description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for the evaporation of liquids, especially monomers containing silicon, for the production of thin coatings containing silicon and/or silicon compounds by chemical vapor deposition (CVD) in a vacuum onto substrates, using a current adjusting device and an evaporator connected to the output of the latter.
In the fields of microelectronics, display technology and telemetering, thin coatings of SiO 2 , Si 3 N 4 , a-C:H, and a-Si:C, among others, are employed. In the prior art the coatings are produced by the low-pressure CVD or plasma-enhanced CVD process. A great variety of gases are used as starting materials for these coatings; for example, SiH 4 (silane) can be used. For a number of applications compounds are suitable which first must be converted to the gaseous phase, since they are liquid at room temperature and have a low vapor pressure. Examples are TEOS=tetraethoxysilane, or HMDS=hexamethyldisilane. In order to produce the said coatings repeatably with these liquids converted to the gaseous phase an absolutely constant, repeatable and controllable gas flow is necessary. For this purpose an inert carrier gas, Ar, He or N 2 can be passed through the liquid compound in a known manner. The carrier gas becomes saturated with the compound by diffusion, so that it can then enter the reactor. The regulation needed for this purpose is accomplished by temperature control and carrier gas control. A disadvantage of this method is the ever present large amount of carrier gas which, of course, is also carried into the reactor and interferes with the process or reduces the process window. Moreover, a very precise and difficult temperature control is necessary, since the loading of the carrier gas depends directly on the temperature.
It is furthermore known to hold the liquid compound in a heated tank. The vapor over the fluid is likewise fed through a heated liquid controller into a reactor. The heating of the liquid controller is likewise very difficult.
An apparatus as well as a method of the kind described above is known (U.S. Pat. No. 4,947,789) which serves for the evaporation of monomers that are liquid at room temperature. For the production of thin coatings containing silicon and oxygen, chemical vapor deposition is used for this purpose. It is furthermore known to use a mass flow controller as the flow adjusting apparatus, wherein the monomer pumped by the latter is fed in liquid state to the evaporator. In this known method the reacted rate of flow is greatly limited, since at high flow rates of over 25 g/h a stable flow can no longer be produced. For this reason no reliable practice of the is possible by the known method.
The invention is addressed to creating an apparatus whereby perfect evaporation of the liquid is achieved in a simple and rapid manner.
The housing of the evaporator has an evaporator body whose surface is roughened, porous, or whose body is made at least partially permeable. In this manner the total surface area of the evaporator is increased in a simple manner and thus the time required for evaporating the liquid is substantially reduced. For this purpose it is advantageous that the surface area of the liquid to be evaporated is increased by atomizing it and thus the mass-flow rate at constant vapor pressure and a given temperature increases, and that the evaporator body is provided between the ultrasonic atomizer and the outlet opening of the housing and the ultrasonic atomizer is equipped with a diaphragm which is made to vibrate by means of an oscillator at medium frequency, or at another suitable frequency corresponding to the liquid. In this manner the liquid provided in a supply tank can be metered to the ultrasonic atomizer through a flow controlling system or metering device. The liquid stream which passes through the nozzle of the ultrasonic atomizer is broken up by the vibrations of the diaphragm into a great number of small droplets of the order of magnitude between 50 and 100 μm. These droplets strike against the evaporator body provided in the housing of the evaporator so that a vaporization of the liquid is accomplished very quickly.
It is furthermore advantageous that the evaporator body divides the housing of the evaporator into an inlet space and an outlet space such that the liquid passes from the inlet space to the outlet space only through the evaporator body.
The evaporator body preferably occupies entire cross-sectional area of the housing of the evaporator.
The evaporator body can be made of a sintered material. In this manner a very great surface area is created in a simple manner without increasing the bulk of the evaporator body.
The evaporator body can be of a truncated pyramidal shape.
The housing of the evaporator body and/or the interior are preferably heated by means of a heating system which is in a working connection with a temperature control system.
The production of many small droplets is of great advantage, because this is a simple way to increase the surface area of the liquid. The evaporator body made of sintered metal makes the flow of liquid or vapor uniform.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIG. is a diagrammatic representation of the evaporation apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A supply tank 1 is connected by a supply line 20 to a liquid controller 3. Between the supply tank 1 and the liquid controller and flow control system 3 there is a shut-off valve 2 so that the supply tank 1 can be disconnected if necessary.
The liquid controller 3 is connected by another supply line 21 to an evaporator 5. The liquid controller 3 can be connected to a control system not represented in the drawing, which controls the feed of liquid from the supply tank.
The evaporator 5 consists of a housing 22 which has in one area an inlet opening 23 and in another area an outlet opening 24.
The evaporator 5 is surrounded by a heating coil 6 which holds the evaporator 5 at the necessary working temperature.
Furthermore, the evaporator and with it the heating coil 6 is surrounded entirely by insulation 7. Advantageously the heater is connected by an electrical line 11 to a temperature control system 10 so that the heating can be regulated between a temperature of, for example 50° C. to 200° C.
In the inlet opening 23 is the ultrasonic atomizer 4, which is connected by an electrical line 19 to an oscillator 9 which sets in vibration a diaphragm, not represented in the drawing, of the ultrasonic atomizer 4.
In the bottom part of the housing 22 is the outlet opening 24 in which an outlet connection 26 is provided, which is connected by a line 8 and an adjustable valve 14 to the reactor 18 of the pieces to be coated, which is represented only diagrammatically in the drawing.
Within the housing 22 of the evaporator 5 is an evaporator body 12, which consists of a porous material so that a very great surface area is obtained. Advantageously, the evaporator body 12 can consist of a sintered material, especially sintered bronze, which can have a pore width between 1 and 200 μm. Any other material ,can be used which provides a large surface area by the nature of its surface.
The method according to the invention for the deposit of Si and/or Si-containing compounds and the apparatus that can be used for that purpose are described below.
First a liquid is put into the supply tank 1, and then an inert gas such as Ar, He, or N 2 , for example, is let into the supply tank 1, placing a pressure of, for example, 1 bar on the liquid. The liquid is then fed through line 20 and the liquid controller or metering device 3 to the ultrasonic atomizer 4. The ultrasonic atomizer 4 is equipped with a nozzle 13 which has a diaphragm (not shown) which is made to vibrate at a medium frequency by means of the oscillator 9. In this manner, the liquid stream which is fed through the nozzle 13 is made to vibrate and broken up into a great number of small droplets of the order of magnitude between 50 and 100 μm. A great number of small droplets form a relatively great surface area for the same volume, i.e., the greater the number of drops that can be formed, the greater becomes the surface of the liquid. The surface of the liquid is very critical to the thermal transfer and thus also for the evaporation of the liquid. This appears from the formula:
Q=k A (Tv=Tt)
In this formula,
Q=heat flow in KJ/s
k=thermal transfer coefficient (W/m 2 K)
Tv=evaporator temperature
Tt=droplet temperature
Since a small droplet evaporates more quickly than a large one it is possible in this manner to very greatly reduce the time needed for the evaporation of the liquid. Also, by means of the atomization a constant flow of liquid is obtained. This appears from the following formula:
t=d.sup.3 hv/(6 Q) ##EQU1##
By the use of ultrasonic atomizers of different configuration and sizes and different sizes of evaporators any desired rate of flow can be set.
The liquid atomized by the ultrasonic atomizer 4 arrives, at the evaporator body 12, which produces the evaporation of the liquid not yet evaporated. Since the temperature prevailing in the housing 22 is greatly reduced by the evaporation it is advantageous if the evaporator 5 as a whole is heated by means of the heater 6.
In this process the temperature control is performed by means of the temperature regulating system which is in working relationship with the electrical heater 6. This assures that the heat is provided to the evaporator body 12 through the housing wall. Furthermore, it is also possible to provide a heater in the interior of the housing 22 of the heat exchanger 4.
Through the method according to the invention and the corresponding apparatus a very uniform, rapid evaporation in a vacuum is obtained without the occurrence of pressure fluctuations or shock pressures due to effects of ebullition.
The housing 22 for the accommodation of the evaporator body 12 is connected by the line 8 connected to the outlet connection 26 and through an adjustable valve 14 to the reactor 18, and by another line 15 and a second valve 16 to a vacuum pump 17. In order to assure that the liquid will reach the reactor 18 from the supply tank 1 only through the evaporator body, the evaporator body 12 of the housing 22 is divided into two sections, namely into an inlet chamber 28 and an outlet chamber 29, which are completely separated by the evaporator body 12.
The evaporator body 12 is preferably permeable such that the liquid can pass from the inlet chamber 28 to the outlet chamber 29. In this manner a relatively great surface area is obtained on the evaporator body 12 with simple constructional means. Furthermore, the evaporator body 12 can be configured in the shape of a truncated pyramid, a cone or a roof. | A heated evaporator housing is provided at its inlet with an ultrasonic atomizer for reducing monomer to small droplets and a permeable porous body completely occupying a cross section of the housing between the inlet and the outlet. A vacuum pump and a reaction chamber for coating substrates are provided downstream of the outlet. | 2 |
FIELD OF THE INVENTION
This invention relates to a method for inserting an elastomeric yarn and a yarn processing system.
BACKGROUND OF THE INVENTION
A longitudinally elastomeric yarn may be processed in a knitting machine when the yarn is released from the yarn supply by a positive feeding device and is fed by the positive feeding device to the respective knitting system. In weaving machines and by weaving machine feeding devices until now only so-called covered elastomeric yarns of restricted longitudinal elasticity could be processed. Covered elastomeric yarns, however, show a stretching property with a stretching curve containing a “knee”, meaning that the covering of the yarn physically increases the stretch force from the knee onwards. During each insertion process in the weaving machine the yarn first is stretched until the knee is reached, and then the yarn can be inserted at relatively stable relationships. Uncovered or bare elastomeric yarns, e.g. natural rubber yarns or elastomeric yarns, however, cannot be processed by weaving machine weft yarn feeding devices for feeding a weaving machine due to the extreme yarn stretchability. The preparation of covered elastomeric yarns by specific spinning processes, however, is costly.
It is an object of the invention to provide a method for inserting an elastomeric yarn into a weaving machine as well as a yarn processing system apt to carry out the method, both allowing the processing of longitudinally elastic elastomeric yarn material as the weft yarn of a weaving machine in a reliable way and independent from the yarn stretchability.
According to the method of the invention, the elastomeric yarn is supplied from the yarn supply to the shuttleless weaving machine such that the yarn first is released from the yarn supply by a positive yarn feeding process, then is intermediately stored in adjacent windings at a winding speed which is synchronised to the positive feeding speed and in a predetermined relation to the positive feeding speed and in a stretched condition, and finally is released for each insertion cycle with a predetermined insertion length. As by the synchronisation between the positive feeding speed and the winding speed for the intermediate storing process of the windings, a predetermined stretched yarn condition will be adjusted, which condition is independent from the stretchability of the yarn in the windings, and since the stretch will be controlled for each insertion cycle by measurement of the yarn release length, the yarn now can be processed by the weaving machine independent from the stretchability of the yarn. In this fashion, bare elastomeric yarn material can be processed for the first time in shuttleless weaving machines. Bare elastomeric yarns, however, can be produced for fair costs and offer an expanded degree of freedom of fabric elasticity in the weft yarn direction. The expanded degree of freedom is advantageous for stretched denim fabric (stretch jeans). An extremely stretchable bare elastomeric yarn does not need to be inserted by each pick into the fabric. A bare elastomeric yarn even may be inserted together with a normal yarn in one and the same pick, e.g. for producing a plated fabric.
The positive feeding device and the yarn intermediate storing and measuring feeding device are co-operating in the yarn processing system with each other such that a substantially uniform stretched yarn condition is maintained in the windings which are intermediately stored for intermittent consumption by the weaving machine. The stretched yarn condition may be precisely controlled by matching the speeds of the positive yarn feeding process and the winding on process. Furthermore, a desired stretch can be adjusted also in the weft yarn, because the weaving machine is inserting the yarn only in the form of precisely measured longitudinal sections and by one longitudinal section per pick. The stretch in the remaining intermittently stored windings cannot relax in the direction of the weaving machine. Only during the insertion cycle, the windings are not under form-fit control in the direction into the weaving machine. However, then the withdrawal force and the friction during withdrawal will cause an active hindrance which substantially suppresses a yarn relaxation acting rearwardly into the windings.
It is advantageous for the method to adjust the insertion length shorter than the weaving width of the weaving machine. This allows the adjustment of a predetermined stretched condition in the weft yarn in the fabric, e.g. about 300%. So to speak, the stretched condition of the weft yarn is frozen in the fabric by the closing action of the shed after the beat-up action.
Expediently, the magnitude of the yarn stretch in the intermediately stored windings can be maintained substantially constant by the measurement of the insertion length during the insertions or picks and also the resting periods between subsequent picks. This means that substantially no yarn length will be pulled back from the weaving machine while yarn fed by the positive feeding device is wound on. This is assured either by the stopping device carrying out the longitudinal measurement or by the withdrawal force during a simultaneously occurring pick. During an insertion only the predetermined and already stretched yarn length is released with which the weaving machine generates a predetermined stretch effect in the fabric. Even extremely stretchable yarn material can be correctly controlled by matching the proportions between the positive feeding speed and the winding on speed and by a phase equalisation (synchronisation). This means that the positive feeding device will start, stop, accelerate, and decelerate its motion as the winding on element does.
A positive feeding device is structurally simple and of reliable function, if it is operating with a driven conveying roller pressed against a rotatable yarn winding package or yarn bobbin. The drive of the conveying roller runs in synchronism with the winding drive and unreels the yarn. The positive feeding device can be mounted to the measuring feeding device and can be driven from the measuring feeding device, e.g. by a belt drive system or a gear transmission. The relation between the positive feeding speed and the winding on speed should be adjustable.
In the yarn intermediate storing and measuring feeding device the already stretched yarn is wound onto a stationary storage body in adjacent windings expediently with yarn separation, i.e., with axial intermediate distances between the adjacent windings. The yarn then will be held under stretch between the winding on element and the stop element. During each pick only the predetermined yarn length is released. Then the withdrawal force and the friction at the storage body will act in a yarn supporting way until the stop element again will support the remaining yarn windings against a relaxation. The stretched condition in the weft yarn in the fabric is adjusted then by releasing only a length which is defined in proportion to the weaving width. Particularly for processing bare elastomeric yarn material in a gripper weaving machine, it is expedient to provide a controlled yarn brake which, e.g. in the yarn transition phase between the bringer gripper and the taker gripper temporarily produces a predetermined braking effect in order to support the transition operation.
A monitoring assembly expediently is provided between the positive feeding device and the measuring feeding device. The monitoring assembly senses the yarn in a contactless fashion and does not generate significant additional friction for the yarn. In case of a yarn breakage or of an emptied yarn winding package or yarn bobbin, a stop signal is generated for the weaving machine.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the object of the invention will be explained with the help of the drawings, in which:
FIG. 1 is a schematic view of a yarn processing system for an elastomeric yarn,
FIG. 2 is a speed-time-or rotation angle-time diagram, and
FIG. 3 is a yarn processing system according to FIG. 1, including modified details.
DETAILED DESCRIPTION
A yarn processing system S shown in FIG. 1 comprises a yarn supply V of a longitudinally elastomeric yarn Y, a positive feeding device P, and downstream of the same a yarn intermediate storing and measuring feeding device M, both defining a yarn feeding device F. Optionally, a controlled yarn brake B is provided downstream of the device M. Furthermore, a shuttleless weaving machine W is provided as a yarn consuming textile machine, preferably a gripper weaving machine having a bringer gripper 1 and a taker gripper 2 which transfer the yarn Y to each other during an insertion substantially in the middle region of a shed 3 . Both grippers 1 , 2 form an insertion device E of the weaving machine W. Instead, the weaving machine W could be a projectile weaving machine.
The yarn Y is longitudinally elastic, e.g. is a bare elastomeric yarn of natural rubber or another elastomeric material. The positive feeding device P (only schematically indicated in FIG. 1) has a feeding roller 4 and a counter roller 5 . The yarn Y may be wound e.g. once or several times around the feeding roller 4 . Both rollers can be driven by a drive 6 . Downstream or upstream of the positive feeding device P a monitoring assembly M 1 (for detecting a yarn breakage or an empty supply) may be provided. A regulation parameter detecting device could co-operate with the drive 6 in order to either let the yarn Y be taken off from the yarn supply V or to feed the yarn to the measuring feeding device M with constant stretch, respectively. The detecting device is not shown.
The yarn intermediate storing and measuring feeding device M has a housing for a rotatable winding element 7 and for a stationary storage body 9 . The winding element 7 is driven by an electric drive motor 8 . The stationary storage body 9 serves to intermediately store the yarn Y in an intermediate supply in adjacent windings formed by the winding element 7 . Expediently, the storage body 9 is equipped with not shown implements serving to create a yarn separation between the windings. The number of the yarn windings or the size of the intermediate supply, respectively, on the storage body 9 is surveyed by sensors D. The sensors D transmit signals to a control device C of the drive motor 8 . Furthermore, a measuring device A is provided for measuring the yarn Y length which is released and taken off during each pick by the weaving machine W. The measuring device A, e.g., includes a stationary stop device 10 and a moveable stop element 11 . The moveable stop element 11 is moveable into a stop position in cooperation with the storage body 9 and into a retracted release position. The storage body 9 can be designed with a variable diameter. The measuring device A can be connected to the control device C. The yarn brake B, e.g. a deflection brake, includes a drive 12 which, expediently, also is connected to the control device C. A control device Cl is associated with the weaving machine W, and is connected to the control device C. Also, the drive 6 of the positive feeding device P is connected to the control device C in order to adjust the positive feeding speed and the winding speed with equal phases and a predetermined relation between both. The relation should be variable.
The positive feeding device D is driven in proportion to and with the same phase (synchronously) as the winding element 7 of the measuring feeding device M. The drive motor 8 is accelerated, decelerated or stopped, e.g. depending upon signals emitted by the sensors D, in order to permanently and intermediately store a number of windings on the storage body 9 which number permanently suffices to cover a momentary or even an expected upcoming yarn consumption of the weaving machine W. To start an insertion cycle or pick a signal is transmitted from the control device C 1 to the control device C (or directly to the stopping device 10 ) to move the stop element 11 from the stop position into the release position. The number of windings withdrawn during the insertion cycle or pick is registered, e.g. by a not shown withdrawal sensor. In order to release the adjusted insertion length of the yarn only, the stop element 11 is moved back into the stop position sufficiently early, e.g. via the control device C. The yarn brake B e.g. is controlled by the control device C, in order to brake the yarn during the transition phase during which the bringer gripper 1 transfers the tip of the yarn Y to the taker gripper 2 .
The functioning of the system produces a stretch condition in the yarn Y in the intermediately stored windings on the storage body 9 . This stretch condition is maintained essentially constant between the winding element 7 and the stop element 11 engaged in the stop position by adjusting the insertion length released for each insertion cycle in relation to the weaving width of the weaving machine W. Furthermore, the stretch of the yarn Y in the shed 3 is increased or decreased in relation to the stretch of the yarn Y in the intermediately stored windings.
The diagram of FIG. 2 shows how the drive motor 8 is accelerated from stand still, is brought to high speed, and finally is decelerated again to stand still following a curve 13 . The dotted line curve 14 indicates the proportional lower speed of the positive feeding device P. At points in time t 1 , t 2 , t 3 picks or insertion cycles are carried out, e.g. depending from the weaving pattern. At the respective point in time, the stop element 11 is moved from the stop position into the release position and, subsequently, i.e. before the released insertion length is reached, again is returned into the stop position. Expediently phase equity is adjusted, i.e. the positive feeding device D starts and stops at the same times as the winding element 7 does.
FIG. 3 shows an embodiment of a positive feeding device P at which the yarn supply V has a rotatable yarn winding package or yarn bobbin 18 . The conveying roller 4 driven for rotation by drive 6 , contacts the yarn package 18 and unreels the yarn Y. The drive 6 is connected to a control device C 2 of the positive feeding device P which control device C receives control signals from the drive motor or the control device C, respectively, of the measuring feeding device M. Reference number 19 indicates the transmission of a stop signal to the weaving machine (in case of a yarn breakage, a disturbance or in case of an emptied yarn package 18 ). The positive feeding device P could be mounted at the entrance side of the measuring feeding device M and could be driven from the same (with an adjustable speed relation).
The core of the invention is to additionally employ a yarn intermediate storing and measuring feeding device M for feeding elastomeric yarn material with a controlled stretch condition into a gripper weaving machine or a projectile weaving machine. The device M conventionally is only used in jet weaving machines, the insertion device of which is unable to define the respectively pulled-off yarn length by itself. The insertion device of a gripper weaving machine or a projectile weaving machine, by nature, automatically carries out the yarn length measurement for each insertion cycle. Despite the automatic length measurement present in such weaving machine types, the measuring feeding device M is used intentionally in order to control the stretched condition of the elastomeric yarn while it is inserted in the weaving machine. The measuring feeding device also is used here, because it is impossible to feed such elastomeric yarns to the weaving machine solely by using a positive feeding device, as the positive feeding device is unable to cope with the strong accelerations and decelerations of the intermittent operation of the weaving machine. The positive feeding device, however, is used to supply the elastomeric yarn to the measuring feeding device already with an adjustable stretch condition. The length measuring device maintains the stretch condition in the intermediately stored windings and adjusts a predetermined yarn stretch condition also in the fabric, namely by co-operation with the automatic length measuring insertion device of this type of a weaving machine. The method and the yarn processing system, according to the invention, respectively, are particularly useful for weaving uncovered elastomeric weft yarns of extreme stretchability. As the employed positive feeding device P, particularly the ELAN-feeder, produced by the company Memminger-IRO GmbH, DE, has proven to operate excellently. | A method for inserting a longitudinally elastic yarn from a yarn supply into a shuttleless weaving machine. The yarn is first removed with positive yarn feed from the yarn supply. Afterwards, the yarn in intermediately stored in adjacent windings with a predetermined elongation while using a winding speed that is synchronized with the positive feed speed, and for each insertion process, the yarn is released only with a predetermined insertion length. | 3 |
RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Ser. Nos. 60/588,142, filed Jul. 15, 2004; 60/587,773, filed Jul. 14, 2004; and 60/588,141 filed Jul. 15, 2004, and is a continuation-in-part of U.S. Nonprovisional application Ser. No. ______, filed Jul. 15, 2005.
FIELD OF INVENTION
[0002] This invention relates generally to apparatus and methods for removing contaminants from aqueous systems, and more specifically relates to filtration devices and methods for removing slightly soluble and/or emulsified organic compounds (such as an oil-in-water emulsions) from such aqueous systems.
BACKGROUND OF INVENTION
[0003] In recent years many previously clean water sources have been found to be contaminated with dispersed oils which are often present as oil-in-water emulsions. A further source of contamination arises from presence in the water of pernicious slightly soluble organic compounds such as benzene, toluene, xylene, halogenated hydrocarbons, ethoxylated glycols, etc. These noxious contaminants are among the more difficult compounds to remove from water, and indeed most are carcinogenic. In the present inventor's U.S. Pat. No. 6,180,010 it is disclosed that the compositions described in the inventor's U.S. Pat. Nos. 5,437,793; 5,698,139; and 5,837,146, and 5,961,823 (all of which disclosures are hereby incorporated by reference) have extremely strong affinities for the aforementioned contaminants in water; and that when aqueous streams containing these noxious contaminants are passed through filtration media incorporating these compositions, the contaminants are immobilized at the media, as a result of which concentration levels of the contaminants in the filtrate may be reduced to very low values.
[0004] Filter configurations incorporating the said compositions may be based on various water permeable substrates, such as shredded, spun or otherwise configured polypropylene or shredded or spun cellulose, which substrates are infused or otherwise treated with the absorbent compositions, which are then cured. These substrates may be packed or otherwise disposed in a cartridge or canister filter; or can be formed into cured and infused bag filters which can be emplaced in canisters through which the contaminated water is flowed. Similarly the said compositions can be incorporated into or upon other filtering substrates and media, such as paper, including compressed pulp materials, particulate porous foamed plastics, mineral particulates such as perlite and vermiculite, and particulate, fibrous or porous ceramic or porous (e.g. sintered) metal substrates and media.
[0005] In a first copending provisional patent application of the present inventor, a further filtration medium and method for its preparation is disclosed which while incorporating certain components of the absorbent compositions of my prior patents, has unexpectedly been found to have markedly superior properties when used as such an absorbent composition in the filtration of organic contaminants from aqueous systems, as for example in removing oils from an oil-in-water emulsion. These further compositions are prepared in part from the absorbent compositions of my prior art patents, which as disclosed in the patents are the reaction product of an oil component and a methacrylate or acrylate polymer component. The absorbent compositions disclosed in the aforementioned copending provisional application are prepared by further combining such prior art reaction product (herein called “reaction product A”) with a photoinitiator system before infusing the combination into the fluid-pervious filtration media. Subsequent exposure of the infused filtration media to actinic UV radiation, effects a very rapid in situ curing of the infused composition, and results in a filter having markedly improved filtration characteristics. Although applicant is not bound by any specific theory, it is hypothesized that the UV in situ curing may result in extensive additional cross-linking of the infused absorbent, with consequent hardening of the infused composition, and pore sizes in the filtration media may in consequence be much smaller than in the filters of my prior methodology. Regardless of the precise mechanism involved, filters so prepared exhibit higher back pressure in use, with consequent increased dwell time for the aqueous streams being passed through the filter. The filters are among other things found to be much more efficient in breaking oil-in-water emulsions than filters prepared by the inventor's prior methodology and compositions. For this reason, and for convenience, such filters shall be referred to herein as “EB” filters, and the corresponding infusion compositions shall at times be referred to as “EB” absorbent compositions. In contrast the filters prepared by the inventor's prior patented methodology and compositions shall, again for purposes of convenience, be referred to as “PA” filters and “PA” absorbent compositions.
[0006] In the general method for preparing an EB filter in accordance with the disclosure of said first copending provisional application, a homogeneous thermal “reaction product A” is initially prepared from an oil component and a polymer component, as in my earlier cited patents. The thermal reaction product A here is preferably prepared in a temperature range of 350° to 550° F., and more preferably at a range of from about 400 to 500 deg. F. A photoinitiator system is separately prepared from a monomer cross-linking agent, a catalyst, and a wetting agent, i.e. an oligomer/adhesion promoter/cross-linking agent. An infusing solution is then prepared by combining the reaction product A and the photoinitiator system together with a solvent such as acetone. This solution is infused into the filtration media, e.g. a conventional filtration cartridge containing a filtration substrate such as fibrous polypropylene. The infused cartridge or other infused substrate is then exposed to UV radiation for a short period, usually of the order of several minutes to effect the desired curing. The EB filter is then ready for use.
[0007] In a second copending provisional patent application of the present inventor, it is additionally disclosed that in many applications the absorbent compositions of my aforementioned patents are improved by a drastic increase in the ratio of oil component to polymer component. Typically for example the oil component may be increased to above 95% and preferably to around 98% by weight of the two components. These higher oil blends appear to have higher affinity for the more soluble organic compounds such as benzene and low molecular weight chlorinated solvents. Also here the thermal reaction product of oil and polymer component is preferably prepared at a temperature range of 350 to 550 F., and more preferably at a range of from about 400 to 500 deg. F. The filtration media that result after infusion, as well as the infusing compositions, shall be referred to herein by the designation “HO”, which is suggestive of the high content of the oil component
[0008] The term “absorbent composition” will be used herein as one of convenience for identifying the said compositions of my aforementioned patents, and will be used as well in referring to the additional compositions disclosed in my cited first and second copending provisional patent applications. The specific mechanism by which the noxious contaminants are removed from aqueous streams by conjunctive use of such “absorbent compositions” is not completely understood, and could include attachment and/or fixation of such contaminants by mechanisms which technically involve various physical and/or chemical interactions. The term “absorbent” as used herein is intended to encompass all of these possible mechanisms.
SUMMARY OF INVENTION
[0009] Now in accordance with one aspect of the present invention a filtration apparatus is provided for separating organic contaminants from an aqueous phase in which the contaminant is solubilized or emulsified. The apparatus includes a canister having an inlet and an outlet for passing the liquid phase therethrough. A fluid-pervious composite filtration media is provided at the interior of the canister in the flow path of the liquid phase proceeding between the inlet and outlet. The contaminant(s) in the liquid phase flowing through the canister come into intimate contact with and are immobilized at the media. The composite media is preferably in the form of a cartridge which is replacebly mounted in the canister The cartridge composite filtration media comprises a central core which is surrounded and wrapped by a plurality of overlying sheets of further fluid pervious filtration media, the overlying sheets creating void spaces therebetween for trapping and immobilizing at least some of the separated contaminants. The composite filtration media is infused with an absorbtion composition comprising a homogeneous thermal reaction product of an oil component selected from the group consisting of glycerides, fatty acids, alkenes, and alkynes, with a methacrylate or acrylate polymer component. The thermal reaction product here is preferably prepared in a temperature range of 350 to 550 F., and more preferably at a range of from about 400 to 500 deg. F. The absorption composition is cured in situ at the composite filtration media, which can be facilitated by exposure to actinic radiation.
