58.97
88.88
3
1000
69.8
−51.1
35.6
62.28
93.55
4
800
74.6
−28.4
19.7
34.56
82.22
5
250
59.1
−37.1
27.4
46.12
74.97
The overall progression in the Table 2 places the highest values on large L*, i.e., high translucency, and large negative a*, i.e., intense green, and moderately high b*, i.e., added yellow. It appears that a* is the most important variable followed by b* in valuing a jadeite gem. Sample 3 is generally out of order and appears to have been incorrectly valued based on color and translucency alone. Other factors, such as inclusions or cracks, may have decreased Sample 3's value from what one might have expected based only on its color and translucency.
Even the least valuable of these gems exhibits a high degree of translucency and highly saturated green color. Inspection of these and other gems reasonably provides a CIELAB specification for “Imperial” jadeite. Jadeite minerals meeting the CIELAB specification discussed above generally will provide the visual impression of “Imperial” jadeite. More translucent and more saturated examples will carry higher values. Surface finishes on the inventive gems are less than 5 micro inch arithmetic average roughness to minimize scattering. FIG. 7 is a photograph of sample number 1 of natural jadeite. Comparison of FIG. 7 to FIG. 1 shows why previous synthetic jadeites were not considered “Imperial” quality. Note that the natural jadeite in FIG. 7 exhibits small dark inclusions, non-uniform color, and is nearly transparent.
The SAS2000 calorimeter also produces continuous transmission spectra of these gem materials. Spectra for the most valuable gems (Samples 1 and 2 in Table 1) are FIGS. 8 and 9 . Both gems have a transmission peak centered at a wavelength of about 530 nm. Sample 1 has a narrower transmission peak, a half height width between about 510 and 565 nm correlating with an intense green color. Less valuable pieces exhibit less transmission and broader transmission bands.
A sample of prior art jadeite was obtained from Dr. DeVries (see DeVries, et al., GE Technical Information Series, supra ) and characterized for color indices. The sample was in the form of semi-polished cabochon with thickness of 2.0 mm and color measurements of L*=41.0, a*=−5.1, b*=4.8. The sample did not visually exhibit the translucency or color saturation required of “Imperial” grade material. The sample also had lower density of 3.26 g/cc.
The prior art jadeite of Zhou, et al. was reproduced using a chromium doped glass, crushed to −60/+100 mesh size powder. The powder was loaded into a high-pressure cell and sintered at 5.2 GPa and 1575° C. for 1 hour. A sintered compact was obtained having a density of 3.28 g/cc, indicating successful conversion to jadeite. The compact was polished to 4-mm thickness. The colorimeter measurements were: L*=32.3, a*=−2.8, and b*=3.2. This sample did not achieve any of the CIELAB index specification requirements.
A jadeite sample of the present invention was produced from a glass with stoichiometric jadeite composition of NaAlSi 2 O 6 containing 0.17 wt-% of Cr 2 O 3 (see Example 1 below). A final density of 3.30 g/cc indicated successful conversion to the jadeite phase. Unlike prior art “synthetic” jadeite, a polished section of this material was completely featureless at 500×. The complete absence of gross or intergranular cracks, or non-uniform color distributions, or second phases is shown in FIG. 10 . The colorimeter measurements of this sample were: L*=61.2, a*=-55.1, and b*=31.8.
The similar transparency and color saturation of valuable natural jadeite gems and the examples cited in this application may be quantitatively presented in L* and C space, as described above. Fitting the theoretical L*,C space to contain the natural “Imperial” samples cited above permits a quantitative assessment perfection achieved by the invention with respect to natural gems and prior art. As shown in FIG. 10 a , the right hand nose (or theoretical L*,C limit) is nearly achieved by both valuable gems and the examples of the inventions. The substantially lower translucency and color saturation of the prior art is obvious from in FIG. 10 a.
Acid etching highlights the grain structure of this jadeite material as can be seen by viewing FIG. 11 at 1000× magnification. This sample has an average grain size of 2 microns. The maximum grain size is approximately 5 microns. The grains are relatively equiaxed, without the elongation noted in prior art jadeite samples. These very fine, uniform grains provide a simple, reliable method of detecting this man-made material. No second-phase artifacts over the 2-micron grain size, cracked grain boundaries, or pullouts are evident. Triple points, if present at all, are smaller than the 2-micron grain size. The SAS calorimeter measurement yielded the following values: L*=60.2, a*=-55.5, and b*=31.7. This material has significantly higher translucency and color saturation than prior art. It falls well within the gem grade attributes in Table 1. This gem is shown in FIG. 12 . Note should be taken that this synthetic jadeite exhibits no inclusions, displays a uniform color, and is translucent. The inventive synthetic jadeite in FIG. 12 should be compared to the natural jadeite sample in FIG. 11 and the prior art jadeite samples in FIG. 1 .
Finally, the transmission spectrum of this sample closely mimics the natural materials. The peak transmission was 530 nm with a half height width between 500 and 565 nm, as can be seen by reference to FIG. 13 . Additionally, the coloration is uniform with no mottling observed up to 200×. None of the lamellar cracking, surface reflections (adventuresence) or polishing defects so evident in prior art jadeite were present in this sample in particular (again, see FIG. 12 ) and not in most samples in general.
The uniform grain size and hardness of the inventive jadeite product make it easier to polish than prior art or natural jadeite material. It is known that natural jadeite must be carefully polished to prevent “undercutting,” or micro scale topography resulting from preferential polishing of oriented jadeite crystals or second phases. Recall that waxes hide these problems in natural gems. Prior art jadeite material also exhibits undercutting. The surface finish achieved on the inventive jadeite was less than 3 micro inches Ra. With such a smooth finish, waxes are not needed, and a more stable, durable product is produced.
To assess product reliability, the process of Example 1 was repeated. The color indices on several samples met the “Imperial” specification range. The observed colorimetric values were as follows: L* was between 55 and 65, a* was between −53 and −56, and b* was between +30 and +33. Grain size, finish, and microstructure features were identical to the sample reported in Example 1. A continuous spectrum of this duplicate sample also closely mimics natural material, peaking at 525 nm with a half height width of 500 to 565 nm.
The L*a*b* values of the natural gem-grade jadeite prior art and inventive samples reported herein are summarized in Table 3, below.
TABLE 3 L*a*b*C Summary Jadeite L* a* b* C (L 2 + C 2 ) 1/2 Example 11 65.9 −61.5 37.5 72.0 97.61 Example 9 68.9 −57.1 31.9 65.4 95.00 Example 7 68.0 −56.3 32.6 65.1 94.14 Example 2 59.9 −56.1 31.8 64.49 88.01 Example 8 68.3 −55.8 31.9 64.3 93.81 Sample 1* 63.4 −55.8 33.7 65.19 90.93 Example 1 61.2 −55.1 31.8 63.62 88.28 Example 3 60.4 −55.1 31.5 63.47 87.62 Example 10 66.9 −54.8 32.8 63.9 92.51 Sample 3* 69.8 −51.1 35.6 62.28 93.54 Sample 2* 66.5 −49.6 31.9 58.97 88.88 Sample 5* 59.1 −37.1 27.4 46.12 74.97 Sample 4* 74.6 −28.4 19.7 34.56 82.22 DeVries** 41.0 −5.1 4.8 7.00 41.59 Zhou** 32.3 −2.8 3.2 4.25 32.58 Comparative 32.3 −2.8 3.2 4.25 32.58 Example 4** *Natural Imperial Jadeite **Prior Art
This tabulated data (sorted by a*) in Table 3 should be compared to the values determined for a jadeite sample to be termed “Imperial” grade, i.e., an L* index exceeding 42, an a* value of less than −6, and a b* value that exceeds 6, with the preferred L*a*b* region being around >60, <−50, >30, respectively. It will be observed that the only jadeite samples that meet these criteria are the natural jadeite samples and the inventive jadeite samples reported in the Examples. In fact, none of the prior art samples have any L*a*b* value within the range suggested for “Imperial” jadeite. Such uniqueness of values, coupled with its other properties, underscores the novelty of the inventive jadeite.
The index of refraction of the novel jadeite material ranges from about 1.655 to 1.659±0.002. Such values were taken on polished (4000 grit paper) facets (4×4 m) using monochromatic light.
Other Jadeite Colors
In addition to imperial Green jadeite induced by Cr impurities, and lavender or magenta jadeite induced by Mn impurities, other desirable colors include, inter alia, clear stoichiometric jadeite without any impurities and black jadeite with high impurity concentrations of Cr or Fe.
Rare earth elements can be added to stoichiometric jadeite to produce a wide range of colors. The color imparted by rare earth elements is largely independent of their site or neighbors in jadeite. The colors of these elements are derived from electronic transitions within the inner f shell, which is shielded from the surrounding ions and ligand fields by the outer 5s25p6 completely filled shell in all the rare earths, which is the reason for the almost identical chemical nature of all of the rare earth elements. The following table gives the rare earth element, their f shell configuration and the color imparted to the jadeite by the rare earth element. Concentrations of the rare earth element should be in the range of just above 0 to about 1 mol-%.
TABLE 4
Element
Trivalent Ion F-Shell
Color
La
4f0
Colorless
Ce
4f1
Yellow to Colorless
Pr
4f2
Green
Nd
4f3
Lilac, pink
Pm
4f4
Pink, Yellow
Sm
4f5
Pale Yellow
Gd
4f7
Colorless
Tb
4f8
Pink
Dy
4f9
Pale Yellow
Ho
4f10
Pink, Yellow
Er
4f11
Lilac, Pink
Tm
4f12
Green
Yb
4f13
Yellow, Colorless
Lu
4f14
Colorless
Opaque White Jadeite
In addition to these colors there is sometimes a demand for opaque white jadeite. This can be produced by one of the following methods:
Method I
Add an extra 0.5 to 1 mol-% Al 2 O 3 to the stoichiometric jadeite and anneal for several hours during crystallization to cause precipitation of very fine Al 2 O 3 precipitates.
Method II
A stoichiometric jadeite crystal with no added impurity is annealed at a temperature below the liquidus region (see FIGS. 15A , 15 B, and 15 C) for a short period of time to cause a precipitation of a small amount of microscopic nepheline (Na 2 O·Al 2 O 3 ·2SiO 2 ) and/or albite (Na 2 O·Al 2 O 3 ·6SiO 2 ). Rayleigh scattering from these microscopic precipitates causes the jadeite to be milky white in color. The optimum anneal time will increase with decreasing temperature because the kinetics of diffusion decrease exponentially with temperature. Note that the liquidus temperature varies somewhat with pressure. It is most convenient to anneal the jadeite at atmospheric pressure where the liquidus is at approximately 1050° C.