[0010] The wrapping of the core in the manner indicated affects the rapidity and degree of curing so that the polymeric compositions infused at the outer portions of the composite filter are at a more advanced stage of cross-linking then progressively inward lying portions. This is due to higher oxygen exclusion at the wrapped inner core (and inside sheets of the wrap), and where actinic radiation is used in curing, to increased blocking of the radiation at inward portions of the composite filter.
[0011] Preferably the flow of the aqueous phase through the canister is in such direction that the flow proceeds from the outside of the cartridge to the inside or axis. The central core and the wrapped portions of the composite cartridge can comprise different substrate materials and the two said portions of the cartridge can be infused with differing absorbtion compositions. Also the number of overlying layers wrapping the core can differ depending upon the desired application for the apparatus.
[0012] The filtration media of the central core can comprise various substrates such as 5 micron/1 micron/meltdown polypropylene, reticulated polypropylene etc. The wrapped sheets may comprise Spun bond poly propylene sheets, or other porous sheet materials such as non woven fabrics (cellulosic, glass fibers, spun bond polypropylene, Nylon, polyamide etc.); and/or woven fabrics such as burlap, cellulosics and other natural fibers. For convenience the composite filters and cartridges described shall be referred to by the designation “WR”, which is suggestive of the wrapped sheets which surround and enclose the central core of the filtration media.
[0013] It will also be clear that the principles of the invention just explained can be applied in other filter geometries, such as those employing rectangular or spherical geometries.
BRIEF DESCRIPTION OF DRAWING
[0014] In the drawings appended hereto:
[0015] FIGS. 1 through 4 schematically depicts preparation of a representative WR filter;
[0016] FIG. 5 is a schematic diagram of a filtration canister containing a pair of WR filters; and
[0017] FIG. 6 is a graph showing the maximum flow rate in gpm for less than 1 psi pressure drop as a function of the number of sheets wrapped around a WR cartridge, as referred to in Example 6.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] A typical WR filter can be prepared as shown in FIGS. 1 through 4 . A 5 micron core filter 10 is wrapped in multiple layers of 1 oz. per square foot melt blown sheet material 12 and affixed using tie wraps. The composite filter is then infused with a solution of the absorbent composition 16 . UV light 18 is used for curing in FIG. 3 . Less UV light penetrates to the core resulting in differential tackiness through the sheets. The finished differential viscosity gradient filter 20 is seen in FIG. 4 . The viscosity gradient enhances coalescence. FIG. 5 shows a filtration canister 22 in which a pair of WR filter cartridges 24 , as in FIG. 4 , function in parallel. The system to be filtered enters via port input 26 . The flow to each filter cartridge 24 proceeds from the outer sheets 28 toward the core 30 , and then exits axially into a discharge reservoir and outflow 34 .
[0019] The wrapping of the core in the manner indicated affects the rapidity and degree of curing so that the polymeric compositions infused at the outer portions of the composite filter are at a more advanced stage of cross-linking then progressively inward lying portions. This is due to higher oxygen exclusion at the wrapped inner core (and inside sheets of the wrap), and where actinic radiation is used, to increased blocking of the radiation at inward portions of the composite filter.
[0020] The WR filter of the invention may also be infused with the high oil reactant content absorbent composition disclosed in my aforementioned second copending provisional patent application.
[0021] Filter constructions utilizing the principles of the present invention can be based upon canisters or drums which are internally packed with composite filtration media comprising substrates such as mentioned above, which have been infused with or otherwise carry absorbent compositions in accordance with the invention, and wherein the infused materials are processed in accordance with the invention. Since the PA absorbent compositions of my cited earlier patents serve as the “reaction product A” as used in preparing the several portions of the composite filtration media used in the present invention, it is appropriate here to describe these PA aborbents in some detail.
[0022] The PA absorbent composition thus disclosed in the first of my aforementioned patents, i.e. U.S. Pat. No. 5,437,793, is characterized therein as a coagulant product which comprises a glyceride such as linseed oil reacted with a polymer such as poly (isobutyl methacrylate) which is then diluted with a solvent, such as 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate. The composition formed by the thermal reaction of the linseed oil with the isobutyl methacrylate polymer is a soft resinous product which, when diluted with a solvent, results in a mixture that in the teaching of the said patent can be sprayed onto an oil spill or otherwise introduced to the oil spill to coagulate the oil. Additionally, however, and as disclosed in my further U.S. Pat. No. 5,698,139 patent and additional patents cited, further experimentation led to the discovery of additional absorbent compositions produced from polymers and a variety of natural animal and vegetable oils, fatty acids, alkenes and alkynes, which absorbent compositions are all utilizable in preparing the filters of the present invention. More generally these latter compositions are the thermal reaction product of a polymer component with an oil component selected from the group consisting of glycerides, fatty acids, alkenes and alkynes. The reaction conditions can be adjusted to provide a “first endpoint” product or a “second endpoint” product. Preferred compositions are disclosed which comprise the thermal reaction products of methacrylate polymers with a glyceride derived from a variety of natural animal and vegetable oils, or the thermal reaction products of methacrylate polymers with a fatty acid or alkene or alkyne containing from about 8-24 carbon atoms. The combination of a methacrylate polymer component with any of these oil components can provide either a first or second endpoint product, depending upon the reaction conditions. The term “first endpoint product” is used to describe the solubility product of the reaction which is a cooperative structure held together by many reinforcing, noncovalent interactions, including Van Der Waals attractive forces. The term “second endpoint product” is used to describe the product of the reaction which is the result of covalent bond formation between the polymer component and the oil component, as indicated by the change in molecular weight.
[0023] In a preferred embodiment, the prior art product is synthesized from an isobutyl methacrylate polymer, and the oil component is one derived from a natural oil, such as linseed oil or sunflower oil. Optionally, the composition is then diluted with a solvent, such as 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate or acetone. The diluted composition can then be applied to a desired substrate for use as a filtration media.
[0024] The polymer component of the said PA absorbent composition is a synthetic polymer such as polymers derived from methacrylates. Preferably, the polymer is derived from methyl methacrylate, ethyl methacrylate, isobutyl methacrylate, or n-butyl methacrylate, or may be a copolymer containing a methacrylate polymer. Most preferably, the polymer is a poly(isobutyl methacrylate) polymer such as that obtainable from ICI Acrylics as ELVACITE® 2045, or a methacrylate/methacrylic acid copolymer such as ELVACITE® 2008 or 2043.
[0025] The test used to determine whether or not a polymer can be used in preparing the prior absorbent compositions is to combine the polymer component in question with the oil component, to see if the resultant combination forms a homogenous product after heating. It is stated in the patent disclosures that the polymer component percentage of the composition should range from about 15-75%, preferably 20-40%, or more preferably from about 25-35%, by weight.
[0026] In one embodiment of the PA absorbent composition, the oil component of the composition is a glyceride derived from oils of vegetable or animal origin. Vegetable oils are obtained by cold pressing the seeds of a plant to obtain the oil contained therein. Of the vegetable oils, drying oils such as sunflower, tung, linseed, and the like; and semi-drying oils, such as soybean and cottonseed oil, have been shown to be useful as the glyceride component. Animal oils, such as, for example, fish oil, tallow and lard can also be used as a glyceride component of the composition. It is anticipated that any drying oil or semi-drying oil will work in the composition. Generally, a drying oil is defined as a spreadable liquid that will react with oxygen to form a comparatively dry film. Optionally, combinations of two or more glycerides can be used as reactants with the polymer to provide useful absorbent compositions.
[0027] A glyceride derived from a drying oil, such as linseed oil, can be obtained from Cargill, Inc. as Supreme Linseed Oil, or sunflower oil. The glyceride should comprise from about 25-85%, preferably about 60-80%, and most preferably, from about 65 -75% of the coagulant composition. All percentages in this disclosure are by weight, unless otherwise stated.
[0028] Where the oil component of the prior composition is a fatty acid or alkene or alkyne utilized as the reactant with the polymer, it contains from about 8 to 24 carbon atoms, and preferably from about 10 to 22 carbon atoms. Such fatty acids, alkenes and alkynes are commercially available from many suppliers. Typical fatty acids include both saturated and unsaturated fatty acids, such as lauric acid [dodecanoic acid], linolenic acid, cis-5-dodecanoic acid, oleic acid, erucic acid [cis-docosanoic acid], 10-undecynoic acid, stearic acid, caprylic acid, caproic acid, capric acid [decanoic acid], palmitic acid, docosanoic acid, myristoleic acid [cis-9-tetradecenoic acid], and linoleic acid. Typical alkenes and alkynes contain at least one and preferably one or two degrees of unsaturation, and from about 8 to 24 carbon atoms, with 10-20 carbon atoms being preferred. Preferred alkenes and alkynes are those such as 1-decene, trans-5-decene, trans-7-tetradecene, 1,13-tetradecadiene, 1-tetradecene, 1-decyne, and 5,7-dodecadiyne.
[0029] The said PA absorbent composition is a product with characteristics different from either of the starting materials or a simple mixture of the two starting materials, thus showing that a new composition is produced by the thermal reaction. Specifically, the oil/polymer absorbent compositions pass a clear pill test after being heated at the elevated temperatures and do not separate into two parts upon being cooled but, rather form a homogenous, uniphase compound.
[0030] The solvent can be selected from aliphatic hydrocarbons, aromatic hydrocarbons, alcohols, ketones, ethers, aldehydes, phenols, carboxylic acids, synthetic chemicals and naturally occurring substances.
[0031] The said PA absorbent composition used is prepared by a thermal reaction process. The first step of the process involves heating the oil component (glyceride or fatty acid or alkene or alkyne) to approximately 235-350° F. at a rate of about 5° F. per minute with continuous stirring. Then, the polymer component, usually in powdered form, is slowly stirred into the heated oil component. Depending upon the particular reactants used, the oil component should range from about 25-85%, preferably about 65-80%, more preferably about 72-77%, and the polymer should range from about 1-50%, preferably about 20-40%, more preferably about 23-28%, of the coagulant composition. After this mixture has been mixed properly, the mixture should be heated to approximately 400-700° F., depending on the particular components utilized for the reaction, and the desired endpoint of the reaction. Typically, reaction temperatures below about 500° F. produce “first endpoint products” while temperatures above about 500° F. produce “second endpoint products”
[0032] The mixture should be heated at that temperature until a clear pill test indicates that the reaction has reached its first end point, i.e., a drop of the reaction mixture when placed on a clear glass plate is clear. When a clear pill test indicates that the reaction has reached its first end-point, the mixture should be cooled to a temperature below 200° F., generally about 180° F. After cooling, the coagulant product can be diluted with a suitable solvent to form a more liquid product that is easier to handle and use. The temperature at which the solvent is added is not critical, but the solvent should be added at a temperature where the coagulant composition is still pliable and the solvent will not rapidly evaporate.
[0033] Two reactions appear to occur between the oil component and the polymer component based upon the temperature and time. The first endpoint of the reaction results in a rubbery viscoelastic, relatively soft product with a melting point in the range of 100° F. to 250° F. This first endpoint product is homogeneous and does not separate upon melting or dissolution. This reaction occurs at 350° F.-500° F. This is designated the “first endpoint product” (solubility product).
[0034] In the second reaction, the polymer undergoes complete or partial chain fission into discrete polymer free radicals at a temperature above about 500° F. At between 350° F. to 500° F., it is believed that partial chain fission of the polymer component (isobutylmethacrylate polymer has a m.w.=300,000 Daltons) occurs at the end of the chain or in the middle. This results in a lower molecular weight product. It is believed that there may also be a solubility reaction occurring (similar to Sn and Pb forming solder) within the ternary composition. The occurrence of a chemical reaction is confirmed, however, due to the change of molecular weight.
[0035] Reactions at above 500° F. and up to 900° F. maintained at temperature from 5 minutes to 20 hours, depending on activation energy of compositions, result in the second endpoint product. This reaction is visually observable by color, rheology, and specific heat change in the product [Note: For the first endpoint product the end of the reaction is observed by change in color and a rheology change and the cessation of solution outgassing. There is also a change in specific heat as measured by Differential Scanning Calorimetry]. The second endpoint product has a weight average molecular weight in the range of about 62,000 Daltons which is consistent with complete chain fission of the polymer, resulting in smaller free radicals which results in a lower molecular weight compound. The melting point of these products is usually above 300° F. if the oil component is highly unsaturated, which results in a solid product due to the formation of highly bonded three dimensional densely packed molecular matrix. If the oil component has a low degree of unsaturation, the resultant product is usually liquid, which is consistent with this type of reaction.
[0036] The oily component and the polymer component are reacted in a thermal reaction that does not appear to be sensitive to the atmosphere under which the reaction is carried out, i.e., whether it is an inert, oxidizing or reducing atmosphere. Absorbent compositions have been prepared by this reaction which range from soft to hard, and elastomeric to brittle in nature depending upon the ratio of the oil component to the polymer component and the choice of the polymer component and/or the oil component used. If the reaction mixture separates into two phases upon cooling it is not useful for the invention. In this manner, any polymer can be identified for use in the invention.
[0037] The mechanism of the thermal reaction remains to be elucidated. While not wishing to be bound by any theory in this regard the reaction appears to be a polymerization or phase transition reaction brought about by heat and which is stable at lower temperatures. It is hypothesized that the elevated temperatures create monomer free radicals of the polymers and copolymers which then crosslink with the unsaturated glyceride molecules. It is also hypothesized that perhaps a phase transition is occurring between the oil component and the polymer component. In an effort to determine what type of interaction or reaction is occurring between the oil component and the polymer component, thermal analysis of several of the absorbent compositions was conducted. The results indicate that a reaction is occurring between the oil component and the polymer.
[0038] Differential scanning calorimetry (DSC) was thus performed on several such compositions. DSC is a thermal analysis technique that measure the quantity of energy absorbed or evolved by a sample in calories as its temperature is changed. The sample and a reference material are heated at a programmed rate. At a transition point in the sample's heating, such as when it reaches a melting point, the sample requires more or less energy than the reference to heat. These points are indicated the typical DSC readout.
[0039] Samples were taken at the beginning of the reaction procedure described earlier and at the end of the reaction. The DSC profile for the initial starting materials is dramatically different from the profile of the product. The initial profile showed two exothermic events when the DSC analysis is carried out from 40-280° C., one event occurring at about 100° C. and the other at about 217° C. In the DSC profile of the reaction product, however, there was only one exothermic event, occurring at about 261° C. The samples were taken at initial and final points during the reaction and allowed to cool to room temperature before being subjected to the DSC.
[0040] In the instance of a further reaction, DSC's of the starting materials and final product were obtained. Again, the DSC curves generated show that two thermal events occurred for the “just mixed” reactants while only one thermal event occurred for the final product. Thus, the DSCs indicated that the occurrence of a reaction or phase transformation. Similar evidence obtained from IR spectra analysis also confirms that the absorbent compositions used in the invention are distinct products from the reactants used to prepare the absorbent compositions.
[0041] Preparation of the additional EB absorbtion composition of my cited first copending provisional patent application is illustrated by the following:
[0042] In the first step a reaction product A of oil component and polymer is prepared as follows:
[0000] Synthesis of “Reaction Product A”:
[0043] 378 g of linseed oil and 4 g of tung oil were added to a 5 liter beaker (1). The oil was mixed using a stirrer. Add 169 g of poly(isobutyl methacrylate) were added to the oil. The contents was heated to 425-450 F. while keeping the contents mixed. The resultant polymer was cooled down to about 100 F.
[0000] Preparation of Photoinitiator Mix:
[0044] 85 g of HDODA (1,6 hexane diol diacrylate, monomer/crosslinking agent of UCB Specialities, Inc.) and 50 gms of Darocure 1173 (2-hydroxy-2-methyl-1-phenyl-propanone photoinitiator catalyst of Ciba Specialty Chemicals) were added to 510 g of CN111 (a difunctional epoxidized soybean oil acrylate oligomer/adhesion promoter/wetting agent product of Sartomer Company) in a 5 liter beaker (2). 1800 ml of acetone were added to the mix and the mix was stirred to dissolve the contents homogenously.
[0000] Preparation of Infusion Solution
[0045] The contents of beaker (2) was added to beaker (1) and the contents were wellmixed using a stirrer to create a homogenous solution of 40% active components and 60% acetone solvent.
[0000] Preparation of Filter Cartridges:
[0046] A 10″ Spunbond PP ((polypropylene product of Osmonics) was dipped in beaker (1) for 4 seconds. The filter was removed and drained of the excess solution for 2-3 min. The cartridge was then exposed to 360 nm wavelength D type UV lamps. The final curing of the cartridges is represented by the optimal weight increase due to crosslinking of the photoinitiator (Darocure 1173) with the monomer (HDODA, CN 111) and reaction product A. The rate of curing depends on the intensity of UV lamps used. E.g. using 600 W/sq inch intensity UV lamp @ 360 nm, curing time=5 min. Using 1 W/sq inch intensity UV lamp @ 360 nm, curing time=5 days.
[0047] The present invention is further illustrated by the following Examples, which are indeed to be considered as merely exemplary and not delimitative of the invention otherwise described:
EXAMPLE 1
[0048] A cylindrical WR cartridge (with EB infusion solution) in accordance with the present invention was prepared as follows:
[0000] Materials used:
[0000]
Filter cartridge: 1 micron Spun Bond Polypropylene or Reticulated Polypropylene cartridges. Dimension: 30″ ht×2.5″ diameter;
Size of Nonwoven polypropylene filter material/cloth. 30″ ht×94″ wide
The “infusion solution” described in the foregoing for preparing a filtration media as in my first copending provisional patent application.
Procedure:
1. The polypropylene filter cloth was wrapped around the polypropylene cartridge so that the numbeer, of layers of cloth around the cartridge was 12.
2. The cloth around the cartridge was clamped using plastic ties to hold the cloth in place.
3. In further steps “A” refers to the wrapped around cartridge as obtained by 2.
4. “A” was infused by dipping it in the infusion solution for 4-6 seconds.
5. “A” was removed from the dipping container and excess solution drained back into the dipping container
6. The “dipped A” was exposed to the UV lamps. The UV lamps used: were 1 W/in2 intensity @310-390 nm wavelength. T curing time depends on the light intensity. In the present Example 5 days under the UV lamps was used.
EXAMPLE 2
[0058] The same procedure used in Example I was followed to produce a further composite cartridge, except that the infusion solution used was that used in my prior patents, notably the “reaction product A” in a solvent. The curing procedure was identical to that in Example 1.
EXAMPLE 3
[0000] Performance Testing on Composite WR Cartridges
[0059] In this Example the performance of the WR composite media filters of Examples 1 and 2 were compared to that of prior art filters. The prior art filters differed from those of Example 1 and 2 primarily in that the filtration media of the cartridges(“control cartridges”) was not the wrapped composite, but rather a conventional cartridge commercially available from Perry Equipment Corporation. Compared composite and control cartridges were infused with the same solutions, and identically cured etc.
Cartridge (a): The wt of 10″ control PA cartridge infused with PA solution of my prior patents: 160 g (10″ ht×2.5″ dia) Cartridge (b): The wt. of 10″ composite WR cartridge infused with PA solution of my prior patents: 235 g (10″ ht×2.7″ dia) Cartridge (c): The wt of 10″ control PA cartridges infused with EB solution of my first provisional application: 275 g.(10″ ht×2.5″ dia) Cartridge (d): The wt. of 10″ composite WR cartridges infused with EB solution of first provisional application: 345 g. (10″ ht×2.7″ dia)
Surface area of (a) and (c) cartridges:
2×3.14×(1.25−0.5)=4.71 in2
Surface area of (b) and (d) cartridges:
2×3.14×(1.35−0.5)=5.34 in2
At a flow rate of 0.16 gpm/in2 surface area of the cartridge on IMO test emulsion fluid C
IMO Emulsion Test Fluid C:
Residual fuel oil:Specific gravity: >0.87 Distillate fuel oil:Specific gravity: 0.82-0.87 Surfactant: Sodium dodecyl benzene sulfonate Particulates: Iron oxide: 0-10 micron
[0068] 3000 ppm of the oil in water emulsion is prepared using the above components and performance of 2 cartridges in series systems are tested.
On 10″ (c) Cartridges: Oil Holding capacity to 5 ppm breakthrough: 10 g On 10″(d) Cartridges: Oil holding capacity to 5 ppm breakthrough: 35 g Ratio of increase in oil holding capacity of (d) cartridges to (c) cartridges=35/10=3.5 Dry wt. of 2-(c) cartridges=2×275=550 g Dry wt. of 2-10″ (d) cartridges=2×345=690 g Ratio of increase in wt of (d) cartridges to (c) cartridges=690/550=1.25
EXAMPLE 4
[0074] In this Example the oil holding capacity of the composite WR media filter of Example 2 was compared to that for a prior art PA filter. The prior art filter differed from that of Example 2 only in that the filtration media of the PA cartridge(“control cartridge”) was not the WR wrapped composite, but rather a conventional PA cartridge commercially available from Perry Equipment Corporation. This is to say that both cartridges were infuse with the same PA solution as in Example 2, and identically cured etc.
[0075] At a flow rate of 0.22 gpm/in2 surface area of the cartridges, 3000 ppm of non emulsified No. 2 oil (Specific gravity 0.85-0.92) in water was made and performance of the control cartridge and Example 2 (“composite”) cartridge were compared.
On 10″ control cartridges: oil holding capacity to 5 ppm breakthrough: 85 gms On 10″ Example 2 composite cartridges: oil holding capacity to 5 ppm breakthrough: 185 g Ratio of increase in oil holding capacity of composite to control cartrdige=185/75=2.46 The weight of 10″ control cartridge: 160 gms (10″ ht×2.5″ dia) The weight of 10″ Example 2 cartridge: 235 gms (10″ ht×2.7″ dia) Ratio of increase in weight of composite cartridge to control cartridge=690/550=1.25
EXAMPLE 5
[0082] Performance of the Example 3 Cartridges.:
Oil Holding Oil holding Fltration capacity of capacity of media of cartrididge (b) No. of infused cartridge (d) of infused of Example 3 Polypropylene Example 3 Cartridge (grams) sheets (grams) 5 micron 135 1 145 reticulated 135 4 185 135 10 300 5 micron 70 g 1 85 melt blown 70 4 120 70 10 240 1 micron 85 g 1 95 melt blown 85 10 275
EXAMPLE 6
[0083] In this Example different numbers of PA absorbent infused sheets were wrapped around a 10 inch 5 micron PA absorbent infused cartridge. The appended FIG. 6 shows the maximum flow rate in gpm for less than 1 psi pressure drop as a function of the number of sheets wrapped around the cartridge.
[0084] While the present invention has been set forth in terms of specific embodiments thereof, the instant disclosure is such that numerous variations upon the invention are now enabled to those skilled in the art, which variations yet reside within the scope of the present teaching. Accordingly, the invention is to be broadly construed and limited only by the scope and spirit of the claims now appended hereto. | A method and apparatus for removing organic contaminants from an aqueous phase in which the contaminant is solubilized. In the method the aqueous phase is passed through a fluid-pervious filtration media which has been infused with an absorbtion composition comprising a homogeneous thermal reaction product of an oil component selected from the group consisting of glycerides, fatty acids, alkenes, and alkynes, and a methacrylate or acrylate polymer component. The absorbtion composition is cured in situ at the filter. The contaminant is immobilized at the media, and the purified filtrate having passed through the filtration media is collected as the product. The media comprises a central core which is surrounded and wrapped by a plurality of overlying sheets of further fluid pervious media, the overlying sheets creating void spaces between sheets for trapping of at least some of the separated contaminants. | 1 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a process for manufacturing substituted triazolinones, which are intermediates in the preparation of herbicidally active compounds. In particular, this invention relates to the alkylation of a non-alkylated triazolinone intermediate product, wherein the improvement comprises conducting the alkylation reaction under pH controlled conditions. In this context the term “alkylation” represents a generic term and thus, includes the use of alkylating agents having an alkyl group, an alkenyl group, an alkynyl group, a cycloalkyl group, a cycloalkylalkyl group, an aryl group or an arylalkyl group.
In a preferred embodiment, the invention relates to the preparation of a 5-alkoxy(or aryloxy)-2,4-dihydro-3H-1,2,4-triazol-3-one, and the alkylation of this non-alkylated triazolinone intermediate product to produce a 5-alkoxy(or aryloxy)-4-alkyl-2,4-dihydro-3H-1,2,4-triazol-3-one.
BACKGROUND OF THE INVENTION
Triazolinones are well known in the art, as are processes for their preparation and use as herbicides. U.S. Pat. No. 5,708,183 describes a process for the preparation of substituted triazolinones by reacting triazolinethiones with methyl iodide, in the presence of an acid binding agent, and then heating the alkylthiodiazole derivative with hydrogen peroxide in the presence of acetic acid. U.S. Pat. No. 5,912,354 discloses a process for the preparation of substituted aminotriazolinones, which includes reacting an oxadiazolinone with hydrazine hydrate in the absence of a solvent. U.S. Pat. No. 5,917,050 describes a process for the preparation of alkoxytriazolinones by reacting thioimidodicarboxylic diesters with hydrazine, hydrazine hydrate or an acid adduct of hydrazine, in the presence of a diluent and a basic reaction auxiliary.
Further, U.S. Pat. Nos. 5,606,070; 5,599,945; and 5,594,148; each describes a process for the preparation of alkoxytriazolinones which includes reacting iminothiocarbonic diesters with carbazinic esters, and then subjecting the resultant semicarbazide derivatives to a cyclizing condensation reaction.
However, these prior art processes produce triazolinones in unsatisfactory yield and purity. Thus, there is a need in the art for a process to manufacture substituted triazolinones in high yield and purity.
BRIEF SUMMARY OF INVENTION
The present invention is related to a process for the preparation of a substituted triazolinone. The process includes the reaction of a thionocarbamate of the following general formula (I)
wherein
R 1 represents an unsubstituted or substituted alkyl, arylalkyl or aryl, and
R 2 represents an unsubstituted or substituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl or arylalkyl,
with hydrazine, hydrazine hydrate or an acid adduct of hydrazine, to produce a triazolinone intermediate product of the following general formula (II)
wherein
R 2 is as defined above.
The intermediate product of the general formula (II) is then reacted under pH controlled reaction conditions with an alkylating agent of the following general formula (III)
R 3 —X (III)
wherein
X represents a halogen, —O—SO 2 —O—R 3 , or —O—CO—O—R 3 , and
R 3 represents an unsubstituted or substituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl or arylalkyl, in the presence of a solvent and a base, to produce a substituted triazolinone of the following general formula (IV)
wherein
R 2 and R 3 are as defined above.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is related to a process for the preparation of a substituted triazolinone by the alkylation of a non-alkylated triazolinone intermediate product. In this context, the term “alkylation” is used as a generic term and thus, expressly includes the definition of R 3 provided below. The process includes the reaction of a thionocarbamate of the following general formula (I)
wherein
R 1 represents an unsubstituted or substituted alkyl, arylalkyl or aryl, and
R 2 represents an unsubstituted or substituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl or arylalkyl, with hydrazine, hydrazine hydrate or an acid adduct of hydrazine, to produce a triazolinone intermediate product of the following general formula (II)
wherein
R 2 is as defined above.
The intermediate product of the general formula (II) is then reacted under pH controlled reaction conditions with an alkylating agent of the following general formula (III)
R 3 —X (III)
wherein
X represents a halogen, —O—SO 2 —O—R 3 , or —O—CO—O—R 3 , and
R 3 represents an unsubstituted or substituted alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl or arylalkyl, in the presence of a solvent and a base, to produce a substituted triazolinone of the following general formula (IV)
wherein
R 2 and R 3 are as defined above.
In a preferred embodiment of the invention,
R 1 represents an alkyl group having 1 to 4 carbon atoms, a benzyl group or a phenyl group, and
R 2 represents an alkyl group, an alkenyl group or an alkynyl group having in each case up to 6 carbon atoms, and each of which is unsubstituted or substituted by cyano, halogen or C 1 -C 4 -alkoxy, or
represents a cycloalkyl group having 3 to 6 carbon atoms or a cycloalkylalkyl group having 3 to 6 carbon atoms in the cycloalkyl moiety and 1 to 4 carbon atoms in the alkyl moiety, each of which is unsubstituted or substituted by halogen or C 1 -C 4 -alkyl, or
represents an aryl group having 6 or 10 carbon atoms or an arylalkyl group having 6 or 10 carbon atoms in the aryl moiety and 1 to 4 carbon atoms in the alkyl moiety, each of which is unsubstituted or substituted by carboxyl, nitro, cyano, halogen, C 1 -C 4 -alkyl, C 1 -C 4 -halogenoalkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -halogenoalkoxy or C 1 -C 4 -alkoxy-carbonyl, and
R 3 represents an alkyl, alkenyl or alkynyl, each of which has up to 6 carbon atoms and each of which is unsubstituted or substituted by cyano, halogen or C 1 -C 4 -alkoxy, or
represents a cycloalkyl having 3 to 6 carbon atoms or a cycloalkylalkyl having 3 to 6 carbon atoms in the cycloalkyl moiety and 1 to 4 carbon atoms in the alkyl moiety, each of which is unsubstituted or substituted by halogen or C 1 -C 4 -alkyl, or
represents an aryl having 6 to 10 carbon atoms or an arylalkyl having 6 or 10 carbon atoms in the aryl moiety and 1 to 4 carbon atoms in the alkyl moiety, each of which is unsubstituted or substituted by carboxyl, cyano, nitro, halogen, C 1 -C 4 -alkyl, C 1 -C 4 -halogenoalkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -halogenoalkoxy or C 1 -C 4 -alkoxy-carbonyl.
More preferably,
R 2 represents methyl, ethyl, n- or i-propyl, n-, i-, s-, or t-butyl, each of which is unsubstituted or substituted by cyano, fluorine, chlorine or bromine, methoxy or ethoxy, or
represents propenyl, butenyl, propinyl or butinyl, each of which is unsubstituted or substituted by cyano, fluorine, chlorine or bromine, or
represents cyclopropyl or cyclopropylmethyl, each of which is unsubstituted or substituted by fluorine, chlorine, bromine, methyl or ethyl, or
represents phenyl or benzyl, each of which is unsubstituted or substituted by cyano, fluorine, chlorine, bromine, methyl, ethyl, trifluoromethyl, methoxy, ethoxy, difluoromethoxy, trifluoromethoxy, methoxycarbonyl or ethoxycarbonyl, and
R 3 represents methyl, ethyl, n- or i-propyl or n-, i-, s- or t-butyl, each of which is unsubstituted or substituted by cyano, fluorine, chlorine or bromine, methoxy or ethoxy, or
represents propenyl, butenyl, propinyl or butinyl, each of which is unsubstituted or substituted by cyano, fluorine, chlorine or bromine, or
represents cyclopropyl, cyclobutyl or cyclopropylmethyl, each of which unsubstituted or substituted by fluorine, chlorine, bromine, methyl or ethyl, or
represents phenyl or benzyl, each of which is unsubstituted or substituted by cyano, fluorine, chlorine, bromine, methyl, ethyl, trifluoromethyl, methoxy, ethoxy, difluoromethoxy, trifluoromethoxy, methoxycarbonyl or ethoxycarbonyl.
Most preferably,
R 1 and R 2 each represents methyl, n- or i-propyl, and
R 3 represents methyl.
The process of the invention may be conducted as a one pot process, without isolation of the intermediate product of formula (II).
The process according to the invention is generally carried out at atmospheric pressure. However, it is also possible to conduct the process under elevated or reduced pressure.
The reaction of a thionocarbamate with hydrazine, hydrazine hydrate or an acid adduct of hydrazine, is carried out at a temperature of from about −10° C. to about 95° C., and preferably at a temperature of from about 0° C. to about 60° C. Examples of suitable acid adducts of hydrazine include hydrazine acetate, hydrazine hydrochloride, and hydrazine sulfate.
In an embodiment of the invention, the reaction of the thionocarbamate with hydrazine, hydrazine hydrate or an acid adduct of hydrazine, is carried out in the presence of a base, a solvent, or mixtures thereof.
Suitable bases include customary inorganic or organic bases or acid acceptors. These include alkali metal or alkaline earth metal acetates, amides, carbonates, bicarbonates, hydrides, hydroxides, or alkoxides such as, for example, sodium acetate, potassium acetate or calcium acetate, lithium amide, sodium amide, potassium amide or calcium amide, sodium carbonate, potassium carbonate or calcium carbonate, sodium bicarbonate, potassium bicarbonate or calcium bicarbonate, lithium hydride, sodium hydride, potassium hydride or calcium hydride, lithium hydroxide, sodium hydroxide, potassium hydroxide or calcium hydroxide, sodium methoxide or potassium methoxide, sodium ethoxide or potassium ethoxide, sodium n- or i-propoxide or potassium n- or i-propoxide, sodium n-, i-, s- or t-butoxide or potassium n-, i-, s- or t-butoxide, and also basic organic nitrogen compounds such as trimethylamine, triethylamine, tripropylamine, tributylamine, ethyl diisopropylamine, N,N-dimethyl-cyclohexylamine, dicyclohexylamine, ethyl-dicyclohexylamine, N,N-dimethyl-aniline, N,N-dimethyl-benzylamine, pyridine, 2-methyl-, 3-methyl-, 4-methyl-, 2,4-dimethyl-, 2,6-dimethyl-, 3,4-dimethyl- and 3,5-dimethyl-pyridine, 5-ethyl-2-methyl-pyridine, 4-dimethylamino-pyridine, N-methyl-piperidine, 1,4-diazabicyclo[2.2.2]-octane (DABCO), 1,5-diazabicyclo[4.3.0]-non-5-ene (DBN), or 1,8-diazabicyclo[5.4.0]-undec-7-ene (DBU).
Suitable solvents include aliphatic, alicyclic or aromatic, unhalogenated or halogenated hydrocarbons such as, for example, benzene, toluene, xylene, chlorobenzene, dichlorobenzene, petroleum ether, hexane, cyclohexane, dichloromethane, chloroform, carbon tetrachloride; ethers such as diethyl ether, diisopropyl ether, dioxane, tetrahydrofuran or ethylene glycol dimethyl ether or ethylene glycol diethyl ether; ketones such as acetone, butanone, or methyl isobutyl ketone; nitriles such as acetonitrile, propionitrile or butyronitrile; amides such as N,N-dimethylformamide, N,N-dimethylacetamide, N-methyl-formanilide, N-methyl-pyrrolidone or hexamethylphosphoric triamide; esters such as methyl acetate or ethyl acetate; sulfoxides such as dimethyl sulfoxide; alcohols such as methanol, ethanol, n- or i-propanol, n-, i-, s- or t-butanol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether; water; and mixtures thereof.
Preferred solvents include water, methanol, propanol, and a commercially available mixture of xylenes containing ethylbenzene, ortho-xylene, para-xylene and meta-xylene.
In an embodiment of the invention, the reaction of a thionocarbamate with hydrazine hydrate is carried out in a mixture of water and methanol, or a mixture of water, propanol, and xylenes.
In another embodiment, a nitrogen flow is maintained through the reaction mixture for the purpose of removing the H 2 S formed in the reaction.
Further, in another embodiment of the invention, benzyl chloride is added to the reaction mixture containing the thionocarbamate and hydrazine, hydrazine hydrate or acid adduct of hydrazine, to improve the purity of the alkylated triazolinone product of formula (IV). The benzyl chloride is added to the reaction mixture at a temperature of from about −10° C. to about 95° C., in an amount such that the benzyl chloride is from about 0.1% to about 10% by mole of the mixture; and preferably from about 3% to about 5% by mole.
In an embodiment of the invention, a base is added to the reaction mixture following the completion of the reaction between the thionocarbamate and hydrazine, hydrazine hydrate or acid adduct of hydrazine. The base is added in an amount such that the pH of the resulting mixture is from about 8.0 to about 12.0. Suitable bases include alkali metal or alkaline earth metal salts of an acid having a pKa value of 5 or higher. Examples of such bases include alkali metal or alkaline earth metal hydroxides, carbonates, bicarbonates, and alkoxides. In a preferred embodiment, the base is potassium hydroxide.
In the process of the invention, following the completion of the reaction between the thionocarbamate and hydrazine, hydrazine hydrate or acid adduct of hydrazine, an alkylating agent is added to the reaction mixture. The alkylation of the intermediate compound of the formula (II) proceeds with high selectivity on the N atom in the 4-position. In this context, the terms “alkylation” and “alkylating agent” (formula III) are used as generic terms and thus, expressly include the above definition of R 3 .
The alkylation reaction is carried out at a temperature of from about −10° C. to about 95° C., and preferably at a temperature of from about 20° C. to about 70° C. As a result of adding the alkylating agent, the pH of the reaction mixture decreases to a value of from about 7.0 to about 9.0. The reaction mixture is then maintained at a pH of from about 7.0 to about 9.0, preferably from about 7.5 to about 8.5, and most preferably from about 7.9 to about 8.1, by the addition of a base to the mixture as necessary.
The reaction time for the alkylation step corresponds to the time that is necessary for the pH of the reaction mixture to remain stable between 7.0 and 9.0, and preferably between 7.5 and 8.5, without the addition of a base.
The base for use in the alkylation step of the present invention includes the conventional inorganic or organic bases. These include, for example, the hydrides, hydroxides, amides, alcoholates, acetates, carbonates, or hydrogen carbonates of alkaline earth metals or alkali metals such as, for example, sodium hydride, sodium amide, sodium methylate, sodium ethylate, potassium tert-butylate, sodium hydroxide, potassium hydroxide, ammonium hydroxide, sodium acetate, potassium acetate, calcium acetate, ammonium acetate, sodium carbonate, potassium carbonate, potassium hydrogen carbonate, sodium hydrogen carbonate, or ammonium carbonate, and also basic organic nitrogen compounds such as trimethylamine, triethylamine, tributylamine, N,N-dimethylaniline, N,N-dimethyl-benzylamine, pyridine, 1,4-diazabicyclo[2.2.2]-octane (DABCO), 1,5-diazabicyclo[4.3.0]-non-5-ene (DBN), or 1,8-diazabicyclo[5.4.0]-undec-7-ene (DBU).
Suitable alkylating agents for use in the process of the present invention include compounds of the general formula (III) as defined above. A preferred alkylating agent is dimethyl sulfate. The alkylation reaction is carried out in the presence of a solvent.
Suitable solvents for use in the alkylation reaction of the present invention include aliphatic, alicyclic or aromatic, optionally halogenated hydrocarbons such as, for example, benzene, toluene, xylene, chlorobenzene, dichlorobenzene, petroleum ether, hexane, cyclohexane, dichloromethane, chloroform, tetrachloromethane; ethers such as diethyl ether, diisopropyl ether, dioxane, tetrahydrofuran or ethylene glycol dimethyl ether or ethylene glycol diethyl ether; ketones such as acetone, butanone, or methyl isobutyl ketone; nitriles such as acetonitrile, propionitrile or benzonitrile; amides such as N,N-dimethylformamide, N,N-dimethylacetamide, N-methylformanilide, N-methyl-pyrrolidone or hexamethylphosphoric triamide; esters such as methyl acetate or ethyl acetate, sulfoxides such as dimethyl sulfoxide, alcohols such as methanol, ethanol, n- or i-propanol, n-, i-, s-, or t-butanol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether; water and mixtures thereof. Preferred solvents include methyl isobutyl ketone, methanol, propanol, water and a commercially available mixture of xylenes containing ethylbenzene, ortho-xylene, para-xylene, and meta-xylene.
In an embodiment of the invention, the alkylation reaction is carried out in the presence of a mixture of water, methanol and methyl isobutyl ketone, or a mixture of water, propanol and xylenes.
In another embodiment of the invention, the substituted triazolinone product of the general formula (IV) is isolated as a hydrate at the end of the alkylation reaction.
Further, in a preferred embodiment, 5-methoxy-4-methyl-2,4-dihydro-3H-1,2,4-triazol-3-one (MMT) is produced by methylating 5-methoxy-2,4-dihydro-3H-1,2,4-triazol-3-one (HMT) in a mixture of MIBK, methanol, and water. The molar ratio of HMT to MIBK is from about 1.0:2.0 to about 1.0:3.5, and preferably about 1.0:2.8. The molar ratio of HMT to methanol is from about 1.0:5.0 to about 1.0:15.0, and preferably about 1.0:9.5. The molar ratio of HMT to water is from about 1.0:3.0 to about 1.0:6.0, and preferably about 1.0:4.8.
Moreover, in a preferred embodiment, 5-propoxy-4-methyl-2,4-dihydro-3H-1,2,4-triazol-3-one (PMT) is produced by methylating 5-propoxy-2,4-dihydro-3H-1,2,4-triazol-3-one (HPT) in a mixture of xylenes, propanol, and water. The reaction mixture contains an aqueous phase and an organic phase. The aqueous phase (lower phase) is discarded and the PMT is recovered from the organic phase (upper phase) at a temperature of 60° C., in the presence of propanol and methanol. The molar ratio of HPT to xylenes is from about 1.0:2.0 to about 1.0:4.0, and preferably about 1.0:3.0. The molar ratio of HPT to propanol is from about 1.0:2.0 to about 1.0:6.0, and preferably about 1.0:4.0. The molar ratio of HPT to water is from about 1.0:3.0 to about 1.0:9.0, and preferably about 1.0:6.1.
The invention is further illustrated but is not intended to be limited by the following examples in which all parts and percentages are by weight unless otherwise specified.
EXAMPLES
Example 1
The Preparation of HMT
To a chilled (i.e., about 0° C.) solution containing 399.0 grams (2.68 moles) of N-methoxycarbonyl-O-methylthionocarbamate (MTC) and 710 grams of methanol, was added 17.8 grams (0.143 mole) of 45% aqueous potassium hydroxide and 40.0 grams of water. At a temperature of about 0° C., 133.8 grams (2.65 moles) of 64% hydrazine hydrate were added to the reaction mixture over a period of about 2 hours at a uniform rate. A net subsurface nitrogen flow (to help remove the H 2 S formed in the reaction) was maintained through the reaction mixture. The reaction mixture was stirred at a temperature of about 0° C. for about 4 hours. The mixture was then heated to a temperature of about 40° C. over a time period of about 2 hours. At a temperature of about 40° C., 17.1 grams (0.135 mole) of benzyl chloride were added to the reaction mixture and the mixture was maintained at this temperature for about 1 hour. The reaction mixture was then heated to a temperature of about 50° C. over a period of about 1 hour and the mixture was maintained at this temperature for about 2 hours. The reaction mixture contained about 262 grams (2.28 moles, 85% yield based on MTC) of 5-methoxy-2,4-dihydro-3H-1,2,4-triazol-3-one (HMT) in a mixture of methanol (MeOH) and water.
At this point, the HMT slurry was either further reacted to produce an 5-alkoxy-4-methyl-2,4-dihydro-3H-1,2,4-triazol-3-one (e.g., Example 3), or the pure HMT was isolated from the reaction mixture. To isolate the pure HMT, the reaction mixture was cooled to a temperature of about 0° C., filtered under vacuum and the filter cake was washed with 2 X 50 ml of cold (about 0° C.) methanol. The filter cake was then dried in a vacuum oven at a temperature of about 50° C. for about 16 hours to obtain 223.6 grams of HMT (96.5% purity and 70.0% yield based on MTC).
Example 2
The Preparation of HPT
To a solution containing 587.0 grams (2.86 moles) of N-propoxycarbonyl-O-propylthionocarbamate (PTC) and 240 grams of propanol, was added 280 grams of xylenes (i.e., a commercially available mixture of ethylbenzene, ortho-xylene, para-xylene and meta-xylene), 70.0 grams of water, and 4.2 grams (0.03 mole) of 45% aqueous potassium hydroxide. The reaction mixture was then cooled to a temperature of about 0° C. At a temperature of about 0° C., 146.0 grams (2.95 moles) of 64% hydrazine hydrate were added to the reaction mixture over a period of about 2 hours at a uniform rate. A net subsurface nitrogen flow (to help remove the H 2 S formed in the reaction) was maintained through the reaction mixture. Following addition of the hydrazine hydrate, the reaction mixture was heated to a temperature of about 20° C. and stirred for about 3 hours. The mixture was then heated to a temperature of about 50° C. over a time period of about 2 hours. The reaction mixture was cooked at a temperature of about 50° C. for about I hour. The reaction mixture was then diluted with 525 grams of xylenes. This slurry contained about 348 grams (2.43 moles, 85% yield based on PTC) of 5-propoxy-2,4-dihydro-3H-1,2,4-triazol-3-one (HPT) in a mixture of xylenes, propanol and water.
At this point, the HPT was further reacted to produce 5-propoxy-4-methyl-2,4-dihydro-3H-1,2,4-triazol-3-one (e.g., Example 4).
Example 3
Preparation of MMT Hydrate from HMT Slurry
To a HMT slurry (e.g., as prepared in Example 1), which contained 262 grams (2.28 moles) of HMT in a mixture of methanol and water, was added 45% aqueous potassium hydroxide (KOH) solution at a temperature of about 50° C., over a time period of about 30 minutes. The KOH solution was added in an amount such that the pH of the reaction mixture was increased to about 10.0. About 650 grams of methyl isobutyl ketone (MIBK) were then added to the reaction mixture, and the mixture was cooled to room temperature (i.e., about 25° C.). About 446 grams (3.54 moles) of dimethyl sulfate were then added to the mixture over a period of about 2 hours, while maintaining the temperature of the mixture from about 25° C. to about 30° C. As the dimethyl sulfate was added, the pH of the reaction mixture decreased. The pH of the mixture was maintained between about 7.9 and about 8.1 by the simultaneous addition of 45% aqueous KOH solution. Following addition of the dimethyl sulfate, the temperature of the reaction mixture was increased to about 60° C. over a time period of about 4 hours, while maintaining the pH between about 7.9 and about 8.1.
The reaction mixture was cooked at about 60° C. until the pH was stable; i.e., the point at which the addition of aqueous KOH was not necessary to maintain the pH between about 7.9 and about 8.1.
A fractional distillation of the reaction mixture was then conducted under reduced pressure to remove the methanol, and isolate the 5-methoxy-4-methyl-2,4-dihydro-3H-1,2,4-triazol-3-one (M MT) product as a hydrate. About 680 grams of water were added to the residue and heated to a temperature of about 75° C. to dissolve the MMT. The mixture was then cooled to a temperature of about 0° C. over a time period of about 4 hours, and stirred for about 1 hour. The resulting two phase slurry was filtered, and then washed with 280 grams of warm MIBK and 280 grams of ice cold water. The filter cake was dried at room temperature for about 8 hours under a 200 mm vacuum, to obtain 261 grams of MMT hydrate (1.74 moles, purity of 98% as hydrate, and yield of 76% based on HMT).
Example 4
Preparation of PMT Solution in Xylenes from HPT slurry in Xylenes/Propanol/Water
To a HPT slurry (e.g., as prepared in Example 2), which contained 348 grams (2.43 moles) of HPT in a mixture of xylenes, propanol and water, was added 45% aqueous potassium hydroxide (KOH) solution at a temperature of about 30° C., over a time period of about 30 minutes. The KOH solution was added in an amount such that the pH of the reaction mixture was increased to about 10.0. About 480 grams (3.77 moles) of dimethyl sulfate were then added to the mixture over a period of about 2 hours, while maintaining the temperature of the mixture from about 25° C. to about 30° C. As the dimethyl sulfate was added, the pH of the reaction mixture decreased. The pH of the mixture was maintained between about 7.9 and about 8.1 by the simultaneous addition of 45% aqueous KOH solution. Following addition of the dimethyl sulfate, the temperature of the reaction mixture was increased to about 60° C. over a time period of about 4 hours, while maintaining the pH between about 7.9 and about 8.1.
The reaction mixture was cooked at about 60° C. until the pH was stable; i.e., the point at which the addition of aqueous KOH was not necessary to maintain the pH between about 7.9 and about 8.1. Stirring of the reaction mixture was stopped and the mixture separated into two phases. The aqueous phase (lower phase) was discarded and the organic phase (upper phase) was subjected to distillation under reduced pressure to remove the methanol, dipropyl ether, propanol and water. The residue, which consisted of crude 5-propoxy-4-methyl-2,4-dihydro-3H-1,2,4-triazol-3-one (PMT) in xylenes, was diluted with fresh anhydrous xylenes to adjust its concentration to about 13% with respect to PMT. At this point the PMT solution contained 319 grams (2.03 moles) of PMT in 2455 grams of total solution. The solvent-free purity of PMT was 82% and the yield was 83.5% based on HPT.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The present invention relates to a process for manufacturing substituted triazolinones, which are intermediates in the preparation of herbicidally active compounds. In particular, this invention relates to the alkylation of a non-alkylated triazolinone intermediate product, wherein the improvement comprises conducting the alkylation reaction under pH controlled conditions. In a preferred embodiment, the invention relates to the preparation of a 5-alkoxy(or aryloxy)-2,4-dihydro-3H-1,2,4-triazol-3-one, and the alkylation of this non-alkylated triazolinone intermediate product, to produce a 5-alkoxy(or aryloxy)-4-alkyl-2,4-dihydro-3H-1,2,4-triazol-3-one. | 2 |
BACKGROUND OF THE INVENTION
The art of the present invention relates to musical instrument bridges in general and more particularly to a musical instrument bridge which efficiently transmits string energy into an instrument body yet maximally isolates individual string energy from other strings on the instrument.
Conventional stringed musical instruments such as guitars have one or more strings affixed or mounted along the length of the instrument. Said strings typically pass over a nut distal the musician and are fixed and tensioned by a tensioning adjustment, tuner, or tuning pegs at a first end. At a second end, said strings pass over a bridge and are anchored to a bridge plate or the instrument body itself. The vibrating length of the string is between said nut and bridge with said bridge typically having parallel adjustment with the string axis in order to shorten or lengthen said vibrating length. Vibrating length adjustment is necessary in order to achieve perfect intonation. That is for the western tonal system, an octave (i.e. twice the fundamental vibrating frequency) represents 12 half steps or logarithmic chromatic frequency divisions between notes of equivalent type. (e.g. A to A, C to C, etc.) Especially for fretted instruments such as a guitar, depression of a string located at the 12 th fret position away from the nut must produce a perfect octave relative to an open string. This intonation adjustment is only achievable if the vibrating length is adjustable since intonation is dependent on string mass and elastic properties.
For playability ease and optimization, it is desirable to minimize the musician imposed force between a string and the fretboard or neck in order to create a desired note. This is typically known as an easy “action” and means that the musician minimizes his or her effort during play. Unfortunately, too easy of an action, i.e. a string positioned very close to the fretboard or neck, creates a “buzz” or nonlinear resonance. Conventional stringed musical instruments thereby require adjustment of the string height relative to the neck or fretboard. Since said nut is usually affixed to the instrument, optimal string height is typically achieved by adjusting the bridge height.
Prior art bridges often provide bridge height adjustment via one or more semi-pointed setscrews threaded substantially perpendicularly through a saddle and seating or bearing upon a metal base plate attached with the instrument body. This prior art configuration transmits string vibration into the instrument body via the tip of said setscrews. Unfortunately, the acoustic impedance mismatch between said setscrew point and said plate and the frictional movement between the aforesaid fails to achieve high quality string tone and sustain. That is, without a solid connection between a string and the instrument body, the string energy attenuates rapidly and does not readily transmit into the body. The resulting poor tonal quality and sustain is especially noticeable for low frequency notes such as found in bass guitars. This is especially true for a bass guitar which often relies upon body and neck resonance for high quality note representation.
The aforesaid prior art bridge systems utilize said base plate mounted via screws to the body of the instrument without an integral attachment there between. Upon this base plate are mounted said bridge saddles that are aligned with and support each string. Unfortunately, the prior art often retains the string via this plate whereby string force tends to pull said plate away from the instrument body. This force further limits the energy transmitted to the instrument body, especially when a minute gap forms there between. That is, the string force prevents a solid connection between the string and instrument body. Variations of the prior art mounting methods are shown and described in U.S. Pat. No. 4,208,941 entitled Adjustable Bridge Saddle by Wechter with issue date of Jun. 24, 1980, U.S. Pat. No. 5,285,710 entitled Adjustable Bridge for a Stringed Musical Instrument by Chapman with issue date of Feb. 15, 1994, and U.S. Pat. No. 5,295,427 entitled Bridge for String Instruments by Johnsen with issue date of Mar. 22, 1994.
Said prior art bridge systems also generate undesirable fundamental or harmonic interaction between the strings on a multi string instrument. Since the bridge comprises a continuous metallic base plate of different acoustic impedance than the wood, polymer, or composite material of the body, acoustic energy is reflected from the interface and retained within said bridge. Since the metallic base plate structure is not highly attenuating, said energy is transmitted to other strings retained by said base plate and induces unwanted vibration thereon.
The present art overcomes the prior art limitations with a uniquely constructed and body attached bridge apparatus which minimizes string energy loss and maximizes acoustic energy transmission into the instrument body. Unlike the prior art, each bridge piece of the present art is a solid construction which is secured to the instrument body and thereby maximizes tonal purity and sustain and minimizes harmonic interaction between the strings.
The present art not only provides the aforesaid benefits via a string support assembly but further utilizes a unique string retention assembly whereby acoustic separation and body transmission is assured. That is, the string retention assembly of the present art is integral with and internal to the instrument body. This arrangement provides an acoustic energy feed directly into the body of the instrument for any energy transmitted past the string support assembly via the strings.
Accordingly, an object of the present invention is to provide an optimally coupled string instrument bridge and method of manufacture which maximizes acoustic energy transmission into the body of the instrument.
Another object of the invention is to provide an optimally coupled string instrument bridge and method of manufacture which maximally isolates fundamental and harmonic vibratory interaction between strings on the instrument.
A further object of the present invention is to provide an optimally coupled string instrument bridge and method of manufacture having strings secured to the instrument body and not the bridge whereby said bridge is not forcibly pulled away from said body.
A still further object of the invention is to provide an optimally coupled string instrument bridge and method of manufacture which provides all of the length and height adjustment features of a conventional bridge without the undesirable coupling and transmission characteristics.
A yet further object of the invention is to provide an optimally coupled string instrument bridge and method of manufacture which minimizes the acoustic impedance mismatch between the bridge assembly and the instrument body.
SUMMARY OF THE INVENTION
To accomplish the foregoing and other objects of this invention there is provided an optimally coupled string instrument bridge and method of manufacture for obtaining maximum energy transmission, sustain, and tonal quality without string harmonic interaction. The apparatus and method is useful with stringed instruments and more particularly with guitars, especially bass guitars.
The apparatus is provided as a bridge comprised of individual assemblies for each string of the instrument. Each individual assembly comprises a string support assembly and a string retention assembly. For a preferred embodiment, each string support assembly comprises an internally threaded base sleeve mounted into the instrument body, a bridge piece capable of adjustable retention within said threaded base sleeve, and a saddle piece within said bridge piece onto which a string is accepted within a groove. Within the preferred embodiment, each string retention assembly comprises an upper guide tube, a retention ferrule into which a string ball end or eyelet seats, and a lower guide tube, all of which are mounted within the instrument body rearward of the support assembly.
Each string support assembly anchors and mates intimately with the instrument body via the base sleeve at an optimal intonation site. Each base sleeve has a substantial cylindrical surface area contacting with and preferably bonded within said body. This large contact area assures maximum transmission of acoustic energy into the instrument body. Each string retention assembly is also bonded or pressed into said body whereby a string is held by the body and not the support assembly. The combination of the aforesaid efficiently transmits vibratory energy into the body of the instrument while also isolating vibrations or energy coupling between adjacent strings.
The threaded mate between the bridge piece and base sleeve further provides the desired string height adjustment via rotation of said bridge piece. Movement of the saddle piece within a channel within the bridge piece further allows intonation adjustment. The aforesaid adjustments are typically performed without tension on the supported string. That is, the strings are removed or partially removed.
The art of the present invention may be manufactured from a plurality of materials including but not limited to brass or copper materials, steels, titanium, aluminum, (and alloys thereof), composites, polymers, woods, or ceramics. In the preferred embodiment, said bridge assemblies are each manufactured from brass.
BRIEF DESCRIPTION OF THE DRAWINGS
Numerous other objects, features and advantages of the invention should now become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a front plan view of an optimally coupled string instrument bridge mounted with a bass guitar and showing the complete guitar for clarity of placement.
FIG. 2 is an exploded front face plan view of an optimally coupled string instrument bridge also mounted with a bass guitar.
FIG. 3 is a perspective view of a preferred optimally coupled string instrument bridge mounted with a body portion of a four string bass guitar.
FIG. 4 is a cross section view taken along line 4 - 4 of FIG. 2 .
FIG. 5 is a top plan view of an optimally coupled string instrument bridge mounted with a stringed instrument.
FIG. 6 is an assembly view of a string support assembly.
FIG. 7 is an assembly view of a string retention assembly.
FIG. 8 is a top plan view of an alternative embodiment showing the string support assembly canted rearward or towards the body rear portion.
FIG. 9 is a cross section view of an alternative embodiment bridge piece taken along the same line as the cross sectional bridge piece of FIG. 4 .
DETAILED DESCRIPTION
Referring now to the drawings, there is shown in FIGS. 1-7 a preferred embodiment and in FIGS. 8 & 9 an alternative embodiment of an optimally coupled string instrument bridge 10 . The bridge 10 provides height and intonation adjustments and also provides better coupling of the string 22 vibration into the instrument body 14 . The apparatus further provides superior acoustic isolation between the strings 22 on the instrument.