Blue Jadeite
True Blue Jadeite has not yet been found in nature (there is a natural reddish-purple, however, that often is referred to as “blue”). To produce blue jadeite, 0.05 mol-% Ti and 0.05 mol-% Fe should be added to stoichiometric jadeite. Fe and Ti will replace Al in the distorted octahedron of 6 oxygen atoms in the jadeite structure. This is the same replacement that occurs when Cr +3 replaces Al in jadeite to give an Imperial Green color. Fe +2 and Ti +4 will be present and an interaction between them is possible when they are on adjacent octahedral sites sharing faces in the c-direction (see FIG. 16 adapted from The Physics and Chemistry of Color , by K. Nassau, p. 142, John Wiley & Sons, NY (1983)).
When the Fe and Ti are on neighboring sites, there is sufficient overlap of the dz2 orbitals of these ions that with a light absorption assist, an electron can pass from Fe +2 to Ti +4 , as follows:
Fe +2 +Ti +4 −(light absorption)→Fe +3 +Ti +3 (10)
The accompanying light absorption causes a broadband absorbance centered at 588 nanometers, thereby coloring the crystal blue ( FIG. 17 adapted from The Physics and Chemistry of Color , K. Nassau, p 142, John Wiley & Sons, NY (1983)).
Orange Color
To produce an orange jadeite, 0.1 mol-% Cr+0.1 mol-% Mg should be added to the jadeite. Each Mg +2 and Cr +3 ion will replace an Al +3 ion in the jadeite. If Cr and Mg occupy adjacent octahedrons, Cr will enter the rare Cr(IV) state with one Mg +2 ion and one Cr +4 ion taking the place of two Al +3 ions and, thereby, producing a charge-neutral crystal. The Cr +4 ion will produce an orange color in the Al 2 O 3 octahedral site in jadeite.
Other Elemental Substitutions
The M2 Na+[8] Site
To improve the quality, translucency, grain size or color of the jadeite or to enhance the manufacturability of the precursor glass, it may be useful to partially substitute other elements or combinations of other elements in the jadeite structure for the Na and Al atoms. For example, the partial substitution of certain elements for Na or Al may lower the melting point of the precursor glass and allow a more homogeneous glass to be formed. Successful substitution of elements or combinations of elements in the jadeite structure is dependent on these elements satisfying Pauling's charge neutrality and size rules (C. Klein & C. S. Hurlbt, Manual of Mineralogy, 21 st Edition, p. 197, John Wiley & Sons, NY, N.Y. 1993). Na occupies an irregular polyhedron with eight-fold coordination in the jadeite crystal as a singly charged ion with eight oxygen nearest neighbors called the M2 site. In geology nomenclature, this is signified by Na+[8]. Other alkali metals can be substituted for Na. For example, a mixture of 42 mol-% K +1 and 58 mol-% Li +1 can partially replace an equal molar amount of Na +1 in jadeite without causing lattice strain or violating charge neutrality. If 10% of the Na were replaced with this mixture, the jadeite would have the composition:
(0.9 Na, 0.042 K, 0.058 Li)AlSi 2 O 6 (11)
Another possible substitution for Na+[8] is a mixture of 16 mol-% K +1 and 84 mol-% Ca +2 for Na +1 . This partial substitution would not cause lattice strain, but would result in an unbalanced charge in the lattice because Ca is a doubly charged ion. This unbalanced charge on Na sites would have to be compensated for by substituting a singly or doubly charged ion for the triply charged Al on the Al sites. For example, Mg +2 can be substituted for Al +3 . If 10% of the Na atoms were replaced with a mixture of 16 mol-% K +1 and 84 mol-% Ca +2 and a charge compensating amount of Mg +2 was partially substituted for the Al +3 , the jadeite would have the composition:
(0.9 Na, 0.016 K, 0.084 Ca)(0.926 Al, 0.084 Mg)Si 2 O 6 (12)
This jadeite composition will be unstrained and charge neutral.
The M1 Al 3 +[6] Site
Triply charged Al ions occupy the M1 octahedral site in jadeite with six nearest neighbor oxygen atoms and are designated as Al 3 +[6]. Various mixtures of elements can be partially substituted for the Al ions in jadeite without causing any lattice strain and without violating charge neutrality. For example, a mixture of 72 mol-% of Mn +3 and 28 mol-% B +3 can be substituted for an equal molar amount of Al +3 on the M1 sites in jadeite. If 10% of the Al ions were replaced, the resulting jadeite would have the following composition:
(Na)(0.9 Al, 0.072 Mn, 0.028 B)Si 2 O 6 (13)
Other mixtures that can partially substitute for Al include: (1) 72 mol-% Fe +3 and 28 mo-% B +3 ; (2) 78 mol-% Cr +3 and 22 mol-% B +3 ; (3) 56 mol-% Sc +3 and 44 mol-% B +3 ; (4) 56 mol-% Ti +4 and 44 mol % Be +2 .
In addition, mixtures that do not preserve charge neutrality can be substituted on the Al +3 M1 sites provided that overall charge neutrality is secured by a parallel charge-cancellation substitution on the Na+ 1 M2 sites. For example, a mixture of 55 mol-% Fe +2 and 45 mol-% B +3 can be substituted on the Al +3 M1 site if a charge cancellation substitution of Mg +2 , Ca +2 , Ba +2 , or Be +2 is made on the Na +1 M2 site. Hence, if this mixture replaces 10% of the Al ions, the resulting jadeite would have the following composition:
(0.955 Na, 0.055 Ca)(0.9 Al, 0.05 5Fe, 0.045 B)Si 2 O 6 (14)
Other mixtures that can partially substitute for Al but which require charge cancellation substitution on Na sites include: (1) 64 mol-% Ni +2 and 36 mol % B +3 ; (2) 55 mol-% Co +2 and 45 mol % B +3 ; (3) 26 mol-% Fe +2 and 74 mol-% Be +2 ; (4) 31 mol-% Co +2 and 69 mol-% Be +2 .
It is interesting to note that the most common substitution in Imperial Green jadeite is Cr +3 for Al +3 and that this substitution is not strain free. A strain-free Imperial Green jadeite should substitute a mixture of 78 mol-% Cr +3 and 22 mol-% B +3 for Al +3 . For example, if this mixture replaced 1% of the Al +3 ions, the Imperial Green Jadeite would have the following composition:
(Na)(0.99 Al, 0.0078 Cr, 0.0022 B)Si 2 O 6 (15)
This jadeite is charge neutral and strain free. Dissolution of Cr into this lattice is easier than dissolution of Cr alone into stoichiometric jadeite, i.e., NaAlSi 2 O 6 .
The absence of lattice strain also affects the grain size of jadeite recrystallized from the glass by reducing atomic nucleation and growth barriers.
While the invention has been described with reference to a preferred embodiment, those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. In this application all units are in the metric system and all amounts and percentages are by weight, unless otherwise expressly indicated. Also, all citations referred herein are expressly incorporated herein by reference.
EXAMPLES
In the Examples
A glass (designated as Y72 with an index of refraction of 1.49742) was melted with a stoichiometric composition of NaAlSi 2 O 6 and containing 0.17 wt-% of Cr 2 O 3 and then cast in the form of an ingot. Cylindrical samples with 0.410″ diameter and 0.400″ height were produced from the glass ingot. The cylindrical glass piece was wrapped all around first with single or multiple layers of 0.002″ thick tantalum foil and then with single or multiple layers of 0.015″ thick Grafoil®. The sample then was placed into a pre-formed pill made of high-purity graphite, sodium chloride, aluminum oxide, or hexagonal boron nitride powder; and loaded in high-pressure cell. Graphite powder is preferred because it is easier to form the pills and it does not melt during high-pressure run.
The cylindrical glass samples were annealed over a wide range of pressure (3 to 6 GPa), temperature (1000° to 1800° C.), and time (5 to 120 minutes) conditions using a cell design as illustrated and described for FIG. 2 . Typically, the process starts with the reaction cell being pressurized to a set pressure of ˜5.5 GPa. The electrical power was turned on when the pressure reached ˜96% of the set pressure. Initially, the glass sample was heated to 700° C. and held there for one minute. Thereafter, the temperature was increased to the set value in eight minutes and held at the set value for approximately one hour, after which the temperature was reduced to 200° C. over seven minutes. The pressure was reduced simultaneously from the maximum set pressure to 3.5 GPa, at which time the heating power was turned off. The cell pressure was held constant for two minutes and then slowly released. The reaction cell was removed from the high-pressure apparatus and jadeite sample recovered by mechanically removing the tantalum and Grafoil layers. It was found that both slow cooling and release of pressure significantly helped in reducing cracking and delamination of jadeite sample.
The samples were analyzed for jadeite phase by X-ray diffraction, Raman Scattering, FTIR Infrared transmission, density measurement, hardness, and index of refraction. The translucency and color of the sample were measured using SAS2000 calorimeter. Examples 1, 2, and 3 are the high-pressure and high temperature runs made using Y72 glass containing 0.17 wt-% Cr 2 O 3 .
Example 1
The sample (Y72-Ta-36) was annealed at 5.2 GPa and 1550° C. for 1 hour. The examination of the sample showed a dense highly translucent green material. The density of the sample was 3.30 gm/cc indicating that glass had fully converted to the jadeite phase. The sample was semi-polished to cabochon shape with a thickness of 2.7 mm. The index of refraction was 1.65480. The calorimeter measurement yielded following values.
L*=61.2 a*=−55.1 b*=31.8
Example 2
The sample (Y72-Ta-40 b ) was annealed at 5.2 GPa and 1575° C. for 1 hour. The run resulted in a dense highly translucent green material with a density of 3.31 gm/cc. The sample was semi-polished to cabochon shape with a thickness of 3.3 mm. The calorimeter measurement yielded following values.
L*=59.9 a*=−56.1 b*=31.8
Example 3
This sample (Y72-56) was annealed at 5.2 GPa and 1575° C. for 45 minutes without using tantalum foil around the glass cylinder. The run resulted in a dense highly translucent greenish yellow material with density of 3.32 gm/cc. The sample was semi-polished to cabochon shape with a thickness of 3.3 mm. The calorimeter measurement yielded following values;
L*=60.4 a*=−55.1 b*=31.5
The continuous spectrum of this sample is set forth in FIG. 14 . Again, an “Imperial” jadeite product has been made.
Example 4
Prior Art Comparison
In order to verify prior art of sintering glass powder by DeVries and Fleischer, supra, and Zhao, et al., supra, Y72 glass (sample Y72-54P) was crushed and −60/+100 mesh size powder was separated. The powder was loaded in the high-pressure cell and was sintered at 5.2 GPa and 1575° C. for 1 hour. A sintered compact was obtained which was almost opaque and light green in color. The density of the compact was 3.28 gm/cc. The compact was polished to 4.6-mm thickness. The colorimeter measurements yielded following:
L*=32.3 a*=−2.8 b*=3.2
The foregoing results clearly show that the solid-glass method described in the current invention (viz., conversion of solid block of glass to jadeite) provides superior results than that of prior art method (sintering and conversion of glass powder to Jadeite) in obtaining a gem quality jadeite with translucency and color comparable to those for natural Imperial grade green jadeite.