A stringed musical instrument incorporating the present art comprises a body 14 having a body face 16 , a body back 18 , and a body rear portion 20 , a neck 12 , and one or more strings 22 supported by a bridge assembly 24 and a nut 11 opposite said bridge 24 . The strings 22 are retained via the tension imparted thereto between a retention assembly 52 mounted with said body 14 and a tensioning adjustment or tuning peg apparatus opposite said retention assembly 52 .
For the preferred embodiment, each string 22 is supported and retained by an individual bridge assembly 24 comprising a string support assembly 26 and a string retention assembly 52 . The string support assembly 24 first comprises a base sleeve 28 mounted within the body 14 through the body face 16 and within a body face hole 17 . That is, in a preferred embodiment, the base sleeve 28 is a cylindrical tube 30 which is recessed and held into the instrument body 14 through the body face 16 and sized to fit said face hole 17 . In a preferred embodiment said sleeve 28 is pressed and adhesively epoxy bonded into said body 14 . Alternative embodiments may utilize only a frictional fit, other adhesives than epoxy, other cross sectional sleeve 28 shapes, or forgo use of said sleeve 28 as a separated element and form said sleeve 28 as an integral portion of said body 14 .
In a preferred embodiment, the base sleeve 28 is a cylindrical tube 30 having internal threads 32 and a flat bottom side 33 which contacts the base 19 of the body face hole 17 . Also in a preferred embodiment, when recessed into the instrument body 14 , a top side 35 is finished substantially flush with the body face 16 , whether said face 16 is curved or flat. The central axis of the base sleeve 28 is mounted substantially perpendicular to the axis of the string 22 in a preferred embodiment or angled whereby the top side 35 is closer to the body rear portion 20 relative to the bottom side 33 , in an alternative embodiment. The alternative mounting method places substantially more of the vectorial string 22 force onto the central axis of the base sleeve 28 and also aids in intonation compensation during string 22 height adjustment.
The string support assembly 24 next comprises a bridge piece 34 which is a substantially solid cylinder 36 in a preferred embodiment. Said cylinder 36 has external threads 38 which are capable of mating with said internal threads 32 of the base sleeve 28 . That is, the bridge piece 34 may be adjustably accepted by said base sleeve 28 . The bridge piece 34 further has a channel 42 on a top surface 40 of preferably rectangular cross section which is capable of accepting a saddle piece 48 . Also in the preferred embodiment, a threaded hole 44 within said piece 34 is substantially perpendicular to and intersecting the run of said channel 42 . Said threaded hole 44 is located to accept a setscrew 46 externally and allow said setscrew 46 to forcibly lock or retain said saddle piece into position. In a preferred embodiment, said setscrew 46 is externally adjustable with the instrument fully assembled. Alternative embodiments may forego use of said channel 42 and incorporate the features of said saddle piece 48 into said bridge piece 34 as an integral saddle piece 48 or utilize channels 42 of various geometric cross sections or utilize said channel 42 for string 22 support. Alternative embodiments may also utilize other methods for adjustment of said bridge piece 34 within said base sleeve 28 including but not limited to steps, notches, pins, screws, or frictional mating.
Further alternative embodiments of said bridge piece 34 minimize the acoustic impedance mismatch between the string support assembly 26 and the body 14 whereby maximum acoustic energy is transmitted into the body 14 . That is, the acoustic impedance of a material is proportional to the material density (ρ) multiplied by the acoustic velocity (c) or the square root of the density (ρ) divided by the modulus of elasticity (λ, Young's modulus) within the material.
Z O ∝ ρ · c ∝ ρ λ
Since the bridge piece 34 is typically of a metallic material such as brass and the body is of a wood, composite, or polymer material, the density, elasticity, and velocity differences within the relative materials create an acoustic mismatch. The acoustic mismatch between the body 14 and string support assembly 26 may be more closely matched and thereby maximize acoustic energy transmission if the aforesaid solid cylinder 36 has a recess or hollow portion 37 which reduces volumetric density. The recess or hollow portion 37 is of a volume determined by a diameter and depth which produces the most desirable amount of energy coupling for the musician. Thus, a musician may have varied and multiple volume bridge pieces 34 on a single instrument in order to minimize or maximize the acoustic energy coupled with the body 14 for each string 22 .
Said saddle piece 48 is of preferably block form and designed to fit into the channel 42 of said bridge piece 34 . The preferred embodiment has a groove 50 in a top end 51 into which the string 22 is accepted and is supported. Preferably said groove 50 is of arcuate form whereby string 22 contact is minimized to a small portion of said groove 50 . If the string 22 contact with said saddle 48 is limited to a specific contact point, the vibrating string 22 length variation during play is minimized and tonal quality is maximized.
The string retention assembly 52 is preferably placed and held within a stepped body retention hole 21 within said body 14 . The assembly 52 first comprises an upper guide tube 54 which is mounted within said body 14 substantially flush with said body face 16 . A retention ferrule 58 having a retention hole 60 larger than said string 22 is positioned within said body 14 between said upper guide tube 54 and a lower guide tube 56 . Preferably said lower guide tube 56 is substantially flush with said body back 18 . That is, the string retention assembly 52 is substantially surrounded by said body 14 within said stepped body retention hole 21 except at the face 16 and back 18 . The lower guide tube 56 inside diameter is of greater diameter and the upper guide tube 54 inside diameter and retention hole 60 is of smaller diameter than a string 22 ball end or eyelet. Alternative embodiments may utilize a string retention assembly 52 having fewer or greater component parts or forgo use of said assembly 52 as a separated element and form said assembly 52 as an integral portion of said body 14 .
Assembly and manufacture of the present art instrument bridge 10 begins with forming or placement of the stepped body retention holes 21 . This is typically performed by drilling a smaller angled hole toward the body rear portion 20 from the body face 16 for upper guide tube 54 retention and counter-drilling said smaller hole to form a larger hole from the body back 18 for lower guide tube 56 retention. Preferably said holes are sized to intimately fit an outer diameter of said guide tubes 54 , 56 . Said upper guide tube 54 is then pressed and preferably adhesively bonded (i.e. epoxy) in place from said face 16 , said retention ferrule 58 is pressed and bonded from said back 18 and thereafter the lower guide tube 56 is also pressed and bonded in place. In the preferred embodiment, said tubes 54 , 56 are finished substantially flush with said body face 16 and back 18 respectively.
In the preferred embodiment, each stepped body retention hole 21 is positioned on said body 14 in order to maintain a relatively and substantially constant distance from the respective individual string support assembly 26 for all of said assemblies 26 . That is, lighter gauge strings typically require said string support assembly 26 positioning slightly closer to said nut 11 in order to optimize intonation. The stepped body retention holes 21 are thereby positioned closer to said nut 11 in order to maintain said constant distance. On many stringed instruments, especially guitars, support assembly 26 and retention assembly 52 placement moves toward the nut 11 distally from the musician since the string gauge is lightest near the body bottom 23 .
The body face holes 17 are then placed in said body face 16 , said base sleeves 28 are pressed into said holes 17 with the bottom side 33 seated onto the base 19 , and each sleeve 28 is adhesively secured (i.e. epoxy) therein. Said placement is chosen to optimize said intonation placement conditions. Bridge pieces 34 are thereafter threaded within said sleeves 28 to the desired depth for optimum action. The saddle piece 48 is placed within said channel 42 and preferably secured with said setscrew 46 .
String 22 placement then proceeds with threading each string 22 through the respective lower guide tube 56 , retention ferrule 58 retention hole 60 , and the upper guide tube 54 . As stated, the ball or eyelet end of the string 22 is larger than the upper guide tube 54 and retention hole 60 inside diameter and thereby seats with said retention ferrule 58 . Each string 22 is then stretched across the respective saddle piece 48 within said top end 51 groove 50 towards the nut 11 , seated with said nut 11 and retained and tuned by the tuning assembly, tuning pegs, or tuners. Upon assembly, intonation is optimized via adjustment of the saddle pieces 48 toward or away from said nut 11 .
Those skilled in the art will appreciate that an optimally coupled string instrument bridge 10 apparatus and method of manufacture and use has been shown and described. Said present art utilizes a bridge assembly 24 with a large contact area between the support assembly 26 and instrument and also utilizes a retention assembly 52 incorporating the instrument body 14 for string retention whereby string forces and energy are concentrated onto and into the instrument body 14 . The present art provides optimum coupling into the instrument body 14 resulting in better tonal quality due to resonances within the instrument whereby different frequencies of the audio spectrum are diminished or reinforced. The integral body 14 mounting further provides an improved sustain characteristic, i.e. the decay time of a plucked string is longer.
Having described the invention in detail, those skilled in the art will appreciate that modifications may be made of the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described. Rather it is intended that the scope of this invention be determined by the appended claims and their equivalents. | An optimally coupled stringed musical instrument bridge having an individual bridge assembly supporting and retaining each string. Each assembly comprises an action (height) and intonation (length) adjustable string support assembly and string retention assembly integrally incorporated into the instrument body. The bridge minimizes acoustic energy lost to friction, thereby increasing sustain, minimizes fundamental or harmonic interaction between strings, and maximizes acoustic energy transmitted to the instrument body, thereby allowing the natural instrument resonances to emanate. The bridge and its attributes are especially suited for use with bass guitars. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a cured rubber body having a cellular structure and useful in a variety of applications not only in various general-purpose applications requiring a so-called spongy rubber such as puffs for spreading cosmetic compositions over the human skin but also in office-automation machines equipped with a spongy rubber roller such as laser beam printers and photocopying machines including development rollers, electrostatic charging rollers, toner-carrying rollers, toner-transfer rollers, cleaning rollers for photosensitive drums, referred to simply as cleaning rollers hereinafter, and the like. The spongy rubber of the invention is particularly suitable as a material for forming the rubber layer of a cleaning roller.
Following is a description of the background situations leading to the use of a spongy rubber roller in office-automation machines. In a laser beam printer or a photocopying machine, namely, it is always the case in toner transfer in the image-forming unit that not all of the toner particles are transferred onto the paper sheet but a substantial amount of the toner particles are left untransferred on the photosensitive drum necessitating provision of a recovery system for the remaining toner particles. If the toner-recovery system works incompletely, the printed matter obtained by a succeeding printing run is necessarily contaminated with the toner particles remaining on the photosensitive drum in the preceding run leading to blur of the printed images not to give a printed matter of high quality.
In view of this problem, it is conventional that a spongy rubber is employed for the rubber layer of a rubber roller such as cleaning rollers, development rollers, toner-transfer rollers and the like working smoothly for removal of the remaining toner particles deposited on the photosensitive drum, for development with fresh toner particles onto the photosensitive drum and transfer of the toner particles onto a paper sheet. The spongy rubber roller here implied is an integral elongated body consisting of a shaft of an electroconductive material including metals and alloys such as iron, aluminum, copper, stainless steels, zinc and brass or a shaft having a plating layer of these metals or alloys on the surface of an insulating rod and a layer of a spongy rubber coaxially formed on and around the shaft.
It is sometimes the case that, in these spongy rubber rollers, the rubber layer is required to have semiconductivity which is imparted to the rubber by compounding a rubber compound or, in particular, silicone rubber compound with a substantial amount of a conductivity-imparting agent such as carbon blacks. Since carbon blacks in general have an activity to inhibit curing of a silicone rubber curable with an organic peroxide as a curing agent, it is desirable that the silicone rubber compound is of the type which is free from the inhibitive effect of carbon blacks on curing such as those curable by the crosslinking mechanism involving the hydrosilation addition reaction. The most conventional blowing agent for forming the foamed cellular structure of the spongy rubber is azobisisobutyronitrile (AIBN). A spongy rubber body is obtained by heating the silicone rubber composition compounded with the curing agent and blowing agent in a hot-air oven, infrared oven, high-frequency induction heating oven and the like to effect simultaneous curing and foaming of the rubber composition under normal pressure.
As a major current in recent years, many of the office-automation machines are designed for the use of a toner having a decreased average particle diameter such as so-called polymerization toners. As a result of this shift toward finer toner particles, a new problem has arisen in conventional cleaning rollers currently under use that the average cell diameter of the spongy rubber layer of the roller, which is 20 μm or larger, is too large to comply with the decrease in the toner particle diameter so that cleaning of the photosensitive drum cannot be complete leaving some toner particles thereon unremoved adversely affecting the quality of the next printed matter. The “cell” of a spongy rubber here implied is the pore of the spongy rubber appearing on the surface and the average cell diameter, referred to simply as the cell diameter hereinafter, is calculated for 10 cells taken at random determining the cell diameter as the diameter of the largest circumcircle to the cell contour. Similarly, another problem is encountered in transfer rollers that the electric field on the spongy rubber layer is dependent on the cell diameter so that, when the cell diameter is too large, the image of the cells is transferred to the printed pattern.
With regard to development rollers, furthermore, the rubber layer on and around the metal shaft in a conventional development roller is formed not from a spongy rubber but from a solid, i.e. non-spongy, rubber in view of the duty of the development roller to put the toner particles uniformly onto the photosensitive drum. In order to comply with the demand for higher quality of printing and increase in the printing velocity, it is a requirement that the rubber layer of development rollers is formed from a rubber having a decreased rubber hardness. If the matter concerned is the rubber hardness alone, the problem can easily be solved by using a solid rubber of an inherently low rubber hardness but another problem must be solved in a development roller made from a low-hardness solid rubber that low-hardness rubbers in general exhibit a large permanent compression set resulting in a decrease in the durability of the rubber roller adversely affecting the printing quality in the long run.
Although it is possible even in the prior art method that a low-hardness spongy rubber having a cell diameter of about 150 μm can be prepared by adequately controlling the curing velocity and foaming velocity, it is a difficult matter to obtain a low-hardness spongy rubber having a rubber hardness not exceeding 40° Hs required for standard products of development rollers if not to mention that such a modification of the process conditions involves a serious disadvantage of a decrease in the productivity.
As regard to the application of spongy rubbers in the general industrial field, on the other hand, or, in particular, in relation to spongy rubber puffs used in cosmetic makeup for spreading a cosmetic composition over the skin, greatly diversified spongy rubbers are employed as the material of cosmetic puffs depending on the formulation and properties of the cosmetic compositions and preference of the respective users while a common problem must be solved in the spongy rubber materials for puffs in general. When the cell diameter of the spongy rubber puffs for spreading of a powdery foundation is too large, for example, a large bit of the foundation particles is held in a single pore of the spongy puff which cannot be spread over the skin with full smoothness and uniformity unless the foundation is spread to form a layer of a large thickness disregarding the unhealthy influences on the skin. Needless to say, a spongy cosmetic puff having cells of too coarse cell diameters is not preferred by consumers in respect of unpleasant touch feeling to the skin.
From the standpoint of giving a solution to the above described problems, spongy rubbers are required to have a cell diameter not exceeding 200 μm or, preferably, not exceeding 100 μm and a rubber hardness in the range from 10 to 40° Hs. In particular, the spongy rubber forming the rubber layer of development rollers is required to have a cell diameter not exceeding 50 μm.
SUMMARY OF THE INVENTION
The present invention accordingly has an object to provide a novel and improved spongy rubber having a cellular structure and free from the above described problems and disadvantages encountered in the prior art when the spongy rubber is used as a material of spongy rubber puffs for cosmetic makeup or as a material of spongy rubber rollers used in photocopying machines and the like.
Thus, the spongy rubber body provided by the present invention is a body having a cellular structure consisting of a blend of 100 parts by weight of a rubber composition, which is preferably a silicone rubber composition, and from 5 to 200 parts by weight of globular, preferably, hollow particles having an average particle diameter in the range from 0.1 to 100 μm.
In particular, the spongy rubber body has a rubber hardness in the range from 10 to 40° Hs according to the Ascar C scale and the cellular structure has an average cell diameter in the range from 10 to 200 μm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, a detailed description is given on the spongy rubber body of the invention but the following description is given mainly for spongy silicone rubbers as a material of the rubber layer of spongy rubber rollers which is imparted with semiconductivity by compounding the rubber composition with a conductivity-imparting agent such as a conductive carbon black. The same description, however, is applicable also to the spongy rubber suitable as a material of spongy rubber puffs for cosmetic makeup when the description relative to the conductivity-imparting agent is disregarded.
As is described above, the spongy rubber body of the invention is formed from a blend of a rubber composition and a specified amount of globular particles having a specified average particle diameter. A great variety of rubber compounds can be used in the above mentioned rubber composition as the base material of the inventive spongy rubber body including NBRs, EPDM rubbers, urethane rubbers, silicone rubbers and the like, of which silicone rubbers are preferable, especially, as a material of spongy rubber cleaning rollers of which controllability of the cell diameter and electrostatic chargeability is essential each in a specified range. Silicone rubber compounds of a preferred type include those comprising a gum-like organopolysiloxane having silicon-bonded vinyl groups compounded with a curing agent which is a combination of an organohydrogenpolysiloxane and a platinum compound as a catalyst, reaction moderator, curing aid, reinforcing filler and other additives as well as a blowing agent.
As is known, the basic ingredients in a silicone rubber compound are an organopolysiloxane gum such as dimethylpolysiloxane gum, methylphenylpolysiloxane gum, methylvinylpolysiloxane gum and the like, a reinforcing silica filler such as fumed silica fillers, precipitated silica gillers and the like and a curing agent. When the organopolysiloxane gum is a methylvinylpolysiloxane gum having at least two silicon-bonded vinyl groups in a molecule, the curing agent is, as is mentioned above, a combination of an organohydrogenpolysiloxane and a catalytic amount of a platinum compound. Admixture of a curing aid such as an organic peroxide has an effect to improve the mechanical strengths and permanent compression set of cured silicone rubber products. Examples of suitable organic peroxides include benzoyl peroxide, bis(2,4-dichlorobenzoyl) peroxide, dicumyl peroxide, di-tert-butyl peroxide, 2,5-dimethyl-2,5-bis(tert-butylperoxy) hexane and the like.
It is optional that a silicone rubber compound is compounded with a non-reinforcing silica filler with an object to further improve heat resistance of the silicone rubber or to modify the rubber hardness of the cured silicone rubber. When a semiconductive spongy rubber roller is desired, the silicone rubber composition of the above described formulation is further admixed with a conductivity-imparting agent such as a carbon black. The cellular structure of the spongy rubber can be obtained by compounding the rubber composition with a blowing agent which is selected from inorganic blowing agents such as sodium hydrogencarbonate and organic blowing agents such as ADCA, AIBN and 1,1′-azobis(1-acetoxy-1-phenyl) ethane as preferable examples in respect of easiness in obtaining a good balance between curing and expansion of the rubber composition proceeding concurrently in molding of the spongy rubber body at a temperature of 100 to 200° C. depending on the decomposition temperature of the blowing agent. The amount of the blowing agent contained in the silicone rubber composition is in the range from 0.5 to 20 parts by weight per 100 parts by weight of the silicone rubber compound. When the amount of the blowing agent is too small, satisfactory expansion of the rubber composition to form the cellular structure cannot be accomplished as a matter of course while, when the amount thereof is too large, the porosity of the foamed silicone rubber would be excessively large so that the spongy rubber body of the so coarse texture is no longer suitable for most applications due to a great decrease in the mechanical strengths.
Examples of the reaction moderator mentioned above include methyl vinyl cyclotetrasiloxanes, acetylene alcohols, siloxane-modified acetylene alcohols, organic hydroperoxides and the like. Organic peroxides serve as a curing aid and non-reinforcing silica fillers serve as an additive for modifying the rubber hardness and improving the heat resistance of the cured and foamed silicone rubber. The platinum compound as a part of the curing agent as combined with an organohydrogenpolysiloxane can be selected from chloroplatinic acid, alcohol-modified chloroplatinic acid and complexes of chloroplatinic acid with an olefin, e.g., ethylene, vinylsiloxane, and the like as well as finely divided elementary platinum supported on a solid carrier material such as silica, alumina, carbon and the like. Various kinds of inorganic fillers can also be used as a non-reinforcing filler in a limited amount with an object of controlling the electrostatic chargeability.
The silicone rubber composition from which the spongy silicone rubber body of the invention is obtained by curing and expansion is prepared by compounding the above described silicone rubber compound with a specified amount of globular particles which serve as an aid for promoting uniform dispersion of the blowing agent in the silicone rubber composition for spongy rubber rollers and spongy rubber puffs so as to ensure uniformity of the cellular structure formed by the thermal decomposition of the blowing agent as well as uniform dispersion of the carbon black particles added to a silicone rubber composition for spongy silicone rubber rollers so as to prevent local non-uniformity in the volume resistivity of the semiconductive spongy silicone rubber layer.
The globular particle implied in the present invention is a particle having a smooth and continuous convexed surface without any acutely angled points and ridges so that the configuration of the globular particle is not limited to a true sphere. Examples of globular particles include so-called spherical silica particles, spherical silicone rubber particles and spherical carbon particles, which may be hollow or non-hollow, though not particularly limitative thereto. The above mentioned non-angular configuration of the globular particles such as spheres and ellipsoids is important when the spongy rubber roller is a cleaning roller or a development roller of a photocopying machine coming into contact with the photosensitive drum. Angled configuration of the globular particles such as quadrangular and triangular pyramids is undesirable because of possible troubles due to occurrence of scratches on the surface of the photosensitive drum by contacting with the spongy silicone rubber roller containing angled particles. In other words, globular particles having a particle configuration of a pyramid can be used if the angled ridhes and points are adequately chamfered or dulled. In this regard, use of globular particles having a hollow structure is advantageous because of a decrease in the occurrence of scratches on the surface of the photosensitive drum by contacting with the spongy rubber roller or the rough touch feeling of the spongy rubber puffs coming into direct contact with the skin of the face.
The amount of the globular particles in the silicone rubber composition for the formation of a spongy rubber roller or spongy rubber puff is in the range from 5 to 200 parts by weight per 100 parts by weight of the silicone rubber compound. When the amount of the globular particles is too small, the advantageous effect to be obtained therewith would be insufficient as a matter of course while, when the amount of the globular particles is too large, difficulties are encountered in respect of the workability of the silicone rubber composition and the spongy rubber body formed therefrom would suffer a decrease in the general properties as a spongy rubber.
As to the particle size distribution of the globular particles, it is desirable that the average particle diameter of the particles is in the range from 0.1 to 100 μm or, preferably, from 0.1 to 50 μm. When the average particle diameter thereof is too small, agglomeration of the particles is sometimes unavoidable while, when the average particle diameter is too large, some of the globular particles eventually fall off the cell walls of the spongy rubber body resulting in a decrease in the general properties of the spongy rubber.
In the following, the spongy rubber body of the invention is described in more detail by way of working examples which, however, never limit the scope of the invention in any way.
EXAMPLE 1
A curable and foamable semiconductive silicone rubber composition was prepared by uniformly blending 100 parts by weight of an electroconductive silicone rubber compound (TCM 5406U, a product by Toshiba Silicone Corp.) with 20 parts by weight of hollow spherical silicone rubber particles having an average particle diameter of 5 μm, 2 parts by weight of an organohydrogenpolysiloxane, 15 parts by weight of 1,1-azobis(1-acetoxy-1-phenyl) ethane as a blowing agent and a catalytic amount of chloroplatinic acid.
Separately, a metal rod as a roller shaft having a diameter of 6 mm and a length of 250 mm provided with a plating layer of nickel by the method of electroless plating was degreased by washing with toluene and then subjected to a primer treatment by coating with a primer solution followed by baking in a Geer oven at 180° C. for 30 minutes and spontaneous cooling to room temperature taking 30 minutes or more.
The silicone rubber composition was extrusion-molded on and around the thus primer-treated metal shaft to form a coaxial layer of the silicone rubber composition which was subjected to a heat treatment in two steps first in an infrared oven at 200° C. for 10 minutes to effect primary curing and then in a Geer oven at 225° C. for 7 hours to effect secondary curing followed by standing at room temperature for 1 hour and then grinding of the surface on a cylindrical grinder to give an outer diameter of the spongy rubber layer of 12 mm.
The semiconductive spongy silicone rubber roller prepared in this manner was subjected to the evaluation tests for the items including; average cell diameter on the surface of the spongy silicone rubber layer; bulk density of the spongy rubber layer; rubber hardness of the spongy rubber layer; permanent compression set of the rubber layer; and roller resistance and the variation range thereof, i.e. the ratio of the largest value and smallest value of the roller resistance. The results of the evaluation tests are shown in Table 1 below.
The testing procedures for the respective test items are given below.
(1) Average cell diameter, μm: A 100 magnification photograph of the roller surface was taken with an optical microscope and the diameters of 10 cells taken at random were measured and averaged.
(2) Bulk density, g/cm 3 : Measurement was made by using a specific gravity tester (Model ED-120T, manufactured by MFD BY A & D Co.).
(3) Rubber hardness, ° Hs: Measurements were made according to the Ascar C scale.
(4) Permanent compression set, mm: The spongy rubber roller was mounted on a horizontal bed and pressed against the bed by hanging a 500 g weight on each of the end portions of the metal shaft extending out of the rubber layer to be kept as such for 2 weeks in an atmosphere of 90% relative humidity at 40° C. The rubber roller taken up by removing the weights was kept standing for 24 hours at 20° C. and the thickness of the rubber layer was measured for the portion under compression for 2 weeks at 40° C. to record the decrease in the thickness of the spongy rubber layer due to prolonged compression.
(5) Roller resistance, ohm: The spongy rubber roller was mounted on a horizontal electrode plate and pressed against the electrode plate by hanging a 100 g weight on each of the end portions of the metal shaft extending out of the spongy rubber layer. The electric resistance between the metal shaft and the electrode plate was determined by four-point measurement using an ultra-high resistance meter (manufactured by Advantest Co.) after application of a DC voltage of 100 volts for 10 seconds and the averaged value was recorded as the roller resistance.
(6) Range of roller resistance: The ratio of the largest value and smallest value obtained in the roller resistance measurement was calculated and recorded.
EXAMPLE 2
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the hollow spherical silicone rubber particles had an average particle diameter of 50 μm instead of 5 μm.
The results of the evaluation tests are shown in Table 1 below.
EXAMPLE 3
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the hollow spherical silicone rubber particles had an average particle diameter of 0.2 μm instead of 5 μm.
The results of the evaluation tests are shown in Table 1 below.
EXAMPLE 4
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the hollow spherical silicone rubber particles were replaced with the same amount of hollow spherical silica particles having an average particle diameter of 5 μm.
The results of the evaluation tests are shown in Table 1 below.
EXAMPLE 5
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the hollow spherical silicone rubber particles were replaced with the same amount of solid, i.e. non-hollow, spherical silicone rubber particles having an average particle diameter of 5 μm.
The results of the evaluation tests are shown in Table 1 below.
EXAMPLE 6
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the hollow spherical silicone rubber particles were replaced with the same amount of solid, i.e. non-hollow, spherical silica particles having an average particle diameter of 5 μm.
The results of the evaluation tests are shown in Table 1 below.
EXAMPLE 7
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the hollow spherical silicone rubber particles were replaced with the same amount of solid, i.e. non-hollow, spherical carbon black particles having an average particle diameter of 5 μm.
The results of the evaluation tests are shown in Table 1 below.
EXAMPLE 8
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the electrically conductive silicone rubber compound (TCM 5406U) was replaced with the same amount of an electrically insulating silicone rubber compound (TSU 2575U, a product by Toshiba Silicone Corp.).
The results of the evaluation tests excepting for the roller resistance are shown in Table 1 below.
Comparative Example 1
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Example 1 except that the hollow spherical silicone rubber particles had an average particle diameter of 150 μm instead of 5 μm.
The results of the evaluation tests are shown in Table 1 below.
Comparative Example 2
The procedures for the preparation of a spongy silicone rubber roller and the evaluation tests thereof were substantially the same as in Comparative Example 1 except that the hollow spherical silicone rubber particles having an average particle diameter of 150 μm were replaced with the same amount of solid, i.e. non-hollow, spherical silicone rubber particles having an average particle diameter of 150 μm.
The results of the evaluation tests are shown in Table 1 below.
Comparative Examples 3 and 4
A foamable silicone rubber composition was prepared in each of these Comparative Examples by compounding in the same formulation as in Example 1 excepting the use of the same amount of hollow or solid, respectively, spherical silicone rubber particles which had an average particle diameter of 0.05 μm instead of 5 μm.
The attempt of extrusion molding with each of the thus prepared silicone rubber compositions failed to give a silicone rubber layer on and around the metal shaft.
TABLE 1
Average
cell
Bulk
Rubber
Permanent
Roller
Range of
diameter,
density,
hardness,
compression
resistance,
roller
μm
g/cm 3
°Hs
set, mm
× 10 5 ohm
resistance
Example 1
75
0.40
28
0.025
2.12
1.31
Example 2
125
0.36
25
0.040
3.19
1.29
Example 3
40
0.55
32
0.021
1.31
1.56
Example 4
80
0.42
28
0.026
2.02
1.38
Example 5
85
0.51
30
0.018
1.81
1.21
Example 6
85
0.53
31
0.020
1.74
1.42
Example 7
75
0.39
28
0.038
3.74
1.11
Example 8
80
0.37
30
0.009
—
—
Comparative
220
0.18
15
0.079
6.14
1.39
Example 1
Comparative
230
0.18
15
0.072
6.06
1.40
Example 2
EXAMPLE 9
A foamable silicone rubber composition was prepared in the same formulation as in Example 1 excepting for the replacement of the electrically conductive silicone rubber compound with the same amount of an electrically insulating silicone rubber compound (TSE 2575U, a product by Toshiba Silicone Corp.).