Example 5
A cylindrical glass sample (Y71-L1) with stoichiometric NaAlSi 2 O 6 composition, dimensions of 22.4 mm diameter and 10.2 mm thick, and weighing 47.2 carats was processed at 6.0 GPa and 1400° C. for 45 minutes. The run resulted in a white translucent material with dimensions of 20.3 mm and 8.9 mm thickness and with a density of 3.32 gm/cc, indicating that glass was converted to jadeite. XRD analysis further confirmed that the resultant sample is jadeite. This example shows that large jadeite samples can be made using the solid glass block approach.
Example 6
A glass sample (75-134-3) containing 4.2 wt-% Mn 3 O 8 and weighing 7 carats was surrounded by 0.015″ thick Grafoil layer and then pressed into a graphite pill. The sample was run at 6.0 GPa and 1400° C. for 45 minutes. The resulting sample was deep purple in color with density of 3.33 gm/cc, indicating that it was completely converted to jadeite.
The following examples (Example 7-11) were made with SP1 glass (jadeite material precursor glass block) having the stoichiometric composition of NaAlSi 2 O 6 and containing 0.17 wt.-% of Cr 2 O 3 . The glass samples were in the form of cylinders that measured 14.0 mm in diameter and were 7.6 mm thick. The samples were wrapped with a single layer of 0.38 mm thick Grafoil graphite sheet and then with a 0.051 mm thick tantalum foil. The following results were recorded.
Example 7
A precursor cylindrical glass sample (SP1-23) was annealed at 5.6 GPa and 1600° C. for 75 minutes. The examination of the sample showed a dense, highly translucent green jadeite material. The density of the jadeite sample was 3.33-gm/cc, indicating that the glass had completely converted to jadeite. The sample was semi-polished to cabochon shape with a thickness of 3.3 mm. The colorimeter results yielded following results.
L*=68.0 a*=−56.3 b*=32.6
Example 8
A cylindrical glass sample (SP1-24) was annealed at 5.6 GPa and 1650° C. for 45 minutes. The examination of the sample showed a dense highly translucent green material. The density of the sample was 3.33-gm/cc indicating that glass had completely converted to jadeite. The sample was semi-polished to cabochon shape with a thickness of 3.3 mm. The calorimeter results yielded following results.
L*=68.3 a*=−55.8 b*=31.9
Example 9
A cylindrical glass sample (SP1-25) was annealed at 5.3 GPa and 1600° C. for 75 minutes. The examination of the sample showed a dense highly translucent green material. The density of the sample was 3.33-gm/cc indicating that glass had completely converted to jadeite. The sample was semi-polished to cabochon shape with a thickness of 3.2 mm. The calorimeter results yielded following results.
L*=68.9 a*=−57.1 b*=31.9
Example 10
A cylindrical glass sample (SP1-27) was annealed at 5.6 GPa and 1650° C. for 45 minutes. The examination of the sample showed a dense highly translucent green material. The density of the sample was 3.35-gm/cc indicating that glass had completely converted to jadeite. The sample was semi-polished to cabochon shape with a thickness of 3.3 mm. The calorimeter results yielded following results.
L*=66.9 a*=−54.8 b*=32.8
Example 11
A cylindrical glass sample (SP1-31) was annealed at 5.6 GPa and 1700° C. for 25 minutes. The examination of the sample showed a dense highly translucent green material. The density of the sample was 3.35-gm/cc indicating that glass had completely converted to jadeite. The sample was semi-polished to cabochon shape with a thickness of 4.0 mm. The colorimeter results yielded following results.
L*=65.9 a*=−61.5 b*=37.5
The results reported for Examples 7-11 are summarized below in the following table.
TABLE 5
Example #
ID #
Thick (in)
L*
a*
b*
C
Hue Angle
GPa
Time (min)
Temp ° C.
Density (g/cc)
7
SP1-23
0.129
68.0
−56.3
32.6
65.1
149.9°
5.6
75
1600
3.33
8
SP1-24
0.130
68.3
−55.8
31.9
64.3
150.3°
5.6
45
1650
3.33
9
SP1-25
0.125
68.9
−57.1
31.9
65.4
150.8°
5.3
75
1600
3.33
10
SP1-27
0.130
66.9
−54.8
32.8
63.9
149.1°
5.6
45
1650
3.35
11
SP1-31
0.158
65.9
−61.5
37.5
72.0
148.6°
5.6
25
1700
3.35 | A jadeite material has a thickness in excess of about 1.0 mm and CIELAB indices of L*>42, a*<−6, and b*>+6. The grain size of the jadeite material is less than about 30 microns and is an equiaxed grain structure. The jadeite material has an optical transmission peak between 500 and 565 nm with an I/I O optical transmission ratio of over 40%. The first step in making the jadeite material is to wrap a glass block, convertible by HP/HT into jadeite and having a nominal composition of NaAlSi 2 O 6 , with a graphite or refractive metal sheet. The wrapped glass block is placed in an HP/HT apparatus, rapidly heated, and subjected therein to a pressure in excess of about 3 GPa and a temperature in excess of about 1000° C. for a time adequate to convert the glass block into jadeite. The jadeite material then is cooled and the pressure subsequently released. | 1 |
FIELD OF THE INVENTION
This invention relates to electronic testing of circuits, such as integrated circuits at operational speeds under varying environmental conditions. More particularly, it relates to the testing of the response of digital electronic devices in order to properly determine the functionality of such devices, in which any test circuit it is at least partially contained within the device under test. More particularly, the invention relates to recording of times of failure. The invention also relates to the testing of electronic integrated circuits while the integrated circuit devices are in wafer form prior to singulation.
BACKGROUND OF THE INVENTION
Integrated circuit memory devices, such as dynamic random access memories (DRAMs) and static random access memories (SRAMs) undergo testing by the manufacturer during production and often by the end user, for example, in a memory test conducted during computer initialization. As densities of the memory device increase, so that individual IC's are capable of storing sixteen or more megabits of information, the time necessary for testing the IC's increases as well.
To reduce the testing time required, it is known in the art to place the DRAMs in a test mode. In a normal operating mode, a DRAM reads and writes one bit at a time, with exceptions for special operating modes. In the test mode, the parts are addressed in a manner which provides a series of outputs from the full array on the part in an expeditious manner, as distinguished from the memory array parts such as normal operating mode, which is intended for rapid access of data. A DRAM could be tested in the normal operating mode, but the time required to conduct exhaustive testing is excessive.
SRAMS likewise undergo testing by the manufacturer. While operating conditions of SRAM's may make performance criteria easier to define, many of the tests which must be performed on DRAMs must also be preformed on SRAMs. The testing of SRAMs must often be performed at higher speed because of the faster response expected from these parts.
In addition, there is an increased interest in providing parts which are fully characterized prior to packaging. This is desired not only because of the cost of the package, but also because there is demand for multichip modules (MCMs), in which multiple parts in die form are tested and assembled into a single unit. While there are various techniques purposed for testing, burning in and characterizing a singulated die, it would be advantageous to be able to "wafer map" the die prior to assembly with as many performance characteristics as possible. Ideally, one would want to be able to map the wafer with full device characterization.
MCMs create a particular need for testing prior to assembly, as contrasted to the economics of testing parts which are discretely packaged as singulated parts. For discretely packaged parts, if the product yield of good parts from preliminary testing to final shipment (probe-to-ship) is, for example, 95%, one would not be particularly concerned with packaging costs for the failed parts, if packaging costs are 10% of the product manufacturing costs. Even where packaging costs are considerably higher, as in ceramic encapsulated parts, testing unpackaged die is economical for discretely packaged parts when the added costs approximates that of cost of packaging divided by yield: ##EQU1## where C=cost
C DIE =manufacturing cost of functional die
C ADDL .KGD =additional cost of testing unpackaged die in order to produce known good die (KGD)
Note that in the case of discretely packaged parts, the cost of the die (C DIE ) is essentially not a factor. This changes in the case of MCMs: ##EQU2## Note that again C DIE is not a factor in modules having identical part types; however, the equation must be modified to account for varied costs and yields of die in modules with mixed part types. With MCMs, the cost of packaging a failed part is proportional to the number of die in the module. In the case of a ×16 memory array module, where probe-to-ship yield of the die is 95%, the costs are: ##EQU3## so the additional costs of testing for known good die (KGD) may be 16 times the cost of testing after assembly of an unrepairable module in order to be economical. This, of course, is modified by the ability to repair failed modules.
One of the test procedures which is used to determine the viability of semiconductor integrated circuits is burnin. In the burnin procedure, the parts are exercised for a period of time with different temperature cycles, including at elevated temperatures. This procedure provides an indication of the operation of the device at the different operating temperatures, and also results in a determination of early part failures. During the burnin process, such early failures, known as "infant mortality," is predicted to occur within a particular amount of time. Therefore, if it can be determined that almost all such failures occur within the first 48 hours of burnin testing, then the burnin test can be completed within that time period. Such factors as temperature, process and device type influence when failures stop happening, so the specific burnin time period will vary with part type and other factors. In the case of testing of packaged discrete devices, each device is able to be separately monitored by external test equipment, so that the external test equipment can be used to provide an indication of the time of failure of that particular part. On the other hand, if testing is be achieved prior to the parts being singulated, it is necessary to either provide external equipment with an indication of the performance of each individual part or to record the failure of each individual part for later mapping.
In actual practice, it is common to matrix discrete parts on a DUT (device under test) board, so that each part is exercised simultaneously. It is nevertheless possible to obtain a general indication of failure by sensing the parts within the matrix.
Digital electronic circuits generally employ two-state output terminals to convey binary logic information. Such two-state output terminals produce one of two output voltages: a relatively high voltage, or a relatively low voltage. These two discernable voltages define two possible binary logic states. The low voltage defines a "0," "false," or "low" logic state. The high voltage defines a "1," "true, or "high" logic state. A voltage corresponding to a "low" is defined to be below a first threshold voltage and a voltage corresponding to a "high" is defined to be above a second, higher, threshold voltage. A voltage between the first and second thresholds is not a valid logic state, and is avoided (except during transitions between valid states) by the specific operational parameters of the electronic devices formed in the integrated circuit or other digital circuitry.
Output terminals of digital circuitry, and integrated circuits in particular, can be constructed to produce a third state. This additional or third state is not defined by a voltage level, but instead is indicated by a high impedance state at the signal terminal. Such a high impedance signal state is assumed during certain operations or under specified conditions. For example, in memory integrated circuits a high impedance state has been used on a data terminal to indicate failure during a testing mode of operation.
The high impedance state or "tri-state" does not usually correspond to a logic state. In some memory chips, such a high impedance state is useful where multiple data terminals are to be electrically connected to a common data bus. The memory of the associated computer control circuitry allows a single memory chip to operate while the data terminal of other chips are placed in a high impedance state. Thus, a single input terminal, with control circuitry selecting which of the output terminals is to be active at any given time. However, the high impedance signal state of a three-state signal terminal can also be used to convey information.
The ability to provide built-in test equipment for semiconductor integrated circuits permits testing to be accomplished in a simplified manner by means of a small number of conductors. In one configuration, testing can be accomplished by applying a supplemental conductive metal mask on the wafer and connecting the wafer to as few as two connections. A built in test circuit on each individual die can perform the test, and record the results of the test. The recorded results can then be read on the discrete die.
In one purposed system, an additional metal mask is applied to the completed wafer and connections to power and ground are made through the mask. After completion of the tests, the mask is stripped and the integrated circuit devices may be scanned for the results of the test. The results may be stored in a PROM arrangement, whereby a failure is indicated by a particular logic output of the PROM section.
The discussion of PROM storage of test information in the present invention is meant to describe the storage of information regarding the test, regardless of whether the format of the stored information conforms with standard PROM definitions and protocols. The purpose of the storage of the test information is simply to permit reading of the test results from the part subsequent to the test.
SUMMARY OF THE INVENTION
In accordance with the present invention, a test circuit is provided for an integrated circuit device, whereby an additional conductive layer is deposited on a semiconductor wafer onto which the semiconductor devices have been formed. The additional layer provides a conductive path to power the test circuits and allows the use of very few electrical connections in order to permit testing of the devices while still on the wafer. The ability to test the devices while still on the wafer facilitates burning in the wafer prior to singulating the parts, since it is not necessary to establish electrical connections at contact points on the individual integrated circuit devices. In one embodiment of the invention, the additional conductive layer is a metal mask and in a further aspect of that embodiment permits external connections to be accomplished at locations outside the die areas, thereby avoiding damage to the integrated circuit devices.
Subsequent to testing of the die in wafer form, the metal mask is stripped and the die are singulated. According to another aspect of the invention, the built in test circuit, without the metal mask may be caused to perform further tests by establishing further connections to the test circuit. In one aspect of the invention, further tests are effected by increasing a test speed by the test circuit. It is also possible to separately address the individual integrated circuit devices in order to read a recorded output of failure detection period.
According to a further aspect of the invention, an internal test device on an integrated circuit sequences through timed counters in order to provide an indication of the time during test at which a failure has occurred. The reading of PROM recorded information is then effected, thereby providing an indication of the failure of the part in further indication of the time of failure in order that an indication of whether the burnin cycle is sufficiently long may be obtained from the recorded information.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top view of a plurality of semiconductor integrated circuit devices on a section of a semiconductor wafer showing the incidents of on pads and "streets" separating the integrated circuit devices;
FIG. 2 is a schematic block diagram showing the use of an on-chip self test circuit in accordance with the present invention;
FIG. 3 shows a nonvolatile register circuit, using a matrix of fuses, which is used to provide an indication of time and occurrence of failure modes; and
FIG. 4 shows a nonvolatile register circuit, using an array of antifuse elements, which is used to provide an indication of time and occurrence of failure modes;
FIG. 5 shows the use of a second address circuit with a nonvolatile register array, used to provide an indication of time and occurrence of failure modes;
FIG. 6 shows a timer circuit used in the circuit of FIG. 2, in which a plurality of counters provides a timer output;
FIG. 7 shows the configuration of the gates used in the timer circuit of FIG. 6;
FIG. 8 shows details of an oscillator circuit used in the self test circuit of FIG. 2;
FIG. 9 shows a clock generator circuit used in the self test circuit of FIG. 2;
FIG. 10 shows a pattern generator circuit used in the self test circuit of FIG. 2; and
FIG. 11 shows use of a metal mask to provide several conductive lines to each die in order to interconnect test pins on a semiconductor wafer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a top view of a portion of semiconductor wafer 11, showing several semiconductor die 13. The semiconductor die, 13 are the electronic circuitry of an integrated circuit devices and are typically mounted to a lead frame or other external connection device (not shown). The die 13 are typically singulated by use of a wafer saw, which grinds the wafer 11 along the wafer cut zones 15 separating the die 13, usually referred to "streets". While the action of the wafer saw normally causes any circuitry which extends into the streets to short to substrate, this is usually avoided by terminating circuit traces prior to their reaching the streets 15.
In accordance with a preferred embodiment of the invention, each die 13 has test circuitry (to be discussed later) thereon. This allows a matrix of conductive traces 21, 22 to extend across the wafer 11 in order to perform functional tests and to exercise the circuitry on each die 13 prior to the die 13 being singulated by being cut from the remainder of the wafer 11 at the streets 15.
In order to accomplish this, the matrix of circuit traces 21, 22 must be connectable to the test circuitry on each die 13 and the matrix of conductive traces 21, 22 must be removed prior to wafer cut.
In accordance with the preferred embodiment, the test circuitry on each die 13 included a nonvolatile memory portion on which tests results on wafer level testing may be recorded. Thus, while all of the die 13 on the wafer 11 are tested simultaneously, it is possible to use probe techniques to separately read the test results on each individual die 13. Since the test circuitry is on the die 13, it is also possible to accomplish a more thorough test regimen at wafer level and to simultaneously test all the die 13 on a wafer 11. Significantly, the ability to simultaneously test all of the die 13 on a wafer 11 will also provide an opportunity to simultaneously test all the die on multiple wafers, including environmental testing, at least of the unpackaged die 13.
In order to permit singulation of the die 13 by use of a wafer saw, it is necessary to remove the conductive traces 21, 22, at least to sever the traces where the traces 21, 22 cross the streets 15 between adjacent die 13. In the preferred embodiment this is accomplished by removing the entire layer of the traces 21, 22, known as a "metal mask layer." This can be accomplished by use of mechanical planarization techniques, such as chemical-mechanical planarization (CMP) or other processes which etch or remove metal.
The CMP process uses a large abrasive disk upon which the wafer 11 is engaged, thereby abrading material from the top surface of the wafer 11. In the case of the conductive traces 21, 22, these are deposited over a passivation layer, and so removal by CMP abrasive techniques which merely accomplish a planarization of the passivation layer. At points in which the conductive traces 21, 22 contact circuitry on the die 13, the material from the matrix of conductive traces 21, 22 would very likely not be completed abraded. This should not cause a problem, since those locations would remain level with the passivation layer and would not hinder package. The conductive locations may still be used for probe activity, thereby enabling one to perform further testing of the die subsequent to the removal of the conductive layer.
FIG. 2 shows a block diagram of the test circuitry with associated RAM circuitry. The figure shows a configuration for an on-chip test circuit for use with a semiconductor array circuit. Example of semiconductor array circuits are Static Random Access Memories (SRAMs), Dynamic Random Access Memories (DRAMs), as well as logic arrays and other circuits which include a repeat pattern of logic circuit elements (not separately shown) are normally addressed through address registers 41 which controls the addressing of logic circuitry (not shown) on the die 13. Address data is supplied through in/out ports 43 which, in the case of SRAMs, may include separate ports for data in and data out. The data transmitted through the data in/out port 43 is written to or read from addresses designated by the address register 41.
An address register buffer 45 is used to transmit address commands to the address registers 41 in accordance with an address protocol, as defined under JEDEC Standards. In order to test the circuit array on the die 13, the address buffer 45 has a test mode, wherein a test enable signal controls an amplifier which transmits a pattern received from an address counter 51. A pad 53 for indicating the test mode is required. The test enable signal is provided through the test pad 53 and is used to enable the address buffer 45, as well as controlling an oscillator 55 and a clock generator 57. The address counter 51 provides a signal to a counter 59. The counter, in turn, controls a control generator 61 and controls a pattern generator 63.
The pattern generator 63 provides a signal to a timer 65 and simultaneously to data in/out circuit 67. A data compare circuit 69 compares data in with data out and generates an error signal to indicate a failure mode. The timer 65 then provides a timer signal, which, when the timer signal coincides with the error signal "burns in" an indication of such failure at a PROM 71.
Referring to FIG. 3, the PROM section 69 consists of a matrixed array of addressable fuse elements 73. In order to sequence these elements to determine time of failure, current to the elements 73 is selectively gated in response to signals from the timer 65, which gates a matrix of transistors 75, 77. In the embodiment shown, the fuse elements 73 are shown as resistive fuses, although other types of fuse elements may be used, provided that the current supply to the die 13 is sufficient to cause the fuse elements 73 to change conductive states upon detection of an error signal.
Likewise, it is also possible to use antifuse elements, whereby an error signal will cause the antifuse element to "short", and thereby be conductive. Typically these antifuse elements take the form of diodes 83, shown in FIG. 4. In any case, the antifuse element 83 changes its conductive state upon the coincidence of an error signal with count signals which direct a clock count to a particular antifuse element 83.
Accordingly, each fuse or antifuse element 73, 83 represents one bit, and bits correspond to a timing of error signals. The fuse or antifuse elements 73, 83 therefore represent nonvolatile register elements.
FIG. 5 shows the use a second address circuit 101 connected to nonvolatile register elements 103, which may be fuse or antifuse elements, such as the fuse or antifuse elements 73, 83 shown in FIGS. 3 and 4. The second address circuit 101 makes it possible to overcome a requirement for high potentials and currents for writing to the nonvolatile register elements 103 of the built in test circuit. By designing the nonvolatile register elements 103 to be written at normal operating potentials, the nonvolatile register elements 103 would be more readily written to. The second address circuit would be current limited, so as not to change the logic states of the nonvolatile registers and thereby permitting the nonvolatile registers to be read without inadvertently writing to the nonvolatile register elements 103.
Such a technique of using a separate address circuit is particularly adaptable to antifuse elements 83, since an antifuse element 83 can easily be written to by providing sufficient current, and by limiting current, the antifuse elements 83 can be prevented from being written to.
It is also possible to provide a current limiter in a read/write address circuit, such as shown in FIGS. 3 and 4. This would also have the effect of positively limiting current to the nonvolatile memory during read operations.
FIG. 6 shows a timer circuit 65 used to provide timed outputs to the PROM section 69 (FIG. 3). The timer 65 consists of a plurality of gates 111, which are used to sequence the gating devices 75, 77 of the fuse matrix 69. These gates 111 receive signals from which correspond to signals from the address generator 51 in order to provide the appropriate timing sequence, once an enable the signal is provided through the test pad 53. FIG. 7 shows the configuration of the gates 81.
FIG. 8 shows an oscillator circuit 55 used to provide a variable speed output for testing circuitry on the die 13 at different speeds. A plurality of adjustable delays 151-154 are used to generate a series of output timing signals, at an "advance" node 157. A "slow" mode is established by providing a "slow" enable signal, at a "slow mode" node 159. While "slow mode" node 159 is shown providing inputs to delay 154, similar nodes (not shown) would be applied to adjustable delays 151-153, thereby providing a capability of substantial adjustment in clock speeds.
A clock generator circuit 57 is shown in FIG. 9, whereby a series of mask options are able to further adjust speed. The "slow mode" node 159 of FIG. 8 is able to be connected through a top mask layer, which is removed subsequent to burning testing of the die 13, whereas the mask options are generally enabled as a part of a design of the part prior to fabrication of the part. While a particular configuration of mask options and slow nodes is shown, it is anticipated that the particular arrangement of speed control methods will vary on different part designs: The "slow node" 159, when grounded, inactivates the slow mode.