The silicone rubber composition was extrusion-molded into a slab having a width of 50 mm, length of 150 mm and thickness of 15 mm, which was subjected to a heat treatment in two steps for curing and expansion first at 200° C. for 10 minutes in an infrared oven and then at 225° C. for 7 hours in a Geer oven followed by standing for 1 hour at room temperature. The thus obtained block of foamed silicone rubber was sliced with a slicing machine in a thickness of 10 mm to expose the cellular structure of the spongy rubber. The 10 mm thick foamed silicone rubber slab was cut in a 45 mm by 70 mm rectangular form which was then chamfered along the ridges to give a spongy rubber puff for cosmetic makeup.
The spongy rubber puff prepared in this manner was subjected to the evaluation tests for the average cell diameter, bulk density and rubber hardness in the same manner as in the preceding examples and for the touch feeling to the skin and unevenness in spreading of a powdery foundation over the skin to give the results shown in Table 2 below. The results of the evaluation tests for touch feeling and foundation spreading were recorded in four ratings of A (excellent), B (good), C (fair) and D (poor).
EXAMPLE 10
The procedures for the preparation of a spongy rubber puff and the evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles had an average particle diameter of 50 μm instead of 5 μm.
The results of the evaluation tests are shown in Table 2 below.
EXAMPLE 11
The procedures for the preparation of a spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles had an average particle diameter of 0.2 μm instead of 5 μm.
The results of the evaluation tests are shown in Table 2 below.
EXAMPLE 12
The procedures for the preparation of the spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles were replaced with the same amount of hollow spherical silica particles having an average particle diameter of 5 μm.
The results of the evaluation tests are shown in Table 2 below.
EXAMPLE 13
The procedures for the preparation of a spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles were replaced with the same amount of solid, i.e. non-hollow, spherical silicone rubber particles having an average particle diameter of 5 μm.
The results of the evaluation tests are shown in Table 2 below.
EXAMPLE 14
The procedures for the preparation of a spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles were replaced with the same amount of solid, i.e. non-hollow, spherical silica particles having an average particle diameter of 5 μm.
The results of the evaluation tests are shown in Table 2 below.
Comparative Example 5
The procedures for the preparation of a spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles had an average particle diameter of 0.05 μm instead of 5 μm.
The results of the evaluation tests are shown in Table 2 below.
Comparative Example 6
The procedures for the preparation of a spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles had an average particle diameter of 150 μm instead of 5 μm.
The results of the evaluation tests are shown in Table 2 below.
Comparative Example 7
The procedures for the preparation of a spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles were replaced with the same amount of solid, i.e. non-hollow, spherical silicone rubber particles having an average particle diameter of 0.05 μm.
The results of the evaluation tests are shown in Table 2 below.
Comparative Example 8
The procedures for the preparation of a spongy rubber puff and evaluation tests thereof were substantially the same as in Example 9 except that the hollow spherical silicone rubber particles were replaced with the same amount of solid, i.e. non-hollow, spherical silica particles having an average particle diameter of 150 μm.
The results of the evaluation tests are shown in Table 2 below.
TABLE 2
Average
cell
Bulk
Rubber
diameter,
density,
hardness,
Touch
Foundation
μm
g/cm 3
°Hs
feeling
spreading
Example 9
65
0.25
15
A
A
Example 10
105
0.19
10
A
B
Example 11
45
0.36
22
B
A
Example 12
70
0.28
17
A
A
Example 13
60
0.48
25
B
A
Example 14
75
0.39
28
B
A
Comparative
20
0.65
42
C
C
Example 5
Comparative
250
0.18
10
B
D
Example 6
Comparative
25
0.72
45
D
D
Example 7
Comparative
230
0.21
12
B
D
Example 8 | Disclosed is a spongy rubber body or, in particular, spongy silicone rubber body useful for forming the semiconductive rubber layer of a rubber roller in photocopying machines and the like as well as for use as a spongy rubber puff in cosmetic makeup. Characteristically, the inventive spongy rubber is compounded with, besides ordinary ingredients in spongy silicone rubbers, a specified amount of globular particles of, preferably, a silicone rubber having a specified average particle diameter. Compounding of globular particles in a spongy rubber has an effect to give a uniformized and decreased average cell diameter of the spongy rubber and also to greatly decrease the permanent compression set of the spongy rubber as required in the rubber layer of a spongy rubber roller. Cosmetic puffs can be imparted with improved touch feeling to the human skin and improved evenness in spreading of a cosmetic composition over the skin. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This patent application claims the benefit of U.S. Provisional Patent Application 61/329,182 filed Apr. 29, 2010 entitled “Method and Apparatus for Measuring the Deflection on Cantilevers in Constrained Spaces.”
FIELD OF THE INVENTION
The invention relates to measurement equipment and more particularly to optical beam deflection apparatus.
BACKGROUND
Studies in the field of muscle Biophysics, Physiology, Nano-Scale Physics and Mechanics have been performed traditionally with preparations ranging from the whole muscle to isolated muscle cells. While these preparations allow measurements of force and muscle mechanics with high reproducibility, they do not allow the investigation of sub-cellular units—myofibrils, sarcomeres, molecules, etc. Recently, studies with myofibrils and sub-cellular units of muscles have emerged—but giving the complexity of the experiments involving these structures, only a few laboratories around the world have this capability.
Furthermore, the systems used so far with myofibrils have several limitations, including a low signal-to-noise ratio, which limits detection of small differences in force observed in different conditions, a very low time resolution which limits the detection of molecular and kinetics events that may happen at the microsecond scale, and the incapacity of measuring force and imaging the myofibrils simultaneously with high spatial and temporal resolution.
An ideal system should be able to provide measurements of minute force measurements in the attonewton (aN) to nanonewton (nN) range in myofibrils with microsecond scale temporal resolution, and high signal-to-noise ratio. From a biological perspective, measurements of molecular kinetics with unprecedented precision are highly desirable. For example, measurements of the kinetics of myofibrils and myofilaments composed of muscle molecules with the time resolution of microseconds should open new opportunities in the fields of physiology and biophysics.
At present the dominant microscope for such measurements and analysis is the Atomic Force Microscope (AFM) because the most evident advantage that atomic force microscopy boasts over all other microscopic and nanoscopic imaging methods is its unique ability to probe forces. A cantilever acts as the force transducer; its interaction with a sample causes a deflection which can be measured and calibrated into a force. The versatility of AFM is highlighted by the fact that the same instrument can be used for probing the piconewton forces of a single covalent bond for example through to studying the forces exerted by cells in the micronewton range.
However, all commercial AFMs are optimized for measuring forces which are perpendicular to the sample surface, which becomes a limitation when the forces of interest are parallel to the sample surface. This has led many researchers to design home-built systems to overcome this problem by the use of the pendulum geometry, wherein the cantilever is positioned with its long axis perpendicular to the sample surface, such that forces in-plane can be measured with high sensitivity. The pendulum geometry prevents the snap-to-contact problem that afflicts soft cantilevers in a regular AFM. Very soft cantilevers enable attonewton force sensitivity which is necessary, for example, in the detection of single spins in magnetic resonance force microscopy (MRFM). At the microscopic length scale, the studies of cellular or subcellular forces which are parallel to the imaging plane of an optical microscope place system performance requirements for high sensitivity force measurements at sampling frequencies beyond available video rates, requirements that can be met by optical measurement techniques.
However, the difficulty in implementing the pendulum geometry lies in the constraint imposed by the focused incoming light or the diverging outgoing light which easily interferes with the sample surface. Additionally in order to obtain the measurements of biological tissue samples in vitro the optical measurement system must satisfy complex physical constraints to provide access to the vertical cantilever and its holder with consideration of solution ingress/egress, temperature control, and pipette for stimulation of the biological sample. Accordingly it would be beneficial to provide an optical measurement system which overcomes these complex physical constraints. According to an embodiment of the invention the geometrical restriction is addressed by the exploitation of an optical periscope.
Beneficially such a system may be employed for many other biological and physical applications and far-reaching potential for studies using measurements of light displacement towards cantilevers in constrained spaces. It can be used to expand the capabilities of atomic force microscopy in all of its current fields of study, such as biophysics, biology, surface science, and the emerging field of magnetic resonance force microscopy (MRFM). Consequently it would be beneficial to provide a system and a method that resolves the aforementioned limitations which will enable the desired measurements.
SUMMARY OF THE INVENTION
In accordance with an aspect of the present invention there is provided a method comprising providing an optical beam component for receiving a first optical beam, directing the first optical beam to exit in a predetermined manner an optical window forming part of the optical beam component; receiving a second optical beam through the optical window; and coupling the second optical beam to an optical photodetector and providing a sample holder for attaching a sample to be characterized, the sample when attached being positioned in predetermined orientation to the optical window of the optical beam component. The method also comprising positioning the optical beam component with respect to the sample holder and determining a characteristic of the sample in dependence upon at least the second optical beam.
In accordance with an aspect of the present invention there is provided a method comprising providing an optical beam component for receiving a first optical beam from an optical train through a face of the optical beam component, directing the first optical beam to exit an optical window forming part of the optical beam component; receiving a second optical beam through the optical window; and coupling the second optical beam to the optical train through the face of the optical beam component, wherein the direction within the optical beam component between the face of the optical beam component and the optical window is through total internal reflection at exterior surfaces of the optical beam component and providing a positioning system for adjusting the position of the optical beam component with respect to a sample wherein the sample is mounted substantially parallel to the optical window. The method also comprising providing the optical train, the optical train receiving an optical signal, processing the optical signal to generate the first optical beam, receiving the second optical beam, processing the second optical beam to a third optical beam, and coupling the third optical beam to an optical photodetector.
In accordance with an aspect of the present invention there is provided a method comprising determining a characteristic of a sample mounted in a test holder comprising at least a cantilever by measuring the deflection of the cantilever perpendicular to the cantilever using an optical beam deflection component in conjunction with a sample manipulation component, an imaging component, and a microscope, and wherein the optical beam component receives a first optical beam from an optical train through a face of the optical beam component, directs the first optical beam to exit an optical window forming part of the optical beam component; receives a second optical beam through the optical window; and couples the second optical beam to the optical train through the face of the optical beam component and optical beam direction within the optical beam component between the face of the optical beam component and the optical window is through total internal reflection at exterior surfaces of the optical beam component.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
FIG. 1 depicts a three-dimensional schematic of an experimental sample environment according to an embodiment of the invention;
FIG. 2A depicts a top view of the of experimental sample environment with the glass needle, cantilever holders and optical periscope according to an embodiment of the invention;
FIG. 2B shows a corresponding three-dimensional schematic of the experimental sample environment according to an embodiment of the invention;
FIG. 2C shows an optical micrograph of the experimental sample environment according to an embodiment of the invention taken from the system on the stage of an inverted optical microscope;
FIG. 3 shows a screen capture of the cantilever displacement measured with a system according to an embodiment of the invention;
FIG. 4 shows various images of the optical beam deflection component according to an embodiment of the invention;
FIG. 5 depicts a schematic of the optical beam deflection component in combination with the experimental sample environment according to an embodiment of the invention;
FIG. 6 depicts a schematic of the optical path in the optical beam deflection component according to an embodiment of the invention;
FIG. 7 depicts optical micrographs of an upper sub-assembly of the optical beam deflection component comprising the optical photodetector and motorized translation stage according to an embodiment of the invention;
FIGS. 8A and 8B depict schematics of the optical periscope for the optical beam deflection component according to an embodiment of the invention;
FIGS. 9A and 9B depict schematics of the optical pathway within the optical periscope of the optical beam deflection component according to an embodiment of the invention;
FIG. 10 depicts an embodiment of the invention with four cantilevers according to an embodiment of the invention;
FIG. 11 depicts an optical beam deflection component according to an embodiment of the invention supporting multiple optical probes and cantilevers;
FIG. 12 depicts a sub-assembly according to an embodiment of the invention supporting multiple optical beam deflection components and multiple beams per component according to an embodiment of the invention; and
FIG. 13 depicts an embodiment of the invention wherein characterization is performed without exploiting a cantilever.
DETAILED DESCRIPTION
The following description is presented to enable a person skilled in the art to make and use the invention. Modifications to the disclosed embodiments will be apparent to those skilled in the art and the general principals described herein may be applied to any apparatus making use of the optical beam deflection method without departing from the scope of the invention. Therefore the present invention is not intended to be limited to the embodiments disclosed herein, but is to be accorded the widest scope.
The invention presented hereinafter consists of a method and apparatus for guiding the light towards the cantilever and measuring the resulting optical beam deflection (OBD), referred to as an optical periscope. It enables the optical beam to be guided onto cantilevers within a constrained space; for example, it the cantilever is perpendicular to a large planar surface, the apparatus allows focusing light onto the cantilever while avoiding obstruction by the planar surface, and couples the reflected optical beam back into the optical beam deflection component for measurement. Beneficially, apparatus minimizes the distance the light needs to travel in free space e.g., liquid or air, to attain the cantilever, thereby reducing potential disturbances which can cause substantial degradation of the signal. According to demonstrated embodiments of the invention the optical beam traverses only 600 micrometers in the liquid environment. The optical periscope is a custom machined optical component which allows the guiding of the laser light toward and away from the cantilever in constraining configurations. The optical beam is beneficially redirected away from the sample surface immediately after reflection from the cantilever because the optical beam spreads due to diffraction.
The apparatus can also be employed in an application where the re-direction of the optical beam in up to 3 dimensions is necessary, overcoming the difficulties commonly encountered in constrained space. It can also be used to simplify the optical setup necessary for the redirection of optical beam as multiple reflecting surfaces can be engineered into one optical component.
Key to the innovation is that the light enters a glass component through a polished surface which is durable and therefore can be easily cleaned, while all the reflections, used to guide the light into a constrained space or redirect the light to a optimum position and direction, are internal reflections with a protected reflective coating, such as a metal layer. The internal reflective surfaces are impervious to damage, if a protective layer is coated onto the reflective coating. Another advantage of this apparatus is that all the relative angles between any number of reflective layers can be optimized in the design process, and be implemented into a single optical component, and therefore any relative alignment between the surfaces is avoided during the usage of the device. This results in a very user-friendly device, which is well characterized.
The apparatus according to an embodiment of the invention can be divided effectively into two components:
(1) a cantilever/sample manipulation and imaging component, and
(2) an optical beam deflection component.
The final apparatus according to embodiments of the invention integrates both components, which allows easy experimentation and efficient data acquisition for measuring cantilever deflections on the nanoscopic or microscopic scale. The separate components will be discussed in the following subsections. While the current apparatus focus on force detection, this is only a particular use of detecting cantilever deflection as would be understood by one skilled in the art. Detecting deflections in nanometer resolution has many applications but can be well understood in the following embodiment where the apparatus was calibrated to calculate forces in nanonewtons from the measured displacements in nanometres.
Cantilever/Sample Manipulation and Imaging Component: This component according to an embodiment of the invention is designed and developed to be used with any inverted microscope with or without fluorescence capabilities, including but not limited to confocal microscopes, two-photon microscopes, among other microscopy techniques. It would be evident to one skilled in the art that the component may be designed for use with other microscope configurations without departing from the scope of the invention. Individual sub-units of the component include those associated with environmental control of the sample environment and the translation stages for positioning of the vertical cantilever.
Laser sub-unit is used for measuring deflection of the cantilever. The laser, or other optical probe, is coupled onto the cantilever after passing through the optical beam deflection (OBD) component and is reflected back onto a photodetector, inserted into the OBD component. It would be evident that the laser, or other optical probe, may be selected according to a variety of factors, including but not limited to the biological sample and the time scale of biological characteristic.
Experimental Sample Environment: The experimental sample environment allows for temperature control, solution exchange, chemical stimulation in an arrangement especially designed for a vertical cantilever configuration. The experimental sample environment is the environment where the experiment takes place and is connected to a fluidic system and a variable speed pump. Typically measurements are required to be performed in a highly constrained space, a unique experimental sample environment is critical to accommodate all material needed for the experiments, as explained below. As such, the sample environment is not similar to any sample environment/chamber commercially available in the market. Referring to FIG. 1 there is depicted a three-dimensional design of the sample environment 100 .
The sample environment 100 allows for temperature control during the experiments, through heat exchange between a first channel 110 surrounding the experimental chamber 120 and the inside solution in the chamber itself—the first channel 110 are continuously fed with solutions that will control the inner temperature, but which do not mix with the experimental environment which is defined by the experimental chamber 120 . The experimental sample environment 100 also has a second channel 130 designed specifically for pumping solutions from the experimental chamber 120 into an external reservoir (or waste) (not shown for clarity), allowing for rigorous control of flow rate together with the perfusion system (as described below). First channel 110 couples to inlet 140 A and first outlet 140 B whereas second channel 120 couples to second outlet 150 .
The experimental sample environment 100 fits the stage of an inverted microscope, and has space for rigid glass needles and cantilevers used for sample manipulation and data collection. It also allows the use of single and multi-barrelled pipettes, in conjunction with a perfusion system for allowing exchanged of solutions surrounding the samples, e.g. solutions with different concentrations of ions, pH, temperature, chemicals, etc. The design has enough space for manipulating samples so to align the cantilever with the OBD probe, and sample positioning by the doubled barrelled pipette.
Micromanipulators with six degrees of freedom (X, Y, Z, roll, pitch and yaw) are typically used to manipulate the glass needles and/or the cantilever within the experimental chamber 120 . The micromanipulators are connected to a ceramic radial piezoelectric tube at one end, and to a holder that is used for positioning the cantilever. The needles and/or cantilever can be moved three-dimensionally with a space resolution of a few microns. The piezoelectric tubes having the characteristics of outside diameter 0.250″±0.003″, wall thickness 0.020″±0.0015″, and length 0.750″±0.005″. The tubes are wired with nickel electrodes with four 90° quadrants, so that they change configuration responding to voltage changes, allowing lateral movements of the needle for example, thereby changing the length of the sample as required. It would be evident to one skilled in the art that alternative designs of needles and/or cantilever may be employed according to the constraints of the physical space, specimen etc for example. Similarly, piezoelectric tubes may be replaced or augmented with micromanipulators. Such micromanipulators where equipped with piezoelectric stages themselves may provide control to nanometre resolution.
The perfusion sub-unit is composed of different pieces that work together to allow controlled flow of varying solutions in pre-determined rates. It is composed of six reservoirs connected to channels, made of silicon tubing in this example, that are controlled by independent electro-mechanical valves. The valves are computer-controlled, and can be opened or closed independently in pre-specified times during the experiments. The reservoirs can be filled with different solutions and/or chemicals for example drugs, pharmaceutical compounds, etc. Selection of the channels providing the solution during the experiments is done by opening and/or closing the channels with the controlled valves. The channels are all coupled to a multiple-barrelled pipette, with two or more channels, which in turn is connected to a stepper motor driven positioning stage that controls the position of the multi-barrelled pipette with fine adjustment. The stepper motor step is used for pipette positioning, for precise delivery and dosing of activation and relaxation agents, wherein the position of the pipette can be moved rapidly (typically a few millisecond) to change the flow that is directed towards the sample(s). Such a method allows a rapid switch of the solutions for measurements of rapid molecular kinetics.
In this particular case, the pipette delivers laminar flow of two solutions continuously, e.g. two types of chemical agents, solutions with and without a specific drug, relaxing and activating solutions for muscle experiments, etc. It would be evident that alternatively a single barrelled pipette may be employed according to the requirements of the experiments being performed.
Imaging of the myofibrils or sarcomeres, or other biological specimens, is performed typically using two instruments simultaneously: (i) a linear array CCD camera or a fast CCD camera (μs/ms time-resolution), and (ii) a CCD camera for sample visualization and video recording. An important issue solved by embodiments of the invention in such apparatus is that the configuration allows imaging of samples that are very close to the cover slip, typically within 100 μm, which is a highly constrained environment. However, embodiments of the design also allow for measurements and imaging of samples placed further from the surface to be made according to the specific requirements of the tests being performed.
Cantilevers with any stiffness can be used in the system for measuring displacements. Such cantilevers are used frequently in studies using atomic force microscopy with high resolution and published repeatability. The cantilevers in the current system were attached using adhesives to a spatula that was attached to a holder mounted onto and controlled by one of the micromanipulators. It would be evident to one skilled in the art that other methods of attaching the cantilever may be employed without departing from the scope of the invention.
Referring to FIG. 2A there is depicted a top view of the of experimental sample environment 210 together with the glass needle 240 , cantilever holder 220 , multi-barreled pipette 230 , and optical periscope 260 according to an embodiment of the invention. Also shown are the solution channel 270 for pumping solutions from the experimental sample environment 210 and the temperature control channel 250 . Referring to FIG. 2B there is shown a corresponding three-dimensional schematic of the experimental sample environment 210 according to an embodiment of the invention with the cantilever holder 220 , multi-barreled pipette 230 , and optical periscope 260 . Now referring to FIG. 2C there is shown an optical micrograph of the experimental sample environment according to an embodiment of the invention taken from the system on the stage of an inverted optical microscope.
During a typical experiment, physical variations in the sample under test result in deflection of the cantilever e.g. a molecular assembly that shrinks upon changes in temperature, a DNA strand that unfolds, a muscle myofibril that contracts upon activation, etc., can be evaluated for several parameters. After a stiffness calibration of the cantilever, its deflection can also be converted into a measured force. The displacement is measured by the OBD component which measures the cantilever deflection and processes the signal, which is recorded during data acquisition, as described in the following section, thereby allowing derivation of the force exerted by the specimen against the cantilever.
In experiments by the inventors to demonstrate the effectiveness of the invention, the OBD component was used to measure the force developed by an activated myofibril or muscle filament over time, with microsecond time resolution, however, it would be evident that the time constant of embodiments of the invention may be established over a wide range in dependence upon factors including, but not limited to, the cantilever, optical photodetector, processing electronics post-photodetector, and optical beam. An objective for the OBD component being to measure the cantilever displacement as a result of any force. When a force is applied by the contracting myofibril, the cantilever is bent and the displacement is measured by tracking the displacement of the laser beam position on a photodetector. The functioning principle is the following: the sample is held by a stiff micro-needle at one end and a cantilever at the other end.
A laser beam is focused on the surface of the cantilever and reflected onto a multi-element photodetector. The output signal of the multi-element detector varies depending on the position of the reflected beam on the multi-element detector. A very small displacement of the cantilever translates into a displacement of the reflected beam on the multi-element detector, which can be recorded.
Amongst the experiments to test the OBD component and overall system was one performed with a myofibril isolated from the rabbit psoas muscle, following an established protocol. The myofibril was suspended between an atomic force cantilever, ATEC-CONTPt Nanosensors™ with nominal stiffness 0.2 N/m, and a rigid glass needle, both connected to three-dimensional micromanipulators. The temperature of the solution surrounding the myofibrils was controlled and maintained constant at 15° C. The myofibril was initially immersed in a bath containing a resting solution with low Ca 2+ concentration (pCa 2+ =9.0) and the sarcomere length and myofibril diameter were measured under 90× magnification using a charge-coupled device (CCD) camera. Activation of the myofibril was achieved by quickly exchanging, <10 ms, the solution surrounding the myofibril using a double barrelled pipette, attached to a multichannel perfusion system. When the myofibril is surrounded by an activating solution with high Ca 2+ concentration (pCa 2+ =4.5), it contracts and exerts a force on the cantilever, measured by the OBD component.
Furthermore, since the glass needle is connected to a computer controlled motor arm, changes in myofibril length can be made rapidly allowing for an accurate biomechanical characterization. The apparatus has recorded cantilever displacements caused by contraction produced at a sarcomere length of 2.4 μm, as depicted in FIG. 3 wherein the as-measured displacement is presented as first trace 300 A. Upon activation, the force increased rapidly to achieve a steady-state level. The force and the rate of force development (K ACT ) upon activation produced by this myofibril before shortening-stretching is comparable to the levels observed previously in other laboratories, see for example Telley et al in “Half-Sarcomere Dynamics in Myofibrils during Activation and Relaxation Studied by Tracking Fluorescent Markers” (Biophys J. 90, pp 514-530, 2006) and Piroddi et al in “Contractile Effects of the Exchange of Cardiac Troponin for Fast Skeletal Troponin in Rabbit Psoas Single Myofibrils” (J. Physiol. 552, pp 917-931, 2003).
When the myofibril is rapidly shortened and re-stretched to the initial length, there is rapid force redevelopment. The rate of force redevelopment (K TR ) is commonly used for probing the mechanisms of interaction between myosin and actin, the two major contractile proteins present in striated muscles. The relaxation phase upon myofibril deactivation can be fitted with a linear function (K LIN ) and an exponential function (K REL ) associated with the detachment of myosin-actin interactions and consequently sarcomere relaxation.
Given the characteristics of force production for activation and relaxation of these myofibrils, it is apparent that the OBD component adequately adapts the pendulum geometry such that forces can be measured parallel to the plane of the sample. The derived force from the sarcomere length of 2.4 μm is shown in second trace 300 B of FIG. 3 together with markers identifying changes to the experimental environment. The displacement to force calculation being according to the formula in Equation (1) below.
F=K·Δd (1)
where F is the force, K is the stiffness of the cantilever, and Δd is the displacement of the cantilever. It is evident from second trace 300 B and insert 300 C that high temporal resolution of physiological changes can be detected, in this instance the response to increase calcium in the in vitro environment. It would be evident to one skilled in the art that the configuration of the OBD component provides also for high spatial resolution so that the muscular response could be measured at multiple points spatially on the muscle to look for variations in either temporal or spatial response.
Optical Beam Deflection (OBD) Component: The purpose of the OBD component is the detection of the cantilever bending, with the potential for applications requiring high spatial and/or temporal resolution, and to perform this detection in constrained spatial environments with non-horizontally disposed cantilevers. The OBD method is where a light beam, e.g. a monochromatic laser, tunable light source, or other optical source, is focused onto a cantilever whose deflection is being measured such that the deflection is converted to an angular displacement that is then measured. The conventional experimental setup has the cantilever nearly parallel to the surface that is under study. However, some applications require a cantilever that is perpendicular to the surface, or at non-horizontal angles, making the OBD method problematic because the surface interferes with the light beam focused onto the cantilever. The OBD method will be briefly explained in this section, followed by a description of the novel method and optical component used to overcome the problems encountered when implementing the OBD method on systems with constrained spaces.
Referring to FIG. 4 there are shown engineering schematics 400 A through 400 C of the OBD component according to an embodiment of this invention, together with an optical micrograph of the actual OBD assembly 400 D. Referring to FIG. 5 elements of the OBD component 500 are depicted beginning with optical input port 510 that couples to the internal optical sub-assembly, not identified, following optical path 515 to the optical periscope 550 wherein the reflected beam is coupled back through the optical sub-assembly to the optical photodetector and translation stage sub-assembly 530 wherein the position of the optical photodetector is adjustable through controller 520 . Disposed on the front of the OBD component 500 are first and second micrometer screws 560 and 570 allowing the position of the optical periscope to be adjusted relative to the main body of the OBD component 500 .
Referring to FIG. 6 there is depicted a three-dimensional cross-section of the OBD component 600 . As shown the optical input beam 5005 enters the OBD component 600 through the optical port, not visible in this cross-section, and impinges on first right angle prism 6010 wherein the beam is coupled vertically to second right angle prism 6020 and then to polarizing beam-splitter 6030 , focussing lens assembly 6040 , quarter-wave plate 6050 and then into the optical periscope 550 which is positioned within the experimental sample station 6090 relative to the cantilever, not shown for clarity. The optical signal is reflected from the sample on the cantilever, propagated through the optical periscope 550 and back through the quarter-wave plate 6050 and focussing lens assembly to polarising beam-splitter 6030 wherein it is coupled vertically to the optical photodetector 6060 which is mounted on the detector circuit card 6080 . The optical photodetector 6060 being positioned relative to the polarizing beam-splitter 6030 through motorised position stage 6070 that is controlled through controller 520 . It would be evident to one skilled in the art that controller 520 may be a stepper motor controller, piezoelectric controller, manual controller or a combination thereof.
As such within the OBD component 600 the incoming collimated optical beam is reflected off two mirrors, first and second right angle mirrors 6010 and 6020 , deviated by 90° upon each reflection. Each mirror is mounted on a rotational stage, which allows the adjustment of the optical beam orientation with 2 degrees of freedom (angular). This adjustment allows the positioning of the focused laser spot onto a chosen position in the cantilever. The laser then crosses a polarizing beam splitter 6030 , such that the outgoing optical beam is p-polarized for example. The optical beam is focused by a focusing lens assembly 6040 , which is mounted on a thread to allow the position of the focal plane onto the cantilever. The optical beam then crosses a quarter-wave plate 6050 that converts it to a circularly polarized optical beam. The optical beam then reflects off the cantilever; its path is deviated according to the cantilever deflection angle and it is converted to a clockwise-polarized optical beam by the quarter-wave plate 6050 .