FIG. 10 shows a typical pattern generator 61. The purpose of the pattern generator 63 is to provide sequences of Data for writing and comparing "read" data for normal operators, so that an entire array of logic circuits (SRAM cells) may be tested.
It is also possible to provide several conductive lines to each die 13, as shown in FIG. 11. If this is done, the additional lines may be caused to overlap in a multiple layer arrangement (not separately shown) or each row of dies will have a separate set of conductive lines. Separate conductive lines would permit the test results from the individual dies to be separately read from a location remote from the dies 13, and most likely remote from the wafer 11. Preferably, in such an arrangement, each die 13 would have at least one unique connection, typically at least one conductive line which connects with that die. That one conductive line would establish a unique address for the die in order that die functions may be separately performed. A significant die function which would be performed separately is the transmission of data. The separate transmission of data may be accomplished by separately enabling the data or by having separate data outputs, or any other technique which will result in the data output being discrete.
OPERATION
The oscillator 55 divides the initial operational timing for both the address registers 41 and the address counter 51. The oscillator 55 receives a test enable signal from the test pad 53 in order to cause the oscillator 55 to become operational. A second operational state is accomplished by the enablement of fast and slow modes of oscillator operation.
"Slow mode" (node 59 of FIG. 8) automatically comes up for burnin. The fast mode can be made by grounding the slow node during further testing.
It is anticipated that the ordinary burnin functions of the die 13 while in wafer form would be accomplished at a slow speed. This is both because the requirement that functional die circuitry be allowed to exercise and that this be accomplished at the varying temperatures which are typical of burnin operation. Once the matrix of conductive traces 21, 22 has been removed from the wafer 11, it is then possible to perform parametric tests on the individual die 13. At that time, the oscillator is enabled to operate at a higher rate, so that tests can be performed at a higher speed.
This accomplishes two things. The first is the ability to provide a much more tightly controlled test environment, as the circuitry on the die 13 is exercised at higher speed. Secondly, during testing of the die circuitry on an individual bases, it is important that the test speed be increased, particularly as a large number of circuit elements much be tested. This can be appreciated when it is considered that, when the entire wafer 11 is tested in parallel, over 100 die, and sometimes upward of 1000 die, are tested simultaneously. A reduction of test speed under such circumstances is not especially significant. In the case of burning testing, speed of testing is less important than the opportunity to exercise the part. In the usual case, the cycle time at which tests can be completed is not even a factor because a minimum time of operation of the parts under the burnin environmental conditions is specified.
The clock generator 57 receives the oscillator signal and further causes the address lines to be registered. The oscillator 55 controls the speed at which the addresses are sequenced. This is accomplished by a gating arrangement, whereby a pair of gates 91, 92 are switched in order to provide different delay times for address pulses. In addition, a plurality of mask options enable the further adjustment of a time delay by selectively bypassing amplifier stages.
In the preferred embodiment, the fast enabling signal is provided during test sequences by applying the fast enabling signal at probe.
In an alternate embodiment, the provision of the fast and slow enabling signals is accomplished by the use of a current divider whereby the matrix of conductive traces 21, 22 pulls the fast and slow pins to the appropriate states for slow operation. After the matrix of conductive traces 21, 22 is stripped, the fast and slow enable signals may be provided by providing a separate probe pad. In that embodiment, the clock generator 57 runs fast with the matrix of conductive traces 21, 22 stripped unless the slow enable signal is applied. This is accomplished by the use of a resistive circuit, whereby, with no enable signal applied, the clock generator 57 is allowed to float to a state wherein the fast mode of operation is enabled. The clock generator 57 generates a two phase output which is used to provide a timed signal to the address registers 41.
The clock generator 57 provides its signal to the address registers 41, which provide addressing information to address the circuitry on the die 13 during the test operation period. The pattern generator 63 generates odd and even inputs such that a pattern is written in to RAM. An output of the RAM is then read out and the output is compared with the pattern which is again generated by the pattern generator 63. The series of patterns are typically checker board, inverted checker board, row stripe, inverted row stripe, column stripe, inverted column stripe, all 0's and all 1's This sequence is calculated to determine whether the array is responding in an appropriate manner or if the array has a fault. The pattern generator 63 provides its signal to the data in/out circuit 43 in accordance with the patterns described.
The following describes a method of doing self test which allows the RAM chip to test itself. This is particularly helpful when a self test is required during burnin testing. This particular test methodology requires only two connections to the die: (V CC , and ground). If the substrate voltage is to be forced, then a connection to the substrate could also be made.
Referring again to FIG. 2, when a potential is applied to the test pad 53, the circuitry on the die 13 enters a test mode. In the preferred embodiment, the potential applied to the test pad 53 is a grounding potential, although the use of an operating potential of the circuit (usually either 3 or 5 volts) would be equally acceptable. When the pin left unconnected, the device is not in test mode.
When the pin 53 is grounded, the device will start the self test sequence. Self test circuitry for random access memory must provide circuits on board to sequence through the address lines. An address counter that generates a binary count to the address pins is required. A driver at each input pin must tri-state itself when the part is not in test mode. When the RAM is in the test mode, the tri-state driver will drive each pin (address lines, control inputs, and data inputs) when in the WRITE cycle. The address counter is incremented by an on board oscillator. The oscillator frequency determines the test cycle time. For a synchronous SRAM the oscillator period is divided into four equal parts, as shown in the oscillator circuit of FIG. 8. The first edge out is the square wave advance signal that causes the counter to count. This positive edge will cause the address to be registered, and the RAM to execute a cycle. The negative edges of Advance and then the clock (CLK) are then generated. FIG. 12 shows the 1 bit of logic for the counter. The carry in (CIN) is feed from the lower stage carry out (COUT).
Each time the counter cycles clear through all the address count, the WE(Read/Write) control is changed: (WRITE the complete RAM then READ the complete RAM). Other controls (OE, BWL, BWH, and DLE) associated with a READ or WRITE operation are also controlled off this bit of the counter. This control is just the next count in the counter. The next three bits in the counter are used to determine which pattern will be generated for writing and comparing the output. (Test patterns such as checkerboard, checkerboard bar, row strip, row strip inverted, column strip, column strip inverted, all 1's, all zero's, diagonal, and diagonal bar) are generated.
Since the self test circuitry is used for burnin, it must do several functions necessary for the burnin tests. It is important for burnin to know when the burnin failures happen. In order to make sure that all the burnin failures have occurred during the burnin time, a recording of the time for the failure is necessary. Most, if not all, of the failures should occur during the first quarter and at least by the first half of the burnin time. If the failures happen in the first part of the burnin, there is a strong indication that all the infant mortality failures have occurred and the burnin time is adequate. The counter is extended in order to have a real time timer available on chip. The last few (2 up to 5) most significant bits of the counter will indicate which portion of the total burnin time the failure occurred. When a failure occurs, a fuse will be blown corresponding to the most significant bit of the timer. Normal burnin times are of the order of 12 to 48 hours. If the last 5 bits are used, and the timer counts for approximately 100 hours, each count of the last 5 most significant bits will represent 3 hours of burnin time. See FIG. 4 for a description of the counters and input circuitry.
As shown in FIGS. 3-5, if a error occurs during the burnin test, the counter is keeping track of the time. The last five bits of the timer is shown as count <18:23>. For a 96 hour timer (assuming a 600 ns cycle time) each bit represents 3 hours. The corresponding time indicator fuse will be blown when ever a error is detected. After the burnin test has been done, the fuses can be read during the final wafer sort before packaging. A fuse is also blown as a test confirmation, in order to indicate that the part has been tested and the high current fuse to each die has not blown.
If the complete wafer 11 is tied to V CC and ground, each device will do its own self test. If a failure occurs, a fuse corresponding to the time of failure is blown. After the burnin time is complete, a wafer sort will be done. Part of the wafer sort will be a verifying that no fuses were blown. If a fuse was blown, the data will be cataloged, and analyzed to verify the burn-in was of sufficient time.
The integrated circuit device therefore includes a functional circuit and a test circuit. While the test circuit is certainly functional as a test circuit, the purpose of the integrated circuit device is to perform a diverse function, such as RAM storage, so that the test circuit is distinguished from the functional circuit in that sense. Additionally, the test circuit will in the preferred embodiment use some portions of the functional circuit, such as a refresh circuit. | Integrated circuit devices are fabricated with an additional conductive layer deposited on a semiconductor wafer onto which the semiconductor devices have been formed. The additional layer provides a conductive path to power the test circuits and allows the use of very few electrical connections in order to permit testing of the devices while still on the wafer. The ability to test the devices while still on the wafer facilitates burning in the wafer prior to singulating the parts, since it is not necessary to establish electrical connections at contact points on the individual integrated circuit devices. In one embodiment of the invention, the additional conductive layer is a metal mask and in a further aspect of that embodiment permits external connections to be accomplished at locations outside the die areas, thereby avoiding damage to the integrated circuit devices. Subsequent to testing of the die in wafer form, the metal mask is stripped and the die may be singulated. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT/KR2011/002250 filed Mar. 31, 2011, which claims the benefit of Korean Patent Application No. 10-2010-0042633, filed with the Korean Intellectual Property Office on May 6, 2010, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to an apparatus for inspection and analysis, more specifically to an apparatus for analysis of an electroluminescence (EL) sample.
BACKGROUND ART
[0003] A solar cell, which is a semiconductor device that converts solar energy to electric energy, has the junction forms of a p-type semiconductor and an n-type semiconductor and has the same basic structure as a diode. When light is incident at a semiconductor, an interaction occurs between the absorbed light and materials constituting the semiconductor. Then, electrons, which have negative charges and positive charges, and positive holes (where electrons are missing) are generated, allowing the electric current to flow or generating electricity. This is referred to as the photoelectric effect. There are two types of semiconductors, one being n-type semiconductors, which attract electrons having a negative charge, and the other being p-type semiconductors, which pull positive holes having a positive charge. The solar cell has these two types of semiconductors joined together. Generally, the negative charges generated in the semiconductor are pulled toward the n-type semiconductor, and the positive charges are pulled toward the p-type semiconductor. Accordingly, the negative charges and the positive charges are gathered, respectively, at either electrode. By connecting both electrodes with an electric wire, electricity flows, and electric power can be obtained. Here, the numbers of the positive charges and the negative charges become the same. Accordingly, power becomes continuously generated as long as there is light. That is, once light is incident, an interaction between the light and the materials occurs within the semiconductor to generate the positive charges and the negative charges, and electricity is flowed by discharging the charges to the outside, allowing the electric energy to operate a motor or turn on a light. Accordingly, the solar cell can covert not only the sunlight but also the light from a fluorescent lamp to electricity.
[0004] Solar photovoltaic power generation systems, which utilize solar cells, are expected to provide at least one of the solutions for the environmental problems and the energy problems caused by the global warming, and the solar photovoltaic power is expected to provide about 70% of the world energy in 2100. One of the most important issues for realizing the energy vision is the improvement of energy conversion. While crystalline Si solar cells takes up about 90% of the entire solar cell production, their efficiency, which is currently about 24.7%, is limited to improve up to 29%, and thus it is difficult to expect a dramatic improvement of the efficiency. The efficiency of 40.8% has been achieved owing to condensing operation of solar cells having a 3-junction structure of InGaP/InGaAs/Ge based on the III-V compound semiconductor technology, and an ultrahigh efficiency of over 50% is expected through multi-junctions, such as 4-junction, 5-junctions, etc.