Upon transmission through the quarter-wave plate 6050 , the optical beam becomes s-polarized and then is collimated by the focusing lens assembly 6040 . Because the optical beam is s-polarized, it reflects off the polarizing beam splitter 6030 rather than travelling straight through, as p-polarized light would. The optical beam then impinges on the optical photodetector 6060 , which is mounted directly on the translation stage 6070 , which allows precise movements. Translation stage 6070 may be one, two or three dimensional. The OBD component 600 may itself be mounted onto a further positional stage in order to provide vertical movement of the OBD component 600 or larger travel in one, two, or three-dimensions according to the requirements of the system. Optionally, the spatial separation of the returned optical beam for coupling to the optical photodetector from the optical beam coupled to the component may be implemented by alternative techniques evident to one skilled in the art of optical system design.
Referring to FIG. 7 there are depicted optical micrographs of an upper sub-assembly 700 of the optical beam deflection component comprising the optical photodetector and motorized translation stage according to an embodiment of the invention, for example optical photodetector and translation stage sub-assembly 530 in FIG. 5 supra. The optical photodetector 710 has four (4) quadrants and is mounted on the OBD body 730 via circuit board 720 to a translation stage 770 that is driven by a linear motor 740 for fine adjustments of the quadrant positions. The output from the circuit board 720 is coupled to an interface board 750 within the OBD body 730 . The output of the interface board is coupled via a cable to the measurement and analysis system operating in conjunction with the OBD component. As shown the cable interface 760 with cable is shown detached from the interface board 750 . Optical photodetector 710 measures the amount of light incident on each of the four quadrants or these may be combined to provide top/bottom or left/right sections. Within an exemplary embodiment of the invention the difference between the top and bottom signals is a measure of the cantilever deflection wherein the cantilever provides single axis deflection. The motorised stage allows the optical photodetector 710 to be initially centered onto the collimated optical beam at the beginning of the experiment.
It would be evident to one skilled in the art that should a two-dimensional deflecting structure be provided instead of a one-dimensional cantilever then the approach is also applicable to measuring the resultant two-dimensional beam deflection through monitoring the four quadrants individually. Equally should the cantilever be rotated to be in the plane of the experimental stage but still be vertically disposed then the right/left signals of the photodetector may be employed. In applications where speed is not a primary importance the four quadrant photodetector may be replaced by a linear CCD array, for one-dimensional deflections, or a two-dimensional CCD array for both two-dimensional tracking and both modes of one-dimensional tracking. In this case the beam profile may be established over multiple pixels in the array and fitting software employed to establish the beam centre at each CCD array readout.
The unique implementation of this specific OBD component is the method of guiding the light towards the cantilever. In the prior art, the cantilever is roughly parallel to the sample surface, and therefore there exist nearly no geometrical constraints for focusing the optical beam onto the cantilever and collecting the reflected light. A large range of incident angles onto the cantilever can be used, because there is free space above the cantilever. In the situation described previously, the cantilever long-axis is positioned perpendicular to the microscope slide, because motions parallel to the microscope slide are of the measure of interest. This arrangement causes difficulties in the focusing and collecting of the optical beam because the cantilever is as close as 10 microns away from the microscope slide. Because the optical beam has a divergence angle necessary to for it to be focused onto the cantilever, the optical beam will inevitably interfere with the surface within millimetres before or after reflection from the cantilever.
Now referring to FIG. 8A there is depicted a schematics of the optical periscope 850 for the optical beam deflection component according to an embodiment of the invention. As shown the optical periscope 830 is mounted to a front assembly 860 that is mounted to the OBD component 870 together with first and second micrometers 810 and 850 respectively. The end-face of the optical periscope 830 being positioned with respect to the cantilever 840 and angularly adjusted through the combination of first and second micrometers 810 and 850 respectively. The path of the optical beam within the OBD component being depicted by light path 820 .
Now referring to FIG. 8B the optical component which allows such work in confined spaces to be performed, the optical periscope, is displayed from computer modelling in several views, namely side elevation 8000 A, close-up side elevation 8000 B, plan elevation 8000 C and perspective view 8000 D. The optical periscope, such as optical periscope 260 in FIGS. 2 A/ 2 B, optical periscope 550 in FIGS. 5 / 6 and optical periscope 850 in FIG. 8 , is a single piece of optical quality glass which is custom machined for the specific application as depicted in these figures discussed supra. The optical periscope as visible external to the OBD component comprises four (4) surfaces which are optically polished for transmission and reflection of the light beam. As shown in side elevation 8000 A two of these surfaces, being upper surface 8100 and lower surface 8200 , were metalized for internal reflection. Optionally total internal reflection can also be used. Metallization provides for more reliable measurements in case of surface contamination with liquid(s) from the experimental stage during the positioning of the optical periscope relative to the cantilever prior to measurements being performed.
The optical beam enters the large aperture of the optical periscope at face 8300 and reflects of the metalized upper surface 8100 , which directs it downwards. The optical beam is undergoing focusing as it travels, and reaches a very small beam diameter when reflected from the metallized lower surface 8200 . This reflection occurs very close to the ground edge of the periscope, and therefore the periscope was manufactured with an edge in that location (finely ground). After this second reflection, the light beam exits the small aperture on measuring face 8400 , shown in more detail in perspective view 800 D. The focal plane of the optical beam is set in front of the measuring face 8400 by design of the optical periscope in combination with the focussing lens assembly within the OBD component and can be established as several microns to several hundred microns past the plane of the measuring face 8400 . Within the OBD components presented supra this location is tuneable by moving the focusing lens assembly, allowing for fine, precise adjustments.
Referring to FIGS. 9A and 9B there are depicted schematics of the optical pathway within the optical periscope of the optical beam deflection component according to an embodiment of the invention. Referring to FIG. 9A a side elevation is depicted showing cantilever mount 910 , cantilever 920 and optical periscope 930 . Also shown are optical beam sections 940 A and 940 B inside and outside the optical periscope respectively for the OBD measurement system under the initial starting conditions, or at a measurement point where the beam deflection is zero. Accordingly a first deflection of α/2 results in first reflected optical path 950 B which becomes first reflected optical path 950 A inside the optical periscope whilst an equal and opposite second deflection of −α/2 results in second reflected optical path 960 B which becomes second reflected optical path 960 A inside the optical periscope.
If ±α/2 represents the displacements of the cantilever when the optical beam has traversed to be completely in the top and bottom sections of the optical photodetector then these represent the maximum displacements measurable with a two-section or four-quadrant detector arrangement representing a total angular beam displacement of α and thus displacement range of the cantilever. Alternatively by exploiting modifications to the optical path, for example reduced collimated optical beam diameter, large one-dimensional CCD arrays, two-dimensional CCD arrays as well as the configuration of the optical path may increase the range of displacement and/or resolution of displacement measurable.
Now referring to FIG. 9B a side assembly view 9000 is depicted showing cantilever 9100 , optical periscope 9200 and other elements of the optical train from optical periscope 9200 to optical photodetector 9500 within the OBD component, not shown for clarity. Accordingly there are shown three optical beam paths 9700 , 9750 A and 9750 B. First optical beam path 9700 representing the path of the optical beam probe as it is coupled through the optical assembly to the cantilever 9100 and reflected back when there is no deflection on the cantilever 9100 . Second and third optical beam paths 9750 A and 9750 B respectively represent the paths extended throughout the OBD component and optical train as described by second and first reflected optical path 960 A and 950 A respectively in FIG. 9A .
These first to third optical beam paths 9700 , 9750 A, and 9750 B then propagate from the lower surface 9200 B to the upper surface 9200 A wherein they are reflected and propagated through the rare facet 9200 C of the optical periscope 9200 wherein they propagate to the quarter-wave plate 9300 and focusing lens assembly 9400 and then to the polarizing beam-splitter 9600 . Accordingly, they are then reflected up towards the optical photodetector 9500 . As with FIG. 9A if second optical beam path 9750 A represents maximum deflection of the cantilever by α/2 then the optical beam has moved Δx in one direction on the optical photodetector 9500 and third optical beam path 9750 B represents maximum deflection of the cantilever in the opposite direction of −α/2 then the optical beam has moved Δx in the other direction on the optical photodetector 9500 . As noted previously if the cantilever 9100 supported deflection in two dimensions, i.e. in the plane of the drawing and out of plane of the drawing then the optical beam on the photodetector would likewise move in the plane of the drawing and out of the plane of the drawing wherein a quadrant photodetector or 2D CCD would allow readout of the resulting beam deflections in x and y directions.
The cantilever 9100 is located near the focal plane of the focusing lens assembly 9400 , and reflects the focused light beam The optical periscope 9200 allows focusing of light parallel to the microscope slide at a distance of around a few microns to millimeters. It does so by delivering the light and collecting it over very short distances, such that the expanding beam does not interact with the microscope slide surface; rather, it expands once it is travelling within the periscope. The key feature therefore is to use internal reflections to deviate light from the surface; allowing the manufacturing of optical components with well-defined edges at obtuse angles, rather than acute angles which are prone to chipping. Another advantage of this design is that the metalized surface is internal, and therefore is not soiled by contaminants (e.g. chemicals). In addition, it is not damaged during cleaning—only the apertures need to be cleaned, which are made of hard glass.
In this particular embodiment of the periscope, the four (4) optical faces form a parallelogram, as seen from FIG. 8 . In this case, the angle of beam at the large aperture and small aperture are equal. However, the angle of all four (4) faces can be tailored to the specific application to optimize the path trajectory for any case. In addition, the optical path need not be constrained to a single plane, as it has been in the descriptions with respect to FIGS. 6 , 8 A, 9 A and 9 B supra, a different optical periscope design could deviate light in multiple directions to accommodate the geometry of any particular instrument.
Additionally this component can also be used for creating compact optical systems where multiple optical paths can be handled with multiple optical components or a single optical component. For example, certain types of atomic force microscopes or variations thereof require multiple probes, or cantilevers, to be manipulated and detected simultaneously with all the probe tips in proximity down to the micron range.
In such a system, it is highly desirable that each probe unit comprising of a probe, optical beam and photodetector is independent from the others. That is, each probe unit can be moved up to the sample independently from all its neighbours. However, because each probe needs clearance from the sample, with a typical range of 5 to 20 degrees, it is inevitable that light paths reflected off the cantilever backside cross each other. Certain systems have solved this problem by constructing special cantilevers that are bent in such a way that the optical beam returns towards the probe unit (see for example www.multiprobe.com), rather than crossing over the sample as is inevitably the case for flat cantilevers that are tilted for clearance.
This results in large cantilevers which have poor mechanical properties for imaging. As such, these systems have resolutions which are far from the atomic scale, as well as reduced imaging speeds. Adding atomic resolution capability to multiprobe systems with a large number of independent probes would be beneficial.
Referring to FIG. 10 the usage of optical beam deflection within a multiprobe system is illustrated by the embodiments depicted in FIG. 10 . Within this embodiment, a four probe system 1010 is depicted, although the principles of this embodiment may be extended to other numbers of probes determined by factors including but not limited to the overall design of the optical beam deflection component, placement and design of the cantilevers, and the microscope/AFM sub-system. Referring to first view 1000 the four cantilevers 1060 used for the measurements are shown to be in proximity, with the necessary clearance angle from the sample, not shown for clarity. The cantilever holder 1030 and the light path 1050 are drawn for a single probe, for simplicity and clarity. This shows more clearly how each probe is independent from the others, and can be moved or removed, without affecting any of the other probes.
The light beam 1050 from the optical beam deflection component, not shown for clarity, enters through an opening 1035 within the cantilever holder 1030 and enters the optical component 1040 through a first optically polished surface, not identified for clarity in first view 1000 , and then travels towards a second optically polished surface 1040 A, wherein it is reflected because of the metal coating deposited on the optically polished surface 1040 A. This reflection redirects the light beam 1050 towards a third optically polished window 1040 B, at the bottom, where it exits the component to reach a cantilever 1060 . After reflecting from the cantilever 1060 , the light beam 1050 returns along a similar path into the optical beam deflection component onto the photodetector and used to measure the cantilever angle.
Referring to second view 1020 a side view of the assembly is shown wherein the first to third optically polished windows 1040 A, 1040 C and 1040 B are clearly visible and accordingly the path traced by the light beam 1050 within the optical component 1040 . Four probe system 1010 depicts a plan view wherein first to fourth cantilevers 1060 A through 1060 D are visible through the optical component 1040 together with their respective cantilever holders 1030 A through 1030 D respectively.
It would be evident to one skilled in the art that other embodiments of the invention may be implemented wherein the incoming and outgoing light paths can be distinct and have different input and output angles and/or orientations to the cantilevers 1060 . Further, multiple internal reflections can be used to redirect the light beam 1050 in any direction required for the desired application.
Within the embodiment depicted in FIG. 10 the optical component 1040 has four-fold symmetry allowing accommodation of four probe units simultaneously. Beneficially, this design allows for the incoming and reflected light beams to be managed with respect to their respective probe units with the use of as little as a single optical component, optical component 1040 , and standard atomic resolution cantilevers 1060 . Furthermore, this optical component 1040 allows for optical access of the sample and all four probes from directly above, as seen in the four probe system 1010 in FIG. 10 . This allows the user to position all the probes on any desired location of the sample.
With such a fixed optical component 1040 positioned at the center of the system, directly above the sample and below a microscope objective, each of the four probe units can be independently positioned, adjusted, and operated, with the use of regular atomic force microscope cantilevers. It would be apparent that the optical component may be designed for other numbers of probes, for example 6, 8 etc through hexagonal, octagonal, and other polygonal optical component designs.
Referring to FIG. 11 there is shown optical beam deflection component 1100 according to an embodiment of the invention supporting multiple optical beams. As shown within the optical beam deflection component 1100 are first and second right angle mirrors 1110 and 1120 , deviated by 90° upon each reflection that reflect incoming collimated optical beams. Each mirror is mounted on a rotational stage, which allows the adjustment of the optical beam orientation with 2 degrees of freedom (angular) allowing adjustment of the positioning of the focused laser spot onto a chosen position in the cantilever. The collimated optical beams then cross a polarizing beam splitter 1130 , such that the outgoing optical beam is p-polarized for example, and are focused by a focusing lens assembly 1140 , which is mounted on a thread to allow the position of the focal plane onto the cantilever. The optical beams then cross a quarter-wave plate 1150 that converts it to a circularly polarized optical beam, where it is coupled to the optical cantilever probe 1160 . When reflected of the cantilevers, not shown for clarity, the optical beams propagate back through the optical assembly to the polarizing beam splitter 1130 , where because they are now s-polarized, they reflect off the polarizing beam splitter 1130 rather than travelling straight through, as p-polarized light would, and then impinge on the optical photodetector assembly 1170 . The optical cantilever probe 1160 being positioned through positioning stage 1180 . Within the optical beam deflection component three optical beams 1190 A though 1190 C are depicted propagating from entry through the optical assembly to the optical cantilever probe 1160 and back to the optical photodetector assembly 1170 .
First insert 11100 depicts a plan view of the optical photodetector assembly 1170 . As shown, there are first to third linear optical detectors 1170 A through 1170 C together with optical beam spots 1190 A through 1190 C positioned on each. It would be evident that each optical beam spot 1190 A through 1190 C may be read out individually in position through the first to third linear optical detectors 1170 A through 1170 C respectively. These being for example linear CCD arrays that are available in pixel counts from 256 upwards to 6,000 or more.
Second insert 11200 depicts a view of the optical cantilever probe 1160 disposed with respect to a cantilever 1185 mounted in a cantilever mount 1195 . As shown each of the optical beams 1190 A though 1190 C probe the sample or samples mounted to the common cantilever 1185 . Referring to third insert 11300 the cantilever mount 1195 is now modified at its tip to accept three discrete cantilevers 1185 A through 1185 C so that each is probed by one of the optical beams 1190 A though 1190 C. Each discrete cantilever 1185 A through 1185 C being decoupled from one another unlike second insert 11200 wherein some coupling through the common cantilever 1185 may occur. In this manner multiple samples or measurements may be taken whilst the environment varies simultaneously to each.
Now referring to FIG. 12 there is depicted a view of a quad optical cantilever probe assembly with multiple probe beams to each optical cantilever probe assembly. Accordingly there is depicted optical component 1250 positioned above the four cantilevers 1240 A through 1240 D. Each of the four cantilevers 1240 A through 1240 D being mounted in the respective one of cantilever probe mounts 1220 A through 1220 D respectively. Accordingly each of the four cantilevers 1240 A through 1240 D is addressed with one of the optical probe beam arrays 1210 A through 1210 D respectively which are coupled to the four cantilevers 1240 A through 1240 D through access ports 1230 A through 1230 D respectively in the cantilever probe mounts 1220 A through 1220 D in a manner similar to that discussed supra in respect of FIG. 10 .
The embodiments presented supra in respect of FIGS. 4 through 12 with respect of the optical beam deflection component have been presented with respect to measuring the deflection of a cantilever to which the sample is mounted. However, it would be evident that the optical probe may be also employed in other configurations that benefit from providing multiple optical probe components that may or may not employ multiple optical beams per probe component. In some configurations the optical beam component may employ one or more optical filters within the optical beam path, including tunable or switchable filters. Likewise the optical beam(s) coupled into the optical beam component may be monochromatic, narrowband sources, broadband sources, or tunable such as from a tunable laser source. Equally they may be modulated, unmodulated, continuous wave (CW) or pulsed and be the same or multiple wavelengths coupled through each optical beam displacement component.
As such they may be used for measuring deflection as in the embodiments presented supra in respect of FIGS. 4 through 12 or alternatively the optical probes may stimulate the sample triggering emission in response to the optical probe under varying environmental stimuli. In such variations the quarter-wave plate and polarising beam-splitter may be replaced with a standard beam-splitter alone or in combination with a filter. Optionally all designs might exploit an optical circulator to couple the received optical probe beam to the sample under test and the returned/emitted signal to the optical photodetector. Additionally, a grating in combination with an optical photodetector may be provided to derive wavelength dependent responses of samples.
Referring to FIG. 13 there is shown an optical probe component 1300 according to an embodiment of the invention wherein characterization of the sample mounted to the sample holder 1340 is performed without a cantilever. Accordingly the optical probe component 1300 comprises a body 1310 containing the optical train including for example mirrors for coupling the input optical beam to a beam splitter, then to a lens for coupling to an optical probe 1320 . Signals coupled back into the optical probe 1330 , including but not limited to the reflected optical signal and optical signals emitted by the sample, and then coupled back via the lens into the optical train to the beam splitter. Where the optical measurement is an absorption then the reflected optical signal is coupled directly to the optical photodetector after the beam splitter whereas when the signal is emitted from the sample an optical filter may be employed to allow only the emitted optical signals to the optical photodetector.
Optionally such measurements can be performed with one optical beam of a multibeam optical beam deflection component whilst a second optical beam is deflected from a cantilever as described supra. It would be evident to one skilled in the art that the optical probe 1330 may be a specially designed solid optical glass component or that it may be other structures that operate through total internal reflection such as multi-mode optical fibre for example.
The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto. | Atomic Force Microscopes (AFMs) allow forces within systems under observation to be probed from the piconewton forces of a single covalent bond to the forces exerted by cells in the micronewton range. The pendulum geometry prevents the snap-to-contact problem afflicting soft cantilevers in AFMs which enable attonewton force sensitivity. However, the microscopic length scale studies of cellular/subcellular forces parallel to the imaging plane of an optical microscope requires high sensitivity force measurements at high sampling frequencies despite the difficulties of implementing the pendulum geometry from constraints imposed by the focused incoming/outgoing light interfering with the sample surface. Additionally measurement systems for biological tissue samples in vitro must satisfy complex physical constraints to provide access to the vertical cantilever. Embodiments of the invention address these geometrical restrictions by exploiting optical periscope approaches that further allows multiple probes to be deployed and multiple optical beams within each probe. | 6 |
FIELD OF THE INVENTION
This invention relates to mobile computing systems. In particular, it relates to the fabrication of an enclosure for a mobile computing system.
BACKGROUND
An important determinant of the utility of mobile computing systems, such as notebook computers and pen-based computing systems is the form factor of such systems. Compact form factors promote utility and are therefore desirable.
Another determinant of the utility of such systems is the weight of these systems. For greater utility, a lightweight system is desirable.
For the above reasons, an enclosure for a mobile computing system should be as thin and as lightweight as possible. However, if the enclosure is made too thin, strength is compromised resulting in breakage or at least damage to the enclosure and to the electronics components within the enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1E show various views of a mobile computing system comprising a tablet unit and a base unit, according to one embodiment of the invention;
FIG. 2 shows a side view of the mobile computing system of FIGS. 1A to 1E , in which the tablet unit and the base unit are positioned for use in a laptop mode configuration;
FIGS. 3A and 3B show views of the mobile computing system of FIGS. 1A to 1E , in which the tablet unit and the base unit are positioned for use in a tablet mode configuration;
FIG. 4 shows a perspective view of an enclosure for the mobile computing system of FIGS. 1A to 1E , in which a top wall of the tablet unit can be seen;
FIG. 5 shows a perspective view of an underside of the top wall of FIG. 4 ;
FIG. 6 shows a partial cross-sectional view through an enclosure for a mobile computing system, in accordance with one embodiment of the invention; and
FIG. 7 shows a partial cross-sectional view through an enclosure for a mobile computing system, in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to avoid obscuring the invention.
Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.
FIGS. 1A to 1E of the drawings show various views of a pen-based computing system in accordance with one embodiment of the invention. In one embodiment, the computing system 10 is in a form of a tablet personal computer (PC) and accordingly includes a tablet unit 12 and a base unit 14 . The base unit 14 is generally rectangular and comprises first and second panels 16 , 18 , respectively. The panels 16 , 18 are hingedly connected together via a hinge 20 which permits articulation of the panels 16 , 18 relative to each other. The first panel 16 bears a keyboard 22 which permits data entry into the tablet unit 12 during a laptop mode of operation.
The tablet unit 12 is generally rectangular and comprises various processing and display modules mounted on a motherboard substrate. For example, the processing modules may include a processor and a memory hierarchy comprising memory devices configured to store code for execution by the processer in response to user input. The display modules may include a mini-screen 24 , which in one embodiment may be a liquid crystal display (LCD) screen, and a large screen 26 . The large screen 26 includes a digitizer associated therewith to convert handwriting input via a pen or stylus into a digital signal which can be converted by handwriting recognition software into appropriate characters.
The components of the tablet unit 12 are enclosed within a generally rectangular enclosure comprising top and bottom walls 28 , 30 , respectively, and peripheral side walls 32 (see FIG. 2 ). The walls 28 , 30 , 32 are generally fabricated of a lightweight material having sufficient strength. In one embodiment, the walls 28 , 30 , 32 may be fabricated using steel, or aluminum.
As will be seen in FIGS. 1B and 1C , the side walls 32 have airflow vents 34 to permit airflow into the enclosure to facilitate cooling of the electronic components therein.
The system 10 includes a carry mode in which the tablet unit 12 is supported on the first panel 16 of the base unit 14 and the second panel 18 is folded over a top of the tablet unit 12 . In order to secure the tablet unit 12 and the base unit 14 in the carry mode configuration, a locking mechanism is provided. The locking mechanism comprises a pair of pivotally mounted latches 36 supported by the second panel 18 of the base unit 14 . The latches 36 are adapted to mate with complementary locking formations provided in the tablet unit 12 . As can be seen in FIG. 1D , in the carry mode configuration, the system resembles a portfolio.
The system 10 also includes a laptop mode configuration, in which the tablet unit 12 is held at an inclined position relative to the base unit 14 by the second panel 18 which functions essentially as a prop to support the tablet unit 12 in the inclined position. The laptop mode configuration is illustrated in FIG. 2 of the drawings. In the laptop mode configuration, the system 10 may be operated in a fashion similar to a conventional laptop, in which a primary mode of data entry is via the keyboard 22 .
The system 10 also includes a tablet mode configuration, in which the second panel 18 of the base unit 14 is folded to lie against the first panel 16 , and the tablet unit 12 is placed over the folded second and first panels 18 , 16 of the base unit 14 , in an orientation in which the large display screen 26 is exposed. In the tablet mode configuration, a user may input data into the system 10 using a pen or stylus by writing directly on the screen 26 as described above.
For greater utility of the system 10 , it will be appreciated that the enclosure should be as lightweight, and as robust, as possible. Further, a form factor of the enclosure should be as compact as possible.
In order to achieve an enclosure of lightweight and robust design, and which has a minimum form factor, in one embodiment each of the top wall 28 and the bottom wall 30 are fabricated to have zones of different thicknesses. FIGS. 4 and 5 of the drawings show perspective views of the top wall 28 of an enclosure for the tablet unit 12 , in accordance with one embodiment. As will be seen from FIG. 4 , an outer surface of the top wall 28 is smooth. However, an inner surface of the top wall 28 includes zones 40 , 42 , and 44 of different thicknesses (see FIG. 5 ). The thickness of each zone 40 , 42 , and 44 is determined by a height by which adjacent electronic components of the electronic assembly housed within the enclosure stand proud of a substrate surface on which the components are mounted. This concept is illustrated in FIG. 6 of the drawings, which shows a portion of a motherboard substrate 50 which includes electronic components 52 to 60 . As will be seen, the electronic components 52 to 60 have different heights by which they stand proud of the substrate 50 . Thus, according to the above described technique for fabricating an enclosure, the top and bottom walls 28 , 30 of the enclosure have zones of different thicknesses, each zone being matched to a height by which the electronic components stand proud of the substrate surface. For example, regions where the electronic components have a greater height above the substrate surface, coincide with zones of those reduced thickness. Conversely, regions that coincide with components of the electronic assembly that have a lesser height, the zones have an increased thickness.
In one embodiment, the thick zones may be between 1.5 and 3.0 mm, and the thin zones would have a thickness of between 0.3 and 0.8 mm.
In another embodiment of the invention, strengthening formations in the form of strengthening beams 70 are used to strengthen the top and bottom walls 28 , 30 . In one embodiment, the strengthening beams 70 have a height of 1 to 3 mm by which they stand proud of the top and bottom walls 28 , 30 and a width of between 0.5 and 2.5 mm. Each of the beams 70 may be integrally formed with top and bottom walls 28 , 30 . In order to add greater rigidity, in one embodiment, the beams are interconnected, as can be seen in FIG. 5 of the drawings.
In another embodiment, in order to achieve the enclosure of lightweight and robust design, and which has a minimum form factor, each of the top walls 28 and the bottom walls 30 are fabricated by first constructing a frame comprising a plurality of interconnected structural beams. Thereafter, the frame is covered with a sheet material which in addition to functioning as a cover to prevent the ingress of dust into the enclosure, also functions as a strengthening element to strengthen the frame by providing resistance to torsional deflection of the frame. Thereafter, side walls are fabricated to interconnect the top and bottom walls.
It will be appreciated that the electronic components of the tablet unit 12 may generate significant quantities of heat. Thus, in one embodiment, the enclosure is provided with a heat sinking mechanism to draw heat away from heat producing electronic components of the tablet unit 12 . FIG. 7 of the heat producing electronic components of the tablet unit 12 . FIG. 7 of the drawings, shows one embodiment of the heat sinking mechanism. Referring to FIG. 7 , reference manual 70 indicates heat producing component mounted on a substrate 72 . The heat sinking mechanism comprises a heat spreader component 74 , which in one embodiment, is integrally formed with the top or bottom wall of the enclosure. As will be noted, the heat spreader component 74 increases in cross-sectional area towards the heat producing component 70 . A heat absorbing block 76 fast with the heat spreading component is in a physical contact with the heat producing component 70 , and defines a thermal interface between the heat spreading component 74 and the heat producing component 70 . A thermal conductivity of the heat spreading component 74 is less than a thermal conductivity of the heat absorbing block 76 . In one embodiment, the heat absorbing block 76 may be of graphite, or diamond, and the heat spreading component 74 may be fabricated of material such as aluminum, copper, steel, etc. In one embodiment, an angle made by inclined side walls 78 of the heat spreading component 74 with respect to a plane that contains the heat absorbing block 76 is between 30 degrees and 60 degrees. In use, the heat absorbing block 76 rapidly absorbs heat from the heat producing component 70 and the heat spreading component 74 transports the heat absorbed by the heat absorbing block 76 to an area 80 of the top and bottom walls with which it is in contact. Since the area 80 is greater than an area of the heat producing component 70 , heat produced by the heat producing component 74 is distributed over a wider area by the heat sink, thus reducing thermal hot spots. The heat transported by the heat spreading component 74 to the surface, is thereafter radiated into the atmosphere.