[0005] An LED (light emitting diode) uses the process of emitting light (light-emitting recombination of electron-hole) while electrons of the semiconductor in a conduction band, which is an excited state, move to a valance band, which is a ground state. Used for practical LEDs are compound semiconductors, of which the band gap structure is a direct transition type. This is because a high probability of light-emitting recombination is achieved only if the momentum of electrons at a bottom of the conduction band and the momentum of the positive holes at a top of the valence band are almost the same. The light emitting color of the LED is determined by the energy band gap of the semiconductor materials constituting an active layer (i.e., light-emitting area). The band gap of GaAS is about 1.43 eV and emits a near infrared ray of 870 nm. A visible light LED uses a material having a greater energy band gap. Used for a high efficiency LED is a multi-layer film that is fabricated through epitaxial growth of a plurality of compound semiconductor films, which have different energy band gaps from one another. For materials for the board, GaAS (infrared ray˜visible light) or GaP (visible light) is used, and sapphire (Al 2 O 3 ) or silicon carbide (SiC) is used for blue light to ultraviolet ray.
[0006] During the early days of LED development, a simple p-n junction was used. The n-type area or p-type area that is close to a depletion layer was used as a light-emitting junction layer. This is an area containing impurities, and thus it was difficult to obtain a high efficiency LED. The most general way to improve the light-emitting efficiency is a double-hetero (DH) structure, in which the band gap of the p-type and n-type areas is made to be greater than the band gap of the active layer. While enhancing the effect of confining the electrons and the positive holes in a quantum-well structure by making the active layer thinner, it has been attempted to improve the density of electron state at an end of the band. The rate of optical power for an electric current put into the LED (i.e., external quantum effect) is determined by an efficiency of emitting the light from a chip and a light-emitting recombination ratio (i.e., internal quantum effect) excluding a Joule loss by series resistance including the electrodes. An LED includes a board and electrodes, by which some of the light generated by the active layer is absorbed. It is preferable that a band gap of the board material is bigger than a band gap of the active layer. Studies are currently underway for problems of surface ruggedness and deteriorated efficiency caused by mold materials, in addition to semiconductor materials.
[0007] As one of the inherent problems that must be solved for solar cells and LED devices, defective charge traps affect the operation characteristics, when the device is operated, by changing the operation conditions as active electrons and holes are captured. Accordingly, in order for such a device structure to take its place as a next generation device, device characteristics with reproducibility and durability are required, and systematics studies are required not only for thin films, which are still not solved, but also for the process of capturing the electrons and holes in a multi-layer structure, the distribution and structure of the traps in an optically-activated multi-layer structure, and energy distribution.
[0008] In the case of the trap that is present in the solar cell and the LED structure, the quantity of traps that can capture the charges is relatively increased compared to its size, and the trap is present in various energy levels. In the case of a poly crystalline structure of device thin film, it is deemed that there could be more traps in addition to the reported defective trap, but there is no analysis method that can cover all of the defective traps due to the limitations of energy band gap of the material, and the scope of observable trap is limited if one analysis technology is used. Moreover, an interface defective trap between layers that is deemed to be surely present is expected to affect operation characteristics of the device, and thus the importance of method of analyzing the surface and interface cannot be neglected. Accordingly, it is expected in the photoelectric device that the interface trap (IT) and the surface trap (ST), as well as the charge trap (CT), will affect the charge separation and its operation life in the structure because, the solar cells, which are exposed to outside environment unlike other devices, are more affected by the defective traps with an increased time. Therefore, by analyzing the precise origin of the charge trap and tracking and controlling its cause, it will be possible to make a contribution to the currently-demanded low-cost, high-efficiency solar cell and LED device.
[0009] Studies for analysis of non-destructive charge traps using principles of photo-electronic physics such as ELTS will be imperative for verification of a wide range of traps and evaluation of device performance in the area of next-generation solar cells and LED.
SUMMARY
[0010] The present invention provides an apparatus for analysis of an electroluminescence sample that can verify information about distribution, structure and energy distribution of defective charge traps that are present within an EL emission device such as a solar cell and LED.
[0011] The present invention also provides an apparatus for analysis of an electroluminescence sample that can integrally analyze information on lifetime of an EL emission device and an EL image as well as information on the defective charge trap through one analysis apparatus.
[0012] The present invention also provides an apparatus for analysis of an electroluminescence sample that can photograph and provide an EL image in micro units for verification of surface defect of an EL emission device.
[0013] An aspect of the present invention features an apparatus for analysis of an electroluminescence sample including: a pulse generator configured for applying a pulse driving signal to the electroluminescence sample; an electroluminescence (EL) detector configured for acquiring a light-receiving signal by receiving electroluminescence emitted from the electroluminescence sample as a result of application of the pulse driving signal; a temperature controller configured for varying the temperature of the electroluminescence sample; and an electroluminescence transient spectroscopy (ELTS) analysis unit configured for acquiring information on a defective charge trap existing in the electroluminescence sample by analyzing a change in a transient section of the light-receiving signal according to a temperature change of the electroluminescence sample.
[0014] In one embodiment, the pulse generator can generate a square wave pulse in correspondence with temperature change of the electroluminescence sample by the temperature controller, and the EL detector can detect EL emitted from the electroluminescence sample in response to the square wave pulse when the square wave pulse is applied.
[0015] In one embodiment, the light-receiving signal obtained by the EL detector can be one of a photo current signal, a photo voltage signal and a capacitance signal.
[0016] The ELTS analysis unit can obtain at least one of information about an activation energy level of the defective charge trap, a concentration of the defective charge trap and a capture cross-section of the defective charge trap by sampling two time points in the transient section of the light-receiving signal, calculating a difference of the light-receiving signal at the two sampled time points, and using a relation of change in the difference of the light-receiving signal according to the temperature change.
[0017] The ELTS analysis unit can further obtain lifetime information by analyzing the transient section of the light-receiving signal obtained at a fixed temperature, and the lifetime information can be at least one of information about a minority carrier and the defective charge trap and can be obtained by calculating a time constant of the transient section that changes exponentially.
[0018] The apparatus for analysis of an electroluminescence sample in accordance with an embodiment of the present invention can also include: a photographing device configured for obtaining an EL image for EL emitted from the electroluminescence sample; and a surface defect analysis unit configured for analyzing a surface defect of the electroluminescence sample based on the EL image.
[0019] A microscope can be positioned in front of the photographing device on an optical path of the EL, and the surface defect analysis unit can analyze the surface defect of the electroluminescence sample based on the EL image in micro units obtained from the photographing device.
[0020] The apparatus for analysis of an electroluminescence sample in accordance with an embodiment of the present invention can also include an optical separator configured for optical separation in such a way that some of the EL emitted from the electroluminescence sample is inputted to the EL detector and the other is inputted to the microscope.
[0021] The apparatus for analysis of an electroluminescence sample in accordance with an embodiment of the present invention can also include a spectroscope configured for detecting a desired wavelength only or cut off an undesired wavelength of EL light emitted from the electroluminescence sample.
Effect of Invention
[0022] An embodiment of the present invention can provide an apparatus for analysis of an electroluminescence sample that can verify information about distribution, structure and energy distribution of defective charge traps that are present within an EL emission device such as a solar cell and LED.
[0023] An embodiment of the present invention can also integrally obtain information on lifetime of an EL emission device and an EL image as well as information on the defective charge trap, saving time and cost for testing and analyzing the EL emission device.
[0024] An embodiment of the present invention can also photograph and provide an EL image in micro units for verification of surface defect of an EL emission device, improving the reliability and accuracy of the surface defect test.
[0025] An embodiment of the present invention can also analyze and measure the information on the defective charge trap and the information on the lifetime of the minority carrier for an apparatus that is integrated in an end product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 shows a brief configuration of an apparatus for analysis of an electroluminescence sample in accordance with an embodiment of the present invention.
[0027] FIG. 2 illustrates pulse driving signals applied to an electroluminescence sample and a photo current as a light-receiving signal having received EL emitted from the electroluminescence sample.
[0028] FIG. 3 illustrates a process of capturing and discharging a carrier and the carrier captured in a trap.
[0029] FIG. 4 illustrates a correlation of transient change of a light-receiving signal according to temperature change and a method of obtaining defective charge trap information through this.
[0030] FIG. 5 illustrates the exponential change of carrier density according to light received by a solar cell.
[0031] FIG. 6 illustrates a method of analyzing a lifetime based on transient sections that decrease exponentially with time through Optical ICTS (Isothermal Capacitance Transient Spectroscopy).
DETAILED DESCRIPTION
[0032] Since there can be a variety of permutations and embodiments of the present invention, certain embodiments will be illustrated and described with reference to the accompanying drawings. This, however, is by no means to restrict the present invention to certain embodiments, and shall be construed as including all permutations, equivalents and substitutes covered by the ideas and scope of the present invention.
[0033] Throughout the description of the present invention, when describing a certain technology is determined to evade the point of the present invention, the pertinent detailed description will be omitted. Moreover, numerals (e.g., first, second, etc.) in the description of the present invention are used only to distinguish one element from another.
[0034] When one element is described as being “connected” or “accessed” to another element, it shall be construed as being connected or accessed to the other element directly but also as possibly having another element in between unless otherwise specified.
[0035] Hereinafter, an apparatus for analysis of an electroluminescence sample in accordance with an embodiment of the present invention will be described with reference to the accompanying drawings.
[0036] FIG. 1 shows a brief configuration of an apparatus for analysis of an electroluminescence sample in accordance with an embodiment of the present invention.
[0037] Referring to FIG. 1 , the apparatus for analysis of an electroluminescence sample in accordance with an embodiment of the present invention can include a vacuum chamber 15 , a pulse generator 110 , a temperature controller 120 , a microscope 130 , an optical separator 142 , an EL detector 140 , a photographing device 150 , an amplifier 160 , an A/D converter 165 , temperature detection and control unit 170 , an analysis unit 180 , etc. As the elements illustrated in FIG. 1 are not essential, it is possible to realize an electroluminescence sample analysis apparatus having more or fewer elements depending on how it is designed.
[0038] By including the above elements, the electroluminescence sample analysis apparatus of the present invention can be utilized as an apparatus having three functions, namely, an ELTS (Electroluminescence Transient Spectroscopy) analysis apparatus, an electroluminescence lifetime analysis apparatus, and a near-infrared image analysis apparatus in an area of micro units. Hereinafter, these three functions of the electroluminescence sample analysis apparatus will be described one by one.
[0039] ELTS Analysis Apparatus
[0040] An electroluminescence sample 10 can be mounted in a mount member 125 and placed in the vacuum chamber 15 . Here, the pulse generator 110 generates and applies a pulse driving signal (a square wave pulse 21 in this example) to the electroluminescence sample 10 in the vacuum chamber 15 .
[0041] Once the pulse driving signal is applied as described above, the electroluminescence sample 10 emits an EL light. For example, in the case of an LED, an EL light in a pertinent color region (i.e., a pertinent wavelength band) can be emitted, and in the case of a solar cell, an EL light in a near-infrared region can be emitted.
[0042] Here, the principle of emitting EL is as follows. EL (electroluminescence) refers to an optical, electrical phenomenon that emits light as a result of recombination of charge carriers having different symbols, i.e., electrons and holes, when a strong electric field is formed or electric current flows through a material (generally, a semiconductor). In order to obtain the EL light, it is necessary to bring the electrons inside a crystal lattice to a higher energy level. Here, the light-emitting intensity depends on a defect density of the sample, and the fewer the defects are, the more photons are emitted.
[0043] In FIG. 1 , the apparatus is configured in such a way that the EL light emitted from the EL sample 10 is passed through the microscope 130 and then permeates through the optical separator 142 before being received by the EL detector 140 . However, this is merely an example of how the analysis apparatus in accordance with the present invention is configured so as to realize both the functions of the ELTS analysis apparatus and an EL image obtaining apparatus for analysis of surface defect in micro units.
[0044] Therefore, it shall be apparent that the apparatus can be designed differently from the configuration shown in FIG. 1 while the above-described two functions are simultaneously realized. In the case of FIG. 1 , some (i.e., permeated light) of the EL light inputted to the microscope 130 is received by the EL detector 140 through the optical separator 142 , and the other (i.e., reflected light) is received by the photographing device 150 , such as a CCD camera, but there can be different ways to design this configuration. For example, the optical separator 142 can be placed at a front end (optical input end) of the microscope 130 , instead of a read end (optical output end) of the microscope 130 . In such a case, the photographing device 150 will receive the EL light having passed through the optical separator 142 and the microscope 130 , but the EL detector 140 will receive the EL light having passed through the optical separator 142 only. Moreover, the microscope 130 and the EL detector 140 can be respectively placed where the EL light emitted from the EL sample 10 can be directly received, in which case the optical separator 142 can be omitted from the configuration.
[0045] Although it is illustrated in FIG. 1 that the EL light emitted from the EL sample 10 passes through the microscope 130 and then is received by the EL detector 140 or the photographing device 150 , this is only an illustrated example, and it is also possible that the EL light emitted from the EL sample 10 is received by the EL detector 140 or the photographing device 150 without passing through the microscope 130 . In addition, although it is illustrated that the EL light received by the EL detector 140 then passes through the amplifier 160 , this is also only an illustrated example, and it is possible to omit the amplifier 160 from the configuration. Meanwhile, it is possible to receive the EL light through a spectroscope (not shown), which separates a particular wavelength of the EL light emitted from the EL sample 10 . Here, the spectroscope can use, for example, a filter to receive a desired wavelength or cut off an undesired wavelength.
[0046] Afterwards, a light-receiving signal detected through the EL detector 140 can be sent to the analysis unit 180 through the amplifier 160 and the A/D converter 170 , as illustrated in FIG. 1 . Here, the EL detector 140 can be a photo diode or a photo detector, and the light-receiving signal obtained through the EL detector 140 can be a photo current signal, a photo voltage signal or a capacitance signal corresponding to the intensity of the EL light.
[0047] In an ideal case (that is, when there is no defect in the EL sample 10 ), the light-receiving signal obtained from the EL detector 140 will have a same wave form as the inputted pulse driving signal but, in reality, will have a wave form with transient sections, as illustrated by reference numeral 22 in FIG. 1 .
[0048] Since such a deformation in the wave form of the light-receiving signal is caused by the defect that is present in the EL sample 10 , it is possible to obtain the information about the defect that is present in the EL sample 10 by analyzing the transient sections of the light-receiving signal. This will be described below with reference to FIG. 2 to FIG. 4 .
[0049] FIG. 2 illustrates pulse driving signals applied to an electroluminescence sample and a photo current as a light-receiving signal having received EL emitted from the electroluminescence sample.
[0050] For ELTS measurement, once the pulse driving signal, such as the one shown in (a) of FIG. 2 , is applied to a junction of the EL sample 10 through the pulse generator 110 , the EL detector 140 senses the EL light emitted from the EL sample 10 to obtain the light-receiving signal according to a response function (current, voltage or capacitance) of the EL detector 140 . Here, the light-receiving signal can be like the one shown in (b) of FIG. 2 .
[0051] In (b) of FIG. 2 , in the case that the response function of the EL detector 140 is a photo current, the F˜C section is where a photo carriers of the EL detector 140 are generated by photo excitation of the sample and the detector current is suddenly increased, and the C˜D section is where the photo carriers generated in the F˜C section are captured in the trap and maintained in a quasi-steady state. The D˜E section is where the current is decreased again by recombination of the photo carriers. Lastly, the E˜F section is where the photo carriers captured in the trap are de-trapped by thermal energy, wherein the current here has a transient curve.
[0052] As described above, the E˜F section of the photo current signal has the form of a transient curve for the following reason, which will be described with reference to FIG. 3 . FIG. 3 illustrates a process of capturing and emitting the carriers as well as the carriers captured in the trap.
[0053] In a perfect crystal that has no crystalline defect and has atoms arranged periodically therein, a potential based on the position also has the shape of a periodical function. However, periodicity of the electric potential is broken where there is a crystalline defect, and such a distortion of potential forms traps for charged particles. Such traps forms a deep level within the crystal, and variables of the deep level are explained through the processes of recombination and generation of the carriers, namely, the processes of electron capture, electron emission, hole capture and hole emission (see (a) of FIG. 3 ).
[0054] The electron emission is a process of emitting an electron to a conduction band after the electron that has been in the trap gains energy, as shown in (a) of FIG. 3 , and the electron capture is a process of capturing an electron that transfers to the trap after the free electron that has been in the conduction band loses energy.
[0055] The hole capture, in which the electron that has been in the trap level loses energy and transfers to a valence band, is a process of the trap capturing a hole, as shown in (a) of FIG. 3 , and the hole emission, in which the electron having been in the valence band gains energy and is excited to the trap level, is a process of the trap emitting the hole. In any trap, the above 4 processes occur at the same time, and the concentration of free electrons is increased in the electron emission process, in which the electrons captured in the trap gain energy and are excited to the conduction band, and decreased in the electron capture process of the trap, in which the free electrons lose energy and transfer to the trap level.
[0056] In (b) of FIG. 3 , E c indicates the energy level of the conduction band, and E v indicates the energy level of the valence band, and E t indicates the energy level of the trap, and ΔE t indicates activation energy required for the electron captured in the trap level to be excited to the conduction band and function as the free electron. Moreover, n refers to the concentration of the free electrons in the conduction band, and n t and p t refer to the concentration of the trap having captures the electron and the hole, respectively. N t refers to the trap density.
[0057] Therefore, in the case that the defective charge trap is positioned in an energy level of the EL sample, it is possible to decrease the concentration of free electrons to be used for emitting EL through the electron-hole recombination process. This is because some of the electrons that would have transferred to the valence band are captured in the trap. As such, if some electrons that have been captured in the trap become to belatedly play the role of the free electrons by gaining the activation energy through the electron emission process, said some electrons generate the transient section, such as the E˜F section shown in (b) of FIG. 3 . Therefore, by knowing the activation energy (ΔE t ) required for excitation from the trap level to the conduction band, it is possible to verify the energy level (E t ) in which the trap is positioned.
[0058] Hereinafter, a method for obtaining information (i.e., activation energy, trap level, cross-sectional capture area of trap, trap concentration, etc.) on the defective charge trap that is present in the EL sample will be described with reference to FIG. 4 .
[0059] FIG. 4 illustrates a correlation of change in transient sections of a light-receiving signal according to temperature change and a method of obtaining defective charge trap information through this.
[0060] In the present invention, the defective charge trap information that is present in an EL sample can be obtained by prompting temperature change in the EL sample and then analyzing a change in the transient sections of the light-receiving signal obtained by the EL detector 140 pursuant to the temperature change.
[0061] That is, as shown in FIG. 4 , the analysis unit 180 of the EL sample analysis apparatus can obtain the information on the defective charge trap by sampling two time points (t 1 , t 2 ) in a transient section of the light-receiving signal, calculating a difference (I(t 1 )−I(t 2 )) of the light-receiving signal at the two sampled time points, and then using a relation of change in the difference of the light-receiving signal according to the temperature change.
[0062] For instance, as shown in FIG. 4 , by measuring the photo current signal the time point t 1 and the time point t 2 , the ELTS signal can be obtained with the following equation.
[0000] I n ( T )=[ i ( t 1 )− i ( t 2 )]/ K ( T )
[0000] I n ( T )= e n [exp(− e n t 1 )−exp(− e n t 2 )]
[0000] with K ( T )= qμ n Aτ n E ( N t +e n /β n ) [Equation 1]
[0063] Here, e n is an emission rate (rate window, sec-1); q is a quantity of electric charge of an electron; μ n is a mobility of an electron; A is an effective cross-section of a sample; E is an applied electric field; τ n is a relaxation time; and N t is a trap density. By using the condition of dI n /d t =0 from [Equation 1], the relation between the sampling time and the emission rate at a maximum ELTS signal location can be obtained as follows.
[0000] exp[− e n ( t 2 −t 1 )]=(1 −e n t 1 )/(1 −e n t 2 ) [Equation 2]
[0064] Here, the emission rate (e n ) is given as [Equation 3] shown below according to the temperature.
[0000] e n =Aσ t T 2 exp(− E t /kT ) [Equation 3]
[0065] From the above [Equation 3], the activation energy (ΔE t ) and the capture cross-section (σ T ) of the trap can be obtained.
[0066] That is, the relation of change in the difference of the light-receiving signal according to the temperature change as the form of an Arrhenius plot having a Gaussian distribution according to the temperature change, as shown in FIG. 4 , and thus, by drawing the Arrhenius plot, the activation energy (ΔE t ) of the trap can be obtained from the slope of the line, and the capture cross-section (σ T ) of the trap can be also obtained.
[0067] EL Lifetime Analysis Apparatus
[0068] In the light emitted in a solar cell or an LED device, a luminous gain generated when the applied charge carrier is trapped by the trap and impurities is significantly reduced by the trap and impurities. Therefore, an analysis of lifetime (τ) of a minority carrier in a material can be a method for evaluating whether crystalline materials can be used as the PV (photovoltaic) material.
[0069] For this, the analysis unit 180 of the EL sample analysis apparatus in accordance with the present invention obtains the information on lifetime of the minority carrier by analyzing the transient sections of the light-receiving signal obtained at a fixed temperature. Here, the charge density of the minority carrier changes exponentially, as shown in FIG. 5 , and the transient sections of the light-receiving signal represents the electric property of the minority carrier, and thus the information on the lifetime of the minority carrier can be obtained by calculating a time constant of the transient sections that changes exponentially.