In one embodiment, the inclined side walls 78 of the heat spreading component 74 are insulated with a thermal jacket (not shown) to prevent heat escaping therethrough. This improves the heat transfer to the area 80 .
Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that the various modification and changes can be made to these embodiments without departing from the broader spirit of the invention as set forth in the claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than in a restrictive sense. | In one embodiment, the invention provides an enclosure for a mobile computing system. The enclosure comprises a hollow body shaped and dimensioned to house a processing module, and a display module for a tablet personal computer, wherein the hollow body is defined by a top panel, a bottom panel, and a peripheral side panel, wherein the top and bottom panels are fabricated to have zones of increased, and reduced thicknesses which correspond to areas of the processing module have produced, and greater height, respectively. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to power generation systems, and more particularly, to a method and system employing a lead-unity-lag power factor operation of a power generation system for a DC power bus.
[0002] Power generation systems (PGS) play a significant role in the modern aerospace/military industry. This is particularly true in the area of more electric architecture (MEA) for aircraft, spacecraft, and electric hybrid technology in military ground vehicles. The commercial aircraft business is moving toward MEA having no bleed-air environmental control systems (ECS), variable-frequency (VF) power distribution systems, and electrical actuation. A typical example is the Boeing 787 platform. In the future, next-generation commercial aircraft may use MEA. Some military aircraft already utilize MEA for primary and secondary flight controls among other functions. Future space vehicles may require electric power generation systems for thrust vector and flight control actuation. Military ground vehicles have migrated toward hybrid electric technology, where the main propulsion is performed by electric drives. Therefore, substantial demand for increased power generation in that area has emerged. These systems should be more robust and offer greatly reduced operating costs and safety compared to the existing Space Shuttle power systems.
[0003] These new aerospace and military trends have significantly increased electrical power generation needs. The overall result has been a significant increase in the challenges to accommodate electrical equipment to the new platforms. This has led to increased operating voltages and efforts to reduce system losses, weight, and volume. A new set of electrical power quality and electromagnetic interference (EMI) requirements has been created to satisfy system quality and performance. One of the latest developments of machines under MEA themes is the energy efficient aircraft where electric power and heat management go hand to hand. Therefore, overall system performance improvement and more specifically, power density increase may be necessary for the new-generation hardware.
[0004] As can be seen, there is a need for a method and system to improve power generation in aircraft.
SUMMARY OF THE INVENTION
[0005] In one aspect of the present invention, a method employing a lead-unity-lag power factor adjustment on a power generation system comprises defining standard parameters for the power generation system; determining a power factor angle for the power generation system based on a power level defined in the standard parameters; calculating a unity power factor point based on the standard parameters; defining an operating power angle based on the unity power factor point; adjusting the power generation system standard parameters to shift the power factor angle to substantially match the operating power angle; and defining operation parameters for the power generation system based on-the unity power factor point.
[0006] In another aspect of the present invention, a method for moving a unity power factor point in a power generation system comprises determining operation parameters for the power generation system; generating a phasor diagram representing operation of the power generation system according to the operation parameters; defining a first vector representing a voltage terminal for the power generation system; defining a first angle based on a distance of the first vector from an originating axis, wherein the first angle represents a power factor angle and wherein the originating axis represents a phase current reference vector for the power generation system; defining a second vector representing an electromagnetic field of the power generation system; defining a second angle from the originating axis, wherein the second angle represents a control angle; defining a third angle between the first vector and the second vector representing a power angle for the power generation system; calculating a reduction in operational power for the power generation system; reducing the power factor angle to cause the first vector to approach the originating axis based on the reduction of the operational power; determining a new unity of power factor point in the power generation system according to the reduced magnitude of the power factor angle; and adjusting the operation parameters for the power generation system according to the new unity of power factor point.
[0007] In yet another aspect of the present invention, an electric power generation system comprises a three phase bridge; a DC link capacitor bank operatively coupled to the three phase bridge; an EMI filter operatively coupled to the DC link capacitor bank and a DC bus; a contactor disposed in operative contact between the EMI filter and the DC bus; and wherein power flow in the power generation system is operated at a nominal power level for the system based on a unity of power factor point adjusted upward from a zero power point to the nominal power level. These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is diagrammatic illustration of an EPGS topology according to an exemplary embodiment of the present invention;
[0009] FIG. 2A is a phasor diagram illustrating qualitative representations of an operation of an EPGS under prior art operating conditions;
[0010] FIG. 2B is a phasor diagram illustrating qualitative representations of an operation of an EPGS according to an exemplary embodiment of the present invention;
[0011] FIG. 3 illustrates a series of steps according to an exemplary embodiment of the present invention;
[0012] FIG. 4 illustrates a series of steps for controlling an EPGS according to an exemplary embodiment of the present invention;
[0013] FIG. 5 is a plot depicting a comparative analysis of performance between a conventionally operated EPGS and an EPGS according to an exemplary embodiment of the present invention; and
[0014] FIG. 6 is an exemplary table of operating parameters for an EPGS according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0016] Various inventive features are described below that can each be used independently of one another or in combination with other features.
[0017] Broadly, embodiments of the present invention generally provide a method and apparatus for moving the unity power factor point of a leading power factor system from zero power point to a power point where the machine operates predominantly. This operating point can thus, become the nominal power of the system. This means, for operation of a system below this new operating power point, the system may operate with a lagging power factor. Operation above of this power point, the system will operate with a leading power factor. Thus, one may improve the power factor and hence, one may also improve the efficiency of the system about the region where the system operates predominantly.
[0018] Referring to FIG. 1 , a power topology of an electric power generation system (EPGS) in accordance with one exemplary embodiment of the present invention is shown. An exemplary EPGS used for an MEA application may be a high-reactance permanent magnet machine (HRPMM) 150 . The topology depicts a three-phase bridge 110 , a DC link capacitor bank 120 , an EMI filter 130 for a DC bus, and a contactor 140 . It should be understood that current and voltage measurement devices for control and protection purposes are shown for illustrative purposes. The contactor 140 may be an optional component for all applications. This exemplary topology has bidirectional power flow capability by applying an appropriate voltage to the machine terminals. A synchronous rotation of the HRPMM 150 may be performed for continuous motoring or self-starting. Power generation may actively regulate DC bus voltage to a desired value.
[0019] One feature of this system provides a short-circuit current at the DC bus during generation to clear a fault. If the DC bus 160 is overloaded, the EPGS 100 may reduce the output voltage linearly to prevent components from overloading. Below certain voltage levels, a pure diode rectification may be used to supply desired current. The reactance of the electric machine 150 may be selected such that the short circuit of the electric power generation system 100 satisfies requirements of a DC bus short circuit current. One typical ratio between the DC bus short circuit current and the electric machine 150 short circuit current may be described as: I DCSC =1.35*I SC , wherein I DCSC is the DC bus short circuit current and ISC is the system short circuit current. The ratio may vary depending on component selection for the three phase bridge 110 and the electro-magnetic interference (EMI) filter 130 . When a short circuit occurs within the power electronics 110 , the HRPMM 150 , or the interface between the HRPMM 150 and the power electronics 110 , control of the generation process may be instantly discontinued. The failure current may be limited by the HRPMM 150 and may be comparable to the operating current.
[0020] Referring to FIGS. 2A and 2B , phasor diagrams of the HRPMM 150 operation in a complex plane may be used for sake of illustration and for providing qualitative assessments. FIG. 2A depicts a phasor diagram according to conventional operations of a power generation system. FIG. 2B depicts a phasor diagram with an adjusted power of nearly unity power factor according to an exemplary embodiment of the present invention. The phasor diagram of an HRPMM 150 in operation can be created according to the following exemplary equation.
[0000]
V
T
=E
EMF
−I
M
*Z
S
[0021] The phase current vector, I M , is aligned with the real (Re) axis of the complex plane. The leading power factor control is achieved by maintaining the power factor angle (θ)<0 (negative). That means the machine phase current vector is ahead of the terminal voltage vector. The terminal voltage vector, V T , is decomposed to two components real [V T ] cos(θ) and imaginary [V T ] sin(θ). Another angle α, may be the angle between the electromotive force (EMF) voltage and the phase current I M . The power angle δ defines the angle between the EMF voltage phasor and the terminal voltage phasor. The phasor V S =I M * Z S represents the internal machine (HRPMM 150 ) voltage drop.
[0022] In terms of application to the HRPMM 150 , machine shaft power P T may be expressed as:
[0000]
P
T
=
3
*
V
T
*
E
EMF
*
sin
(
δ
)
X
S
,
[0000] wherein V T is the terminal voltage, E EMF is the HRPMM 150 back EMF voltage, and X S is the HRPMM 150 reactance.
[0023] Expressing output power may be described as:
[0024] P OUT =P T *η pe *η m , wherein P OUT is the output power of the HRPMM 150 , P T is the shaft power, η pe is the efficiency of power electronics, and η m is the efficiency of the HRPMM 150 .
[0025] One expression describing the power angle (δ) may be derived from the HRPMM 150 shaft power (P T ) and the output power (P OUT ) according to the following equation:
[0000]
δ
=
sin
-
1
(
(
P
out
η
pe
*
η
m
)
*
E
EMF
*
X
S
3
*
V
T
*
E
EMF
)
[0000] wherein the variables are described by the aforementioned equations.
[0026] In accordance with these equations, one may adjust the power angle (δ) so that the power factor angle (θ) is reduced and the terminal voltage V T phasor is shifted toward the Re axis of the complex plane. One exemplary result may be seen when comparing FIG. 2A to FIG. 2B where the power angle (δ) approaches the angle α. Thus, a unity power factor point of the electric power generation system 100 may be adjusted to operate where the system predominantly operates. Thus, in practice, defining the unity power factor point may be achieved by determining the EPGS 100 characteristic parameters. An exemplary table of input conditions and constraints for an EPGS 100 may be seen in FIG. 6 .
[0027] Exemplary input conditions as illustrated in the table of FIG. 6 may include parameters 605 which may include a P Load 610 , a η pe 620 , a η m 630 , a V DC 640 , a SC factor 650 , a V T 660 , a E EMF 670 , a frequency 680 , and a X S 690 . The P Load 610 may represent an output power at a load. The η pe 620 may represent an efficiency of power electronics in the EPGS 100 . The η m 630 may represent an efficiency of the HRPMM 150 . The V DC 640 , may represent an output DC voltage in the EPGS 100 . The SC factor 650 may represent a maximum short circuit DC current above a maximum operating current in the HRPMM 150 . The V T 660 may represent a HRPMM terminal voltage. The E EMF 670 may represent a back EMF voltage of the HRPMM 150 . The frequency 680 may represent the HRPMM 150 electrical operating frequency. The X S 690 may represent the HRPMM 150 reactance. Thus, in one exemplary operation, adjustment of those parameters may be made to achieve a desired unity power factor point as illustrated in the following exemplary methods.
[0028] Referring to FIG. 3 , a series of steps illustrate an exemplary method according to the present invention. In step 210 , standard system parameters may be defined. Exemplary parameters may be extracted from a table of values such as that one shown in FIG. 6 . In step 220 , a unity of power factor operating power point may be defined for the system for a given power level based on the extracted system parameters. In step 230 , a system short-circuit current may be computed. The short-circuit DC current may be described as I scdc =(P load /V DC )*(1+SC factor ). In step 240 , a back EMF (E EMF ) voltage may be computed for the unity power factor power point. One exemplary equation that may be used to calculate the power factor (PF) as a function of the back EMF (E EMF ) may be described as:
[0000]
PF
(
E
EMF
)
=
cos
(
cos
-
1
(
V
T
-
E
EMF
*
cos
(
δ
)
E
EMF
2
+
V
T
2
-
2
*
E
EMF
*
V
T
*
cos
(
δ
)
)
-
π
2
)
[0029] wherein the variables are previously described. In step 250 , a system reactance may be computed. One exemplary equation describing the system reactance may be described as X S =E EMF /I sc . In step 260 , the system parameters may be assessed for controllability. In step 270 , a modified HRPMM 150 may be designed based on the parameters obtained from steps 210 - 250 .
[0030] Referring now to FIG. 4 , an exemplary method of controlling the lead-lag-unity power factor is shown according to another exemplary embodiment of the present invention. In step 305 , demand power may be computed from a measured bus voltage and current. In step 310 , current demand may be computed from a difference between the computed demand power and nominal power. In step 315 , a position decoder may be used to measure machine rotor position that may be used for reference frame transformations. In step 320 , machine terminal currents may be measured and transformed to a Park vector in the stationary reference frame using the rotor position measured in step 315 . In step 325 , the current Park vector may be transformed from a stationary reference frame to a synchronous reference frame. In step 330 , a voltage command error may be computed. The voltage command error may be computed based on the DC voltage and measured feedback voltage. and DC bus current feedback. In step 335 , the voltage command error in step 330 may be regulated, and the regulated voltage error and the DC bus current feedback may be used to compute current command magnitude. In step 340 , the current command magnitude and angle may be transformed into a vector in the synchronous reference frame. In step 345 , a current command error may be generated from current feedback vector (step 320 ) and current command vector (step 340 ) and regulated. The current regulator outputs may be inverter voltage commands. In step 350 , the inverter voltage command may be transformed back to the stationary reference frame. In step 355 , space vector modulation may be used to transform inverter voltage command to desired machine terminal voltage.
[0031] Referring to FIG. 5 , exemplary results showing a comparative analysis of machine current employing conventional operation of an electric power generation system against an exemplary operation of the EPGS 100 as a lead-unity-lag system according to an embodiment of the present invention is illustrated. Taking the lead-unity-lag system current as a percentage of the leading system current, it may be seen that the lead-unity-lag system of the EPGS 100 requires 10% lower current at full load than a system under conventional operation. Since the current at full load determines the rating of the system, this may be a significant efficiency improvement. Also, the rating of the three-phase bridge and machine-electronics may be reduced by 10%. Thus, reduced electric machine size and power electronics may be expected.
[0032] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | A method employing a lead-unity-lag adjustment on a power generation system is disclosed. The method may include calculating a unity power factor point and adjusting system parameters to shift a power factor angle to substantially match an operating power angle creating a new unity power factor point. The method may then define operation parameters for a high reactance permanent magnet machine based on the adjusted power level. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a tellurium containing nutritional formulation that enhances the cumulative weight gain and feed efficacy in poultry. There is compelling evidence from the investigation of chick models that tellurium compounds act to influence the growth performance of chicks. The additive effects in increasing body weight are dose related and most significant at tellurium compound feed concentrations of 12.5 g/metric ton.
2. Description of the Related Art
The present invention is based on the discovery that the addition of a tellurium species to the diet of poultry a few days after hatching increases the growth rate of the young chicks.
Prior research has shown that improvement of the quality of the nutrition of broilers have provided the possibility of increasing their growth rate in modem broiler strains. The increased growth is reflected in either an increased weight of the adult chicken, or a reduction in the period of time required for obtaining an adult chicken. The most dramatic growth rate increase is manifested primarily in the first four weeks after hatching. An increased growth rate in these first four weeks has been found to involve an increased weight of grown up broilers at the age of 42 days, an age that they are typically ready for consumption.(Zubair A. K., 52 WORLD POULTRY SCIENCE J. 189–201 (1996)). According to the state of the art, at 14 days, approximately 50% of the broilers have a body weight of between 365 and 390 grams, and at 42 days, approximately 60% of the broilers have a body weight between 2100 and 2300 grams.
Growth of the young chick only starts after the yolk sac has been resorbed. Further, it is state of the art to deprive the hatched chick of nutrition in the first days of its life in order to enable it to exhibit compensatory growth. An earlier start of growth is reflected in an increased weight of the grown up chicken. It is, therefore, desirable to feed chicks a food composition that accelerates absorption of the yolk sac.
Materials promoting growth, the so-called “growth stimulants”, are typically employed in animal feed for producing quicker growth and increased meat tissue production. The known growth promoting materials may be categorized as either antibiotics, synthetic chemical growth promoters, or sexual hormones. The use of sexual hormones has been forbidden in certain countries.
There are a number of prior art food compositions to enhance growth of young chicks. U.S. Pat. No. 6,258,399 discloses a composition containing monosaccharides, disaccharides, oligosaccharides fed immediately after hatching and during the first days of life that has a growth enhancing and mortality reducing effect.
Others have added various nutrients and vitamins to feed to prevent disease. For example, U.S. Pat. No. 5,516,525 discloses the addition of vitamin D derivatives to animal feed to prevent development of tibial dyschondroplasia.
Increasing interest has been drawn to the substances known as trace elements, i.e. elements absolutely vital to the human organisms, albeit in minute amounts. Selenium is an essential trace element for proper physiological function in humans. Deficiency can lead to improper functioning of the body's metabolic processes, and to various diseases and disorders. Selenium deficiency has been seen in people who rely on total parenteral nutrition (TPN) as their sole source of nutrition. Selenium deficiency is most commonly seen in China, where the selenium content in the soil, and therefore, selenium intake, is very low. It is characterized by Keshan Disease which results in an enlarged heart.
A blood selenium concentration of 0.02 μg/ml may be considered the critical threshold in defining selenium deficiency. The Food and Drug Administration (FDA) established Recommended Dietary Allowance (RDA) for selenium is 55 μg for adults and 70 μg for lactating women.
Several studies reporting the beneficial effects of selenium supplementation in animals have appeared in the literature. With supplementation with intraruminal pellets of selenium the live weights of ewes receiving selenium were generally but not consistently higher than those of unsupplemented ewes. However, fleece weights were significantly greater in selenium supplemented ewes.(Langerlands, J. P. et al; Subclinical Selenium Deficiency. 1-Selenium Status and the Response in Live Weight Gains and Wool Production of Grazing Ewes Supplemented With Selenium. 31 AUST. J. EXP. AGR. 25–31 (1991)). Supplementation with selenium has been observed to help lamb survival rate.(Langerlands, J. P. et al; Subclinical Selenium Deficiency. 2-The Response in Reproductive Performance of Grazing Ewes Supplemented With Selenium. 31 AUST. J. EXP. AGR. 33–35 (1991)). Lamb weights increased significantly at all ages when their dams were supplemented with selenium.(Langlands, J. P. et al; Subclinical Selenium Deficiency. 3-The Selenium Status and Productivity of Lambs Born to Ewes Supplemented With Selenium. 31 AUST. J. EXP. AGR. 37–43 (1990); Langlands, P. J. et al; Selenium Supplements for Grazing Sheep. 28 ANIMAL FEED SCI. TECH. 1–13 (1990)). Administration of intraruminal pellets selenium to dairy heifers resulted in weight gains of 0.11–0.12 kg/day over control.(Wichtel, J. J. et al; The Effect of Intra-ruminal Se Pellets on Growth Rate, Lactation and Reproductive Efficacy in Dairy Cattle, 42 NEW ZEALAND VET. J. 205–210 (1994)).
Selenium has been recognized as an essential nutrient in the production of livestock because of its preventive action against certain diseases such as liver necrosis in pigs, white muscle disease in calves and lambs, and pancreatic degeneration and exudative diathesis involving the capillaries in poultry. The level of selenium in feeds such as cereal grains and soybeans is in most areas inadequate to meet the nutritional needs of livestock. U.S. Pat. No. 4,042,722 discloses selenium containing additives for use as supplements in livestock feeds having a selenium content of not more than 5,000 ppm. Further, FDA has approved the use of selenium as a livestock feed supplement at levels of 0.1–0.3 ppm. Commercial trace mineral premixtures which are sometimes added to animal feed may contain MnO 2 , ZnO, FeSO 4 , FeCO 3 , CuSO 4 . Additionally, they sometimes contain trace amounts of selenium but not tellurium.
The nontoxic tellurium compound AS101, ammonium trichloro(dioxyethylene-O,O′)tellurate, first developed by the present inventors has been shown to have beneficial effects in diverse preclinical and clinical studies. Most of its activities have been attributed in part to stimulation of endogenous production of a variety of cytokines. The immunomodulating properties of AS101 play a crucial role in preclinical studies demonstrating a protective effect in parasite and viral infected mice models, in autoimmune diseases, and in a variety of tumor models. AS101 has also been shown to have protective properties against lethal and sublethal effects of irradiation and chemotherapy, including protection from hemopoietic damage and alopecia, resulting in increased survival. Phase I and II clinical trials with AS101 on cancer patients showed it was non-toxic and exerted immunomodulatory effects that are associated with its beneficial clinical effects.
A number of human commercial dietary supplement products contain trace amounts of tellurium. The present invention is based on the discovery that a source of tellurium when administered orally, could positively affect the livability, weight gain or feed conversion efficacy of poultry. No one has added tellurium compounds to animal feed.
SUMMARY OF THE INVENTION
The invention comprises the administration in a pharmaceutically acceptable carrier including animal feed, of an effective amount of a source of tellurium to improve the health and enhance the livability, cumulative weight gain and feed conversion efficacy of poultry and other animals. One or more objects of the present invention are accomplished by the provision of a method of supplementing standard feed with a source of tellurium. The tellurium may be administered as free tellurium, inorganic tellurium or organic tellurium and fed immediately after hatching or birth of the animal or the animals afflicted with or susceptible to poor growth performance. Organic tellurium is preferred.
Accordingly, it is a primary object of the invention to provide a method to enhance growth performance and feed conversion efficacy, prevent poor growth performance in animals susceptible to same, or treat poor growth performance in animals using a source of tellurium. The method comprises feeding the hatchlings a tellurium supplemented diet at a point in time preferably within the first five days of hatching, more preferably within the first three days of hatching.
It is an object of the present invention to provide a feed composition with which the undesired mortality of young chicks can be reduced.
It is also an object of this invention to provide a novel feed composition which is resistant to degradation, nontoxic, low cost, readily assimiable, which does not leave a toxic residue in the meat of animals, and which can be packaged in bulk, shipped and divided into dosage units form at the point of use. The process can be carried out efficiently and meets requirements important for commercial production.
These and other objects of the invention will become apparent from a review of the specification.
DETAILED DESCRIPTION OF THE INVENTION
Surprisingly, it has been discovered that the growth of poultry can be stimulated, the livability, cumulative weight gain and feed conversion efficacy of the poultry can be improved by feeding a formulation of the present invention.
An advantage of the present invention is to increase the livability of poultry, fed the feed composition of the invention. “Livability” is judged by determining the proportion of animals on a particular feed regimen which are alive after a particular period of time. When poultry, are grown for food production, there is generally a loss of a small but constant percentage of the animals prior to bringing the animals to market. This means that the feed eaten prior to death of the animals and the other costs expended on the animals that do not survive are wasted. The decrease in death rate of the animals during the growing period of the present invention and improved feed conversion efficacy, results in reduced costs of raising such animals.
The compositions can also be fed in a feed composition as a treatment for failure to thrive or already established low birth weight in the animal.
The term “organic tellurium” is defined to mean any tellurium element bonded to an organic moiety, including via atoms that differ from carbon, such as oxygen. Preferred organic tellurium compounds for use in the invention are described in 37 INORG. CHEM. 1707 (1998) incorporated herein by reference and include those of the formula:
or
Te(ethylene glycol) 2 Te(citrate) 2
An organo or inorgano compound containing tellurium oxide
or
TeO 2 or complexes of TeO 2 (C)
or
PhTeCl 3 (D)
or
TeX 4 , when X is Cl, Br or F
or the following complex: TeO 2 .HOCH 2 CH 2 OH.NH 4 Cl;
or
(C 6 H 5 ) 4 P+(TeCl 3 (O 2 C 2 H 4 ))— (E)
wherein t is 1 or 0; u is 1 or 0; v is 1 or 0; R, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , and R 9 are the same or different and are independently selected from the group consisting of hydrogen, hydroxyalkyl of 1 to 5 carbons, hydroxy, alkyl or from 1 to 5 carbon atoms, halogen, haloalkyl of 1 to 5 carbon atoms, carboxy, alkylcarbonylalkyl of 2 to 10 carbons, alkanoyloxy of 1 to 5 carbon atoms, carboxyalkyl of 1 to 5 carbons atoms, acyl, amido, cyano, amidoalkyl of 1 to 5 carbons, N-monoalkylamidoalkyl of 2 to 10 carbons, N,N-dialkylamidoalkyl of 4 to 10 carbons, cyanoalkyl of 1 to 5 carbons alkoxy of 1 to 5 carbon atoms, alkoxyalkyl of 2 to 10 carbon atoms and —COR 10 wherein R 10 is alkyl of 1 to 5 carbons; and X is halogen; while the ammonium salt is illustrated, it is understood that other pharmaceutically acceptable salts such as K+ are within the scope of the invention. The compounds with the five membered rings are preferred.
As used herein and in the appended claims, the term alkyl of 1 to 5 carbon atoms includes straight and branched chain alkyl groups such as methyl; ethyl; n-propyl; n-butyl, and the like; the term hydroxyalkyl of 1 to 5 carbon atoms includes hydroxymethyl; hydroxyethyl; hydroxy-n-butyl; the term halkoakyl of 1 to 5 carbon atoms includes chloromethyl; 2-iodoethyl; 4-bromo-n-butyl; iodoethyl; 4-bromo-n-pentyl and the like; the term alkanoyloxy of 1 to 5 carbon atoms includes acetyl, propionyl, butanoyl and the like; the term carboxyalkyl includes carboxymethyl, carboxyethyl, ethylenecarboxy and the like; the term alkylcarbonylalkyl includes methanoylmethyl, ethanoylethyl and the like; the term amidoalkyl includes —CH 2 CONH 2 ; —CH 2 CH 2 CONH 2 ; —CH 2 CH 2 CH 2 CONH 2 and the like; the term cyanoalkyl includes —CH 2 CN; —CH 2 CH 2 CN; —CH 2 CH 2 CH 2 CN and the like; the alkoxy, of 1 to 5 carbon atoms includes methoxy, ethoxy, n-propoxy, n-pentoxy and the like; the terms halo and halogen are used to signify chloro, bromo, iodo and fluoro; the term acyl includes R 16 CO wherein R 16 is H or alkyl of 1 to 5 carbons such as methanoyl, ethanoyl and the like; the term aryl includes phenyl, alkylphenyl and naphthyl; the term N-monoalkylamidoalkyl includes —CH 2 CH 2 CONHCH 3 , —CH— 2 CONHCH 2 CH 3 ; the term N,N-dialkylamidoalkyl includes —CH 2 CON(CH 3 ) 2 ; CH 2 CH 2 CON(CH 2 —CH 3 ) 2 . The tellurium based compounds that are preferred include those of the formula:
wherein X is halogen. The preferred halogen species is chloro.
Other compounds which are based on tellurium and may be used in the practice of the invention include PhTeCl 3 , TeO 2 , TeO 2 .HOCH 2 CH 2 OH.NH 4 Cl and TeX 4 (C 6 H 5 ) 4 P+ (TeCl 3 (O 2 C 2 H 4 ))— (Z. Naturforsh, 36, 307–312 (1981). Compounds of the following structure are also included:
Other compounds useful for the practice of invention include:
wherein R 11 , R 12 , R 13 and R 14 are independently selected from the group consisting of hydrogen, hydroxy-alkyl of 1–5 carbons atoms, hydroxy and alkyl of 1–5 carbons atoms.
Useful dihydroxy compounds for use in the preparation of compounds of structure A or B, include those of formula I wherein R, R 1 , R 4 and R 5 are as shown in the Table:
TABLE
(I)
R
R 1
R 4
R 5
H
H
H
H
H
Cl
H
H
H
OCH 3
H
H
H
COOCH 3
H
H
H
H
CN
H
H
CHO
H
H
H
H
COOH
H
H
CH 2 COOH
H
H
H
H
CH 2 COOCH 3
H
H
I
H
H
H
H
Br
H
H
H
CONH 2
H
H
H
CH 2 OH
H
H
COOH
H
H
Other dihydroxy compounds for use in the preparation of compounds A and B include those of formula II wherein R, R 1 , R 2 , R 3 , R 4 and R 5 are as shown in the Table:
(II)
R
R 1
R 2
R 3
R 4
R 5
H
H
H
H
H
H
H
H
Cl
H
H
H
H
CH 2 OH
H
H
H
H
H
H
OH
H
H
H
H
H
H
CH 3
H
H
H
H
H
CH 2 Cl
H
H
H
H
H
COOH
H
H
H
H
H
CH 2 COOH
H
H
H
H
H
CHO
H
H
H
H
H
H
H
CH 2 CHO
H
H
CONH 2
H
H 2
CH 3
H
H
H
CN
H
H
H
H
H
H
CH 2 CONH 2
H
H
H
H
COOCH 3
H
H
H
H 3
OCH 3
H
H
H
Other dihydroxy compounds for use in making compound of formula A and B include those of formula III wherein R, R 1 , R 2 , R 3 , R 4 and R 5 are as shown in the Table.