[0070] That is, in the present invention, the lifetime of minority carrier, which is one of the indicators of apparatus quality of an EL sample, such as a solar cell, LED, etc., and affects its efficiency, is measured through the ELTS analysis apparatus. In a method of measuring the lifetime of solar cell and LED through this apparatus, the lifetime of the minority carrier and trap, which is exponentially decreased with time, is analyzed by analyzing the transient sections from the response function (current, voltage or capacitance) signal obtained through the EL detector from the EL emitted from a semiconductor sample by applying the pulse type of driving signal to the sample.
[0071] Moreover, the lifetime can be analyzed by measuring the time division sections for electrostatic capacity among the response functions of the light at a particular temperature. In other words, the lifetime, which is exponentially decreased with time, according to the transient sections is analyzed through optical ICTS (Isothermal Capacitance Transient Spectroscopy) (see FIG. 6 ). The equation for this is as follows.
[0000]
S
(
t
i
K
,
T
)
=
[
C
(
Kt
i
)
-
C
(
t
i
)
]
/
ln
K
C
(
t
i
)
=
Δ
C
(
t
i
)
/
C
0
?
=
(
N
t
/
2
N
A
)
[
e
p
0
/
(
e
n
0
+
e
p
0
)
]
exp
[
-
(
e
n
0
+
e
p
0
)
t
i
]
?
indicates text missing or illegible when filed
[0072] Here, K is a constant; N t is the concentration of a trap; N A is the concentration of an acceptor; e p o is an optical hole emission rate; and e n o is an optical electron emission rate.
[0073] Today, the cell defect and the lifetime for the solar cell and the LED product are measured with separate test instruments. Therefore, with the EL sample analysis apparatus of the present invention, the cell defect and the lifetime for the solar cell and the LED product can be integrally analyzed by a single analysis apparatus, making it possible to save time and cost required for analysis and test.
[0074] EL Image Obtaining Apparatus for Analysis of Surface Defect in Micro Units
[0075] Moreover, with the configuration illustrated in FIG. 1 , the analysis unit 180 of the EL sample analysis apparatus of the present invention can inspect the surface defect of the EL sample 10 in micro units, based on the EL image obtained through the microscope 130 and the photographing device 150 .
[0076] In other words, the EL sample analysis apparatus of the present invention can be utilized as an apparatus for obtaining a micro EL image for surface defect analysis of an EL sample, such as a solar cell, an LED device and the like, in addition to the above-described ELTS analysis apparatus and EL lifetime analysis apparatus. Accordingly, the EL image emitted from the solar cell or the LED device can be photographed in micro units, making it possible to detect the surface defect and minute external defect of the solar cell or the LED device more precisely.
[0077] While the present invention has been described with reference to a certain embodiment, the embodiment is for illustrative purposes only and shall not limit the invention. It is to be appreciated that those skilled in the art can change or modify the embodiment without departing from the scope and spirit of the invention. | Provided is an apparatus for analyzing an electroluminescence sample, which comprises: a pulse generator for applying a pulse driving signal to the electroluminescence sample; an electroluminescence (EL) detector for receiving electroluminescence which is emitted from the electroluminescence sample according to the application of the pulse driving signal, thereby acquiring a light-receiving signal; a temperature controller for varying the temperature of the electroluminescence sample; and an electroluminescence transient spectroscopy (ELTS) analysis unit for analyzing a change in a time division section of the light-receiving signal delayed depending on a change of the temperature of the electroluminescence sample, and acquiring information on a defect-type charge trap which exists in the electroluminescence sample. | 6 |
This is a continuation of application Ser. No. 07/037,043, filed Apr. 10, 1987, now U.S. Pat. No. 4,839,233, issued June 13, 1989.
BACKGROUND OF THE INVENTION
This invention pertains to medical grade film and a method of sterilizing medical grade film and, more particularly, to medical grade film and a method of sterilizing the same wherein the film can be gamma or electron beam sterilized without any color change, and the sterilized medical grade film produced thereby.
Medical grade film, e.g., film meeting the requirements of Class VI plastics as set forth in the U.S. Pharmacopeia, Volume XX, is useful for manufacturing products which can be used for medical treatments and for manufacturing containers for products such as pharmaceuticals, cosmetics and foods. Suitable applications for such films are enteric feeding bags, kidney dialysis bags, barium enema bags, colostomy bags, bloodwashing bags, blood storage bags, urinary drainage bags, incontinent products, inflatable splints, hospital I.D. bracelets, traction devices, burn mattresses, comfort cushions and waterproof hospital sheeting.
Currently, the medical industry utilizes a medical grade film containing polyvinyl chloride (PVC) resin. The industry sterilizes this medical grade film using ethylene oxide. However, this is a cumbersome, time-consuming and expensive method of sterilization. The industry prefers using the gamma-radiation sterilization method since it is more effective biologically, less expensive and less time-consuming. However, irradiation levels of 1 to 5 megarads used in this sterilization method cause the polyvinyl film to yellow. While this yellowing does not render the film nonfunctional, it is considered undesirable aesthetically.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a medical grade film which may be gamma or electron beam sterilized without any color change.
It is a further object of the present invention to provide a method of sterilizing a medical grade film with gamma or electron beam radiation without any color change in the film.
It is an additional object of the present invention to provide a sterilized medical grade film.
These objects are accomplished by providing a halogen containing resin film including barium sulfate. The halogen containing resin is preferably a vinyl chloride resin such as PVC. In addition to polyvinyl chloride and barium sulfate, the film can also contain a plasticizer such as di-2-ethylhexyl adipate, epoxidized soybean oil, a stabilizer such as an orango zinc soap blend or an organotin salt, and a lubricant such as stearic acid.
The medical grade film of the present invention can be successfully gamma or electron beam sterilized without any color change. For example, gamma radiation doses can range from 1 to 5 megarads.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A medical grade film of the present invention includes a halogen containing resin and, more particularly, a vinyl chloride resin. The vinyl chloride resin may be a homopolymer of vinyl chloride or a mixed polymer, such as copolymers or graft polymers of vinyl chloride which have been prepared by known continuous or batch polymerization processes. Suitable monomers for copolymerization with vinyl chloride are olefins, vinyl esters of carboxylic acids, acrylonitrile, styrene and cyclohexylmaleimide. Polymers useful for graft polymerization with vinyl chloride include elastomeric polymers of butadiene, ethylene, propylene, styrene and/or acrylonitrile.
The medical grade film of the present invention may contain any of a number of known stabilizers. Suitable stabilizers include organo zinc soap blends and metallic soaps of calcium and zinc. A preferable stabilizer is Mark QTS (an organo zinc soap blend manufactured by Argus Chemical Division of Witco Chemical Corp.).
The medical grade film of the present invention may contain any of a number of known lubricants. Such lubricants include calcium stearate, hydrogenated tallow and fatty acids (food grade): Preferable lubricants include stearic acid and calcium stearate.
Known plasticizers may also be included in the medical grade film of the present invention. Examples of such plasticizers are phthalate plasticizers such as dioctyl phthalate (D.O.P.). However, the preferred plasticizer is di-2-ethylhexyl adipate.
The medical grade film may contain other additives such as epoxidized soybean oil and FDA approved pigments.
The advantageous effects of the present invention are obtained by including barium sulfate in the medical grade film.
The foregoing raw materials are preferably included in the medical grade film of the present invention in the following proportions by weight percent: the amount of PVC resin preferably contained in the composition is 60 to 69%; the amount of plasticizer is preferably 19 to 25%; the amount of stabilizer is preferably 0.5 to 1.3%; the amount of lubricant is preferably 0.15 to 0.2%; the amount of epoxidized soybean oil is preferably 9.5 to 10.5%; and the amount of barium sulfate is preferably 0.5 to 5%, most preferably 2.9%.
The raw materials can be mixed by blending then Banburying. The composition obtained thereby can then be calendered to form films having a thickness in the range of 2 to 30 mils, preferably 6 to 18 mils.
The films can be shaped by known techniques such as electronic heat sealing to form useful articles.
Sterilization is preferably accomplished by exposing the films or shaped articles to gamma radiation. Gamma radiation sources are known in the art, e.g., a cobalt 60 source may be used. Typical irradiation levels are in the range of 1 to 5 megarads. Electron beam radiation may also be employed.
EXAMPLE 1
A film was prepared by blending the following raw materials followed by Banburying and calendering:
PVC resin--100 parts by weight,
Di-2-ethylhexyl adipate (DOA plasticizer)--33 parts by weight,
Mark QTS (an organo zinc soap blend manufactured by Argus Chemical Division of Witco Chemical Corp.)--0.75 parts by weight,
Drapex 6.8 (epoxidized soybean oil manufactured by Argus Chemical Division of Witco Chemical Corp.)--15 parts by weight,
Barium sulfate--4.47 parts by weight, and
Industrene 7018 FG (Food Grade 70% stearic acid manufactured by Humko Chemical Division of Witco Chemical Corp.)--0.25 parts by weight.
The film was successfully sterilized using 1 to 5 megarads of gamma radiation without any color change.
Large scale processing of the film can be accomplished in the following manner. The PVC resin can be stored in resin silos. Bulk plasticizer such as D.O.P. and epoxidized soybean oil can be stored in separate plasticizer tanks. Bulk PVC resin, D.O.P. and epoxidized soybean oil can be pumped and weighed into blenders. The other ingredients, such as lubricants and barium sulfate, can be kept in drums and/or bags and can be weighed into the blender. The total weight of the raw materials in the blender can be approximately 4,000 lbs. These materials are then blended for 25 minutes at approximately 200° F.
Two-hundred-fifty pounds of the blended raw materials are then transferred into the Banbury where the materials are mixed for 31/2 minutes, reaching a temperature of 340° F., until the formulation is fused. The plastic formulation is then transferred to a two-roll mill which is at a temperature of 320° F. This mill performs the function of mixing and storage.
The material is then transferred to an extruder-strainer which is at a temperature of 325° F. The material is strained and extruded into a continuous web approximately 3 inches in diameter which is fed to a calender. A calender, such as a four-roll inverted-L calender, can be used. The calender rolls are heated, top to bottom, from 350° F. to 310° F. The calender forms the (webbed) material into a sheet of various widths and thickness. The calender sheet is then cooled by cooling drums and a beta gauge measures the thickness of the sheet. A winder rolls the sheet into a roll which is then slit into smaller rolls on a slitter. The rolls can then be packaged into, e.g., a polyethylene bag which is wrapped with Kraft paper. The thus-formed medical grade film can be used to fabricate desired products by conventional electronic heat sealing equipment. The film or products can be sterilized using gamma or electron beam radiation.
While the invention has been described and illustrated by the example included herein, it is not intended that the invention be strictly limited thereto, and other variations and modifications may be employed within the scope of the following claims. | A medical grade film, a method of sterilizing a medical grade film and the sterilized medical grade film produced thereby, wherein the film contains a vinyl chloride resin, such as PVC, and barium sulfate. The film can be sterilized by exposure to gamma radiation of one to five megarads without any color change. Electron beam radiation may also be employed. | 2 |
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