(III)
R
R 1
R 2
R 3
R 4
R 5
R 8
R 9
H
H
H
H
H
H
H
H
H
H
Cl
H
H
H
H
H
H
H
H
H
Br
H
H
H
H
H
OCH 3
H
H
H
H
H
H
H 2
CONH 2
H
H
H
H
H
H
Br
H
H
Br
H
H
H
H
H
H
H
CH 2 COOH
H
H
H
H
H
Cl
Cl
H
H
H
H
H
CH 2 COOH
H
H
H
H
H
H
H
H
CH 3
H
H
H
H
H
H
CH 3
H
H
H
H
H
H
H
CH 2 Cl
H
H
H
H
H
H
H
H
H
I
H
H
H
H
H
CH 2 CN
H
H
H
H
H
H
H
H
H
H
CH 2 CH 2 OH
H
H
H
Additional dihydroxy compounds include those of formula IV wherein R, R 1 , R 2 , R 3 , R 4 and R 5 are as shown in the Table.
(IV)
R
R 1
R 2
R 3
R 4
R 5
R 6
R 7
R 8
R 9
H
H
H
H
H
H
H
H
H
H
H
H
Cl
H
H
H
Cl
H
H
H
H
H
Cl
Cl
H
H
H
H
H
H
H
H
CONCH 3
H
H
H
Br
H
H
H
H
H
Br
H
H
H
CON(CH 3 ) 2
H
H
H
H
H
H
OCH 3
H
H
H
H
H
H
H
H
H
H
OCH 3
H
H
H
H
H
H
H
H
H
CH 2 COOH
H
H
H
H
H
H
H
COOH
H
H
H
H
H
H
H
H
CH 3
H
H
H
H
H
H
H
H
CH 3
H
H
H
H
CH 3
H
H
H
H
H
CH 2 CH 3
H
H
H
H
H
Cl
H
H
H
CH 2 CN
H
H
CH 2 OH
H
H
H
H
H
H
H
H
I
H
H
H
H
CN
H
H
CH 2 CH 2 COOH
H
H
H
H
H
H
H
H
H
H
CHO
H
H
H
H
H
H
H
H
H
H
F
H
H
H
H
H
H
Compounds of the following formula are also included:
herein R 15 , R 16 , R 17 and R 18 are independently selected from halogen, alkyl of 1–5 carbons; aryl, acyl of 1–5 carbon hydroxyalkyl of 1–5 carbons and aminoalkyl of 1–5 carbons may be made by reacting the appropriate di, tri or tetrahalotelluride with the appropriate hydroxy compound which may be of the formula: HO—R 19 ;
wherein R 19 ; is alkyl of 1 to 5 carbons, haloalkyl of 1 to 5 carbons, aryl, alkylaryl, alkylamido of 1 to 5 carbons, alkylcarbonyl of 1 to 5 carbons, cyanoalkyl of 1 to 5 carbons, cyanoalkyl of 1 to 5 carbons, and an alkoxyalkyl of 2 to 10 carbons. Specific examples of R 16 include methyl, ethyl, n-propyl, phenyl, tolyl, amidoethyl, cyanomethyl, methyloxymethyl and CH 2 CH 2 COOH.
These compounds are described in U.S. Pat. No. 4,761,490 which is incorporated by reference. In addition, inorganic tellurium compounds such as TeCl 4 ; TeBr 4 and compounds which give in aqueous solution TeO 2 preferably in the form of a complex such as for example TeO 2 complex with citric acid or ethylene glycol may be used.
The preferred compound is ammonium trichloro (dioxoethylene-O,O′) tellurate. The tellurium compound may be administered orally, via yolk sac injection, parenterally, in ovo, or via inhalation by spray. The parenteral route of administration may be intravenously, subcutaneously, intramuscularly etc. The composition of the present invention will mostly be supplied in the solid state, for example as a powder, in pellets or crumbs.
In one embodiment of the invention, the source of tellurium may be administered orally or added to the standard feed and direct fed or administered via a compatible liquid vehicle. It may be supplied as such or mixed with conventional nutrients such as, for example corn or soya. It will be understood by those skilled in the art that the active tellurium derivatives described herein can also be fed in combination with together commercially formulated or similar feeds for chickens and other animals. Tellurium is preferably combined with the feed by mixing to evenly distribute. Adding a fixed amount of tellurium directly to the feed has the advantage of convenience and is more economical, than weighing animals and adjusting dosages each day.
Alternatively, oral administration may be as a solid dosage form i.e. a daily dietary supplement tablet with conventional excipients such as lactose, microcrystalline cellulose and the like. It has been found that the tellurium compounds useful in the practice of the invention will hydrolyze in the presence of water. These hydrolyzed compositions are active in vivo and in vitro although the hydrolyzed compositions eventually decompose and lose their ability to induce lymphokine secretion. For this reason, the compositions should be freshly prepared. Preferably, the compounds should be kept under anhydrous conditions until just prior to being used.
Pharmaceutically acceptable carriers or diluents may be, for example, binders, (e.g., syrup, gum Arabic, gelatin, sorbitol, tragacanth, polyvinylpyrrolidone, etc), excipients (e.g., lactose, sucrose, corn starch, sorbitol), lubricants (e.g., magnesium stearate, talc, polyethylene glycol, silica, etc.), disintegrants (e.g. microcrystalline cellulose, potato starch, etc.), wetting agents (e.g. sodium lauryl sulfate, etc.), and the like. These pharmaceutical preparations may be in the form of a solid preparation such as tablets, capsules, powders, etc., or in the form of a liquid preparation such as solution, suspension, emulsion, etc., when administered orally. When administered parenterally, the pharmaceutical preparations may be in the form of a suppository, an injection or an intravenous drip, a physiological salt solution, and so on.
The tellurium may also be administered with vitamin, microbial (e.g. Lactobacillus), antimicrobial, enzyme, and forage additives. Examples of antibiotics approved for use in animal feed include bacitracin, bacitracin methylenedisalicylate, lincomycin, or virginiamycin. Vitamin additives may be selected from vitamins A, B1, B6, B12, biotin, choline, folic acid, niacin, panthothenic acid, riboflavin, C, D, E, and K. Mineral additives may be added from calcium, phosphorous, selenium, chlorine, magnesium, potassium, sodium, copper, iodine, iron, manganese, chromium, and zinc. The concentration of the vitamins and minerals will generally be between about 0.01% and about 5% by weight of the dry matter.
In another embodiment of the present invention, the source of tellurium may be combined with immunoactive agents, such as vaccines; other therapeutic drugs, such as growth promotants or hormones; digestion enhancers, such as bile salts; palatability modifiers, such as spices or gums; or feed intake regulators, such as food coloring.
A variety of other substances can be employed as adjuvants in the present invention. Some examples include: polysaccharides, peptides, macromolecules.
The ratio of selenium to tellurium in the feed composition can be in the range between about 1:1 and about 1:50.
In addition to chickens, the nutritional composition is equally effective in enhancing growth in other fowl including turkeys, pheasants, and ducks.
EXAMPLE 1
The dose of ammonium trichloro (dioxoethylene-O,O′) tellurate or a pharmaceutically acceptable salt thereof varies depending on the administration route, ages, weights and animal type, but may be in the range of from 0.1 gram to 20 grams per metric ton, preferably from 1 to 15 grams/metric ton, and most preferably 12.5 grams per metric ton, administered daily in one or more divided doses.
The efficacy of the invention has been demonstrated in three day old inanited chicks where three concentrations of AS101 were introduced into the feed (500–12,500 mg/metric ton) for three weeks. Each chick included in the study weighed exactly 80 g. via accurate electronic scale and each chick was marked. There were five different treatment groups, each group comprising ten chicks in four repetitions. The five groups of animals were tested as follows: Group 1 received a standard feeding diet without selenium; Group 2 received the standard feeding diet supplemented with 500 mg/metric ton of selenium; Group 3 received the same diet as Group 2 with the addition of AS101 at a concentration of 500 mg/metric ton; Group 4 received the same diet as Group 2 with the addition of AS101 at a concentration of 2,500 mg/metric ton; Group 5 received the same diet as Group 2 with the addition of AS101 at a concentration of 12,500 mg/ton. All the experiments were randomized and open. The results of each group represent the mean of 40 chicks.
For growth period days 3–24, the performance of groups of three day old birds, fed AS101 concentrations of 500 mg/metric ton, 2,500 mg/metric ton or 12,500 mg/metric ton were compared to groups of control birds fed either a standard feeding diet without selenium or a standard feeding diet with an addition of 300 mg/metric ton selenium. Body weight (BW) was measured after 24 days. At the end of 24 days, the animals were examined for gross signs of toxicity. A gross visual examination was carried out. The liver of each chick was extracted and weighed. No pathological changes were observed in histological studies. The survival rate was 100%. Since there were no mortalities in any group, it is clear that AS101 had an effect on livability.
Results are presented in Table 1. The group with the lowest mean body weight was Group 1, where the diet was the standard feeding diet without selenium. Group 2, which was fed the diet of Group 1, with an addition of 300 mg/ton of selenium showed a 0.4% increase in BW over Group 1. The increase in BW is caused by the addition of the selenium to the mixture.
Addition of AS101 to the same diet as Group 2 resulted in the highest feed efficacy. The addition of AS101 to the mixture, that includes selenium, showed a BW increase of 1.7% at a concentration of 500 mg/ton, 2.3% at a concentration of 2,500 mg/ton, and 5% at a concentration of 12,500 mg/ton. Group 5, which was fed the highest level of tellurium, showed a 5.4% increase in BW over Group 1.
It appears that food intake is not altered by feeding with AS101. At day 21 the difference is only 12 g or about 1%. The differences in BW between AS101 supplemented and unsupplemented groups was highly significant, even though feed intake was almost identical in all groups.
A significant increase in BW was found at 12.5 g/ton AS101.
TABLE 1
PERFORMANCE DATA OF CHICKS AT THE GROWTH PERIOD 3–21 DAYS
DIET WITH AS101
TREAT-
FEED
FEED
MENT
BW-24D
BW, % OF
INTAKE
EFFICACY
FE, % OF
LIVER, %
#
g.
CONTROL
g.
g./g.
CONTROL
OF BW
1
1013
94.6
1376
0.679
96.2
2.36
2
1072
100
1405
0.706
100
2.32
3
1090
101.7
1382
0.731
103.5
2.36
4
1097
102.3
1375
0.74
104.8
2.48
5
1126
105
1417
0.738
104.5
2.39
From these results it can be concluded that by feeding three day old chicks standard diet containing at least 0.5 gm of selenium per metric ton supplemented with 12.5 gm of tellurium compound per metric ton, the growth rate of the young chicks can be increased up to 5% by day 21.
The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. All such obvious modifications and variations are intended to be within the scope of the appended claims. | A novel nutrient formulation containing tellurium for use in poultry, and a method of feeding it which improves subsequent livability, cumulative feed efficacy or weight gain is disclosed. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to sensing and control techniques for laundry apparatus, and is particularly concerned with methods and apparatus for sensing the moisture content of a clothes load within a dryer and controlling the operation of the clothes dryer on a digital basis.
2. Description of the Prior Art
U.S. Pat. No. 3,702,030 discloses a high voltage sensor circuit for an integrated circuit control that produces repetitive pulses when the clothes load is drier than a given dryness level for resetting a second counter to prevent the second counter from resetting a first counter. The first counter, upon reaching a predetermined count, ends the sense portion of the drying cycle. Similar circuits are utilized in U.S. Pat. Nos. 3,762,064 and 3,769,716.
U.S. Pat. No. 3,621,293 discloses the use of a field effect transistor for sensing voltage build up on a capacitor in a dryer control.
U.S. Pat. No. 4,215,486 discloses a dryer control circuit which utilizes the output of an oscillator, which is frequency dependent on the dryness of the clothes, to feed an amplifier, the output level of which is dependent on the frequency of the oscillator. The output of the amplifier is fed to a comparator which compares the amplifier output with a reference voltage and shuts down the dryer when that voltage is reached.
SUMMARY OF THE INVENTION
The present invention provides a means of sensing clothes load moisture in a microcomputer controlled dryer based on the level of moisture retention measured in the clothes load.
A low voltage sensor circuit senses the degree of dryness of a load of clothes within the dryer and sends either a high or low signal, depending on the sensed dryness, to a microcomputer. The microcomputer repetitively reads the input from the sensor circuit at very short intervals. In the preferred embodiment, if it reads a low or wet signal, a pre-selected number of consecutive times, indicating a valid wet signal, the microcomputer resets a search counter. As the clothes load continues to dry, valid wet signals decrease until a sufficient length of time between valid wet signals occurs allowing the search counter to run out. When the search counter has run out, the sensing portion of the process will end and the control circuit will cause the remainder of the selected program to continue.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an automatic dryer embodying the principles of the present invention.
FIG. 2 is a schematic diagram of a dryer including a dryer control circuit according to the present invention.
FIG. 3 is a schematic electrical circuit diagram utilized in the present invention.
FIGS. 4a and 4b comprise a flow chart illustrating the operation of a low voltage sensor control process.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 there is generally shown an automatic dryer 10 having a cabinet 12 and a control console 14 with controls 16 thereon. The controls 16 are generally shown as touch control switches, however, the controls may be of any number of types commonly known in the art. The controls provide fabric selection, automatic dry, timed dry, air and touch-up drying cycles. A range of selections are available in the automatic and timed dry cycles.
A front 18 of the cabinet 12 has door 20 which provides access to the interior of the dryer 10 including a rotatable drum 22. Provided in a rear stationary bulk-head 24 at the rear of the drum 22 there is an air inlet aperture 26 with a perforate cover plate 27 across the aperture 26 and an air outlet aperture 28 formed by perforations 25 in the bulkhead 24 through which air is circulated by a blower or fan 29 during the drying process.
As seen in FIG. 2, a heating element 38 is provided in the air flow path designated by broken line arrow 40 which is selectively energized by a control logic circuit 60 to provide heated air to the interior of the dryer 10 as required. Blower 29 is connected in an air flow relationship with the air inlet and outlet apertures so that air is drawn into the drum 22 by way of the aperture 26 after first passing the heating element 38 and is withdrawn from the drum through the aperture 28. An electric motor 42 drives the blower 29 and is also provided to rotate the drum 22 by means of a drive pulley 43, a tensioning idler pulley 41, and a belt 44.
At least one sensor 30 is provide which can be in contact with the clothes load during the drying operation while the drum is rotating. The sensor 30 is comprised of two electrodes 32 and 34 which are connected by a pair of conductors 50, 52 to a low voltage moisture sensor circuit 36 as shown in FIG. 2.
A digital control circuit is generally shown at 48 and includes the sensor circuit 36 which is connected to the sensor electrodes 32, 34, a digital millisecond counter circuit 54 which is driven by a timing crystal 56, a memory storage 58 and the control logic circuit 60 for reading the states of the counter 54 and the stored values in the memory storage 58 for indexing the memory storage 58.
The control logic circuit 60 includes a plurality of outputs for controlling various machine functions and, accordingly, for controlling the program of the dryer. A first output is indicated by the electrical connection line 61 which extends from the control logic circuit 60 to the heating element 38 for controlling the application of heat to the interior of the drum 22. A second output is indicated by means of an electrical connection line 62 which extends from the control logic circuit to the electrical drive motor 42 for controlling rotation of the drum 22 and blower 29.
A third output is indicated by means of an electrical connection line 63 which extends from the control logic circuit 60 to a display circuit 64 which controls a number of indicator lamps behind the panel on the console 14 of the dryer 10 to indicate to the operator which drying functions have been selected and in which portion of the drying cycle the dryer is currently operating. Another output is evidenced by the electrical connection line 66 which may be employed, for example, as a master power control lead for disconnecting the circuits from the electrical supply at the termination of the drying program.
As will be appreciated by those skilled in the art, the electrical connections 61, 62, 63 and 66 are in schematic form only, and in practice appropriate interface circuitry such as is well known in the art would be necessary to enable the relatively low level signals developed by the logic circuitry to be used to control the power supply to the machine components.
In the control the low voltage moisture sensor circuit 30 senses the moisture content in a clothes load represented by the electrical resistance of the clothes and produces a corresponding voltage level signal at an input to a microcomputer. The microcomputer determines if the signal is a valid wet signal, and if it is, resets a counter. In the absence of a valid wet signal, the counter reaches a preselected count representative of a given level of dryness of the clothes load and terminates the sensed portion of the drying cycle.
FIG. 3 details the electrical circuitry utilized in the present invention. A transformer 68 is connected to a source of 120 volt alternating current by conductors 70 and 72. The alternating current is rectified to direct current by means of diodes 74 and 76. A capacitor 78 to protect against voltage spikes, a power supply regulator 82, and a low voltage shut down circuit 84 are provided in a power line conductor 80 to insure a constant voltage level is supplied to a microprocessor or microcomputer 86. The timing crystal 56 supplies a timing pulse to the microcomputer along conductors 88, 90. A plurality of input switches 92 are connected through resistors 94 and conductors 96 to the microcomputer 86 in order to alert the microcomputer as to certain conditions such as an open door or a filled lint receptacle.
Output signals on conductors 120, 122 and 124 are sent through drivers 130, 132 and 134 to operate relays 140, 142 and 144 which send appropriate signals along lines 61, 62 and 66 to the heating element, motor and master switch as described above.
Output signals are also sent on a series of conductors representatively shown by lines 126 and 128 which are strobed through transistors 136 and 138 alternatingly providing closed circuits along a plurality of conductors 129 for various LED's 146 in the display circuit 64. The lines 126 and 128 represent any number of lines which are multiplexed to reduce the power requirements of the display circuit.
Output signals from the microcomputer 86 also are sent on a plurality of conductors 150 through driver amplifiers 152 and on a plurality of conductors 63 to energize the appropriate LED's 146. Output signals are also sent on conductor 154 through drivers 156 to energize an end of cycle alarm 158 at the end of the drying cycle.
Input switches 160 form a part of the controls 16 which are provided for the operator to make the appropriate selections of the various drying cycle operation options. These input signals are supplied to the microcomputer 86 through a plurality of conductors 162.
The sensing circuit 36 is comprised of a JFET operational amplifier or comparator 98 whose inputs are a reference voltage on a conductor 105 and a voltage associated with the moisture sensor 30 on a conductor 110. A low pass filter capacitor 100 is used on the sensor input to eliminate effects of noise and static. A pair of diodes 104 and 102 act as clamps between a ground G and a low voltage source 107, respectively, to prevent excessive voltage excursions in both the positive and negative direction.
The reference voltage for the positive input of the JFET amplifier 98 on line 105 is the result of the voltage division of low voltage source 107 between resistors 106 and 108. This reference voltage is compared with the voltage on negative input line 110 which is low if wet clothes are in contact with the sensor element 30 and high if dry clothes or no clothes are contacting the element. The negative input voltage on line 110 is essentially the voltage division created by a resistor 103 connected to low voltage source 107 and the clothes load resistance across sensor 30, integrated by the capacitor 100 and a resistor 111.
When no clothes or dry clothes are in contact with sensor element 30, the capacitor 100 begins to charge due to the current flow from low voltage source 107 through resistor 103, allowing the voltage on line 110 to increase. When the voltage on line 110 increases above that on line 105, the output signal from the amplifier 98 goes low. If wet clothes come in contact with the sensor 30, the capacitor 100 discharges and the voltage on line 110 drops. This causes the amplifier 98 to produce a high output signal.
The output signal from the amplifier 98 passes through a voltage divider comprising a pair of resistors 112 and 113, and is inverted by a transistor 114 prior to being input to the microcomputer 86. Thus, the microcomputer receives a high signal when dry clothes or no clothes bridge the sensor 30 and a low signal when wet clothes bridge the sensor.
FIGS. 4a and 4b illustrate the operation of the apparatus of the present invention during an automatic cycle of operation. FIGS. 4a and 4b are in functional block diagram form, with the various blocks indicating steps performed in sequence during the performance of the method of the present invention, and also indicating the structure which is employed during the operation of the dryer. Although a preferred embodiment of the present invention employs a microcomputer controller for the performance of the dryness sensing controlling program, the present invention also contemplates an organization in which each of the blocks illustrated in FIGS. 4a and 4b corresponds to an individual control unit. Control of the operation is passed from control unit to control unit, to execute the program in its proper sequence. The operation proceeds by a sequence of steps.
The first step in the performance of the automatic operation of the dryness sensing control is by control unit 200 which is periodically energized from a strobe line 202. The microcomputer 86 as utilized in the present invention has four strobing circuits under control of a strobing or K-scan unit 205 one of which (202) is devoted to the sensing and time dry portion of the drying cycle. The other three strobes control the scanning of the inputs, the selection of the output relays, and the selection of the output lights.
Control unit 200 inspects the drying cycle selections to determine if the drying cycle is complete. If the drying cycle is complete, then control is passed to unit 204 which performs the various control operations for the cycle selected before returning the strobe line to the K-scan unit 205. If control unit 200 determines that the drying cycle is not complete, then control is passed to unit 206.
Control unit 206 inspects the cycle selections to determine if the dryer is currently in the anti-wrinkle portion of the cycle. If unit 206 determines that it is, then control is passed again to unit 204 which would perform the control operations for the anti-wrinkle portion of the cycle before returning the strobe line to the K-scan unit 205. If control unit 206 determines that the dryer is not in the anti-wrinkle portion of the cycle, then control is passed to unit 208.
Control unit 208 inspects the cycle selections to determine if the dryer is in the sensing or timed portion of the cycle. If unit 208 determines that it is not, then control is passed to unit 210 which inspects the cycle selections to determine if the cool down option has been selected. If unit 210 determines that it has, then control is passed again to unit 204 which would perform the control operations for the cool down cycle prior to returning the strobe line to the K-scan unit 205.
If control unit 210 determines that cool down has not been selected, then control is passed to unit 212 which inspects the cycle selections to determine if add-on time is over. If unit 212 determines that it is, then control is passed to unit 204 to perform the various control operations for the cycle selected. If unit 212 determines that the add-on time is not over, then control is passed to a unit 214 which increments a seconds counter in control logic 60 which keeps track of total run time and an A counter in control logic 60 which is used to determine if the clothes load has reached a selected level of dryness. Then control is passed to a unit 216 which stores the total run time.
If control unit 208 determines that the dryer is in the sensing or timed portion of the cycle, then control is passed to unit 218 which inspects the cycle selections to determine if the damp dry dryness level has been selected. If unit 218 determines that damp dry has not been selected, then control is passed through a series of units ending with unit 220 which inspects the cycle selections to determine if the very dry level of dryness had been selected.
Although only two dryness level inquiries, damp dry and very dry, have been shown in FIG. 4a as performed by units 218 and 220, it should be understood that any number of dryness levels may be utilized in the program which would allow an operator to select from a range of dryness levels for the fabrics being treated in the dryer. The following control unit functions would be the same for any level of dryness selected.
If control unit 218 determines that the damp dry level has been selected, control would be passed to unit 222 which inspects counter A to determine if a preselected delay count A for damp dry has been reached. The delay count A is a given interval of time in which the sensor 30 has not recorded a valid wet signal. As an example, the delay count A for damp dry could be 15 seconds.
If control unit 222 determines that delay count A for damp dry has been reached, then control is passed to unit 224 which stores total run time to be used in setting the cool down time by unit 204. Unit 222 also sets an add-on time in accordance with the procedure disclosed in U.S. Pat. No. 3,762,064 issued to Carl R. Offutt on Oct. 2, 1973 and assigned to the Whirlpool Corporation, the disclosure of which is incorporated herein by reference. After control unit 224 has stored the count and set the add-on time, control is passed to the unit 214 which increments the seconds counter and the A counter and then passes control to unit 216 which stores the total run time. If control unit 222 has determined that the delay count A for damp dry has not been reached, then control is passed directly to unit 214.
If any of the other levels of dryness, such as very dry, have been selected, the same steps would be performed by control units as are performed by units 218, 222 and 224. Specifically, control unit 220 determines if the very dry level has been selected. If it has, then control is passed to unit 226 which inspects counter A to determine if delay count A for very dry has been reached. As an example, the delay count A for very dry could be two minutes.
If control unit 226 determines that delay count A for very dry has been reached, then control is passed to unit 228 which stores the total run time and sets the add-on time as described with reference to unit 224. Then control is passed to unit 214 as described above. If control unit 226 determines that delay count A for very dry has not been reached, then control is passed directly to unit 214.
If control has passed from unit 218 through all of the various dryness level control units to unit 220 and control unit 220 determines that the very dry level has not been selected, then control is passed to unit 230 which inspects the cycle selectors to determine which timed dry period has been selected and it inspects the total run time stored by unit 216 to determine if the time period has completely elapsed. If the control unit 230 determines that the time has elapsed, control is then passed to unit 232 which stores the total run time to be used by unit 204 in determining the cool down time and control is then passed to unit 214. If control unit 230 determines that the time period has not completely elapsed, then control is passed directly to unit 214.
As described above, control unit 214 increments the seconds counter and the A counter and then passes control to unit 216 which stores the total run time. Control is then passed to unit 234. Control unit 234 determines if the sensor 30 is being utilized. If unit 234 determines that the sensor is not being utilized, then control is returned to the K-scan unit 205.
If control unit 234 determines that the sensor is being used, then control is passed to unit 238 which inspects the total run time stored by unit 216 to determine if the dryer has been on for ten minutes. The ten minute initial run time allows the dryer and the clothes load to reach a minimum drying time required for any small clothes loads. If the dryer has been on for less than ten minutes, then control is passed to unit 240 which resets a milliseconds count equal to zero and resets the A counter to zero. Control is then passed to unit 205.
If control unit 238 determines that the dryer has been on for at least ten minutes, then control is passed to unit 242 which increments the milliseconds count by one, representing four milliseconds. A millisecond counter is utilized to keep track of the total time accumulated since the last dry signal. In the preferred embodiment, four strobe lines are utilized and each strobe uses one millisecond, therefore each time the K-scan strobes line 202 and passes through this portion of the program, four milliseconds have elapsed. Thus, control unit 242 increments the milliseconds by four.
Control is then passed to unit 244 which inspects the sensor input to determine if there is a dry signal. If there is, then control is passed to unit 246 which resets the milliseconds count to zero and control is passed to unit 205. If control unit 244 determines that there is not a dry signal at the sensor input, then control is passed to unit 248 which inspects the millisecond count to determine if the millisecond count is less than 32, representing 128 milliseconds.
If the count is below 32, then control is passed to unit 205. However, if the millisecond count is equal to or greater than 32, then control is passed to unit 240 which sets the millisecond count equal to zero and resets the A count to zero. Thus, control unit 248 determines if there have been thirty-two consecutive wet signals. If thirty-two consecutive wet signals have been received, unit 244 determines this to be a valid wet signal and both the millisecond counter and the A counter are reset to zero to restart the search for a given dry period without a wet signal.
The strobing continues until the dryness level selected has been reached and then the program moves on into the add-on and cool down and/or anti-wrinkle cycle selected, control unit 204 performing the various control operations for the cycle selected. After unit 204 has performed the various control operations, control is passed to the K-scan unit 205.
Thus, it is seen that there is provided a low voltage moisture sensor for a dryer which senses the moisture content in the clothes load and sends an appropriate signal to a microcomputer for use in timing and control functions. A first counter is utilized to measure the time since a last valid wet signal has been sent. A second millisecond counter is utilized to determine if a valid wet signal has been sensed by the sensor. The first counter is reset each time the second counter determines that a valid wet signal has been sensed. The first counter continues to count, in the absence of a valid wet signal, until a preselected count representing a given level of dryness has been reached.
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 we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art. | A fabric treating apparatus, such as a domestic clothes dryer, is provided with a microcomputer controlled circuit and a sensor system which cooperates to terminate a fabric treatment operation when the fabric reaches the desired condition. A conductivity sensor senses the moisture content of the fabric within the drying zone. A sensing circuit electrically connected to the sensor generates a voltage level proportional to the moisture condition sensed. The microcomputer reads the voltage level at spaced intervals in time and generates a valid wet signal whenever a given consecutive number of readings indicate a wet condition of the fabric within the drying zone. A counter within the microcomputer counts pulses from a source of timing signals and is repeatedly terminated and restarted whenever a valid wet signal is generated. The fabric drying operation is terminated upon the accumulation of a preselected count in the counter such that the termination coincides with an optimum dryness condition. | 3 |
FIELD OF THE INVENTION
This invention relates to the alkylation of hydrocarbons such as aromatics and paraffins to produce useful chemicals and motor fuel. This invention specifically relates to a method for wetting solid catalyst particles in an alkylation process.
BACKGROUND OF THE INVENTION
Hydrocarbon alkylation is widely used in the petroleum refining and petrochemical industries to produce a variety of useful acyclic and cyclic hydrocarbon products which are consumed in motor fuel, plastics, detergent precursors, and petrochemical feedstocks. Much of the installed base of alkylation capacity uses liquid phase hydrofluoric acid, generally referred to as HF, as the catalyst. The use of HF in these applications has a long record of highly dependable and safe operation. However, the potential damage from an unintentional release of any sizable quantity of HF and the need to safely dispose of some byproducts produced in the process has led to an increasing demand for alkylation process technology which does not employ liquid phase HF as the catalyst.
Numerous solid alkylation catalysts have been described in the open literature. However, these catalysts appear to suffer from unacceptably high deactivation rates when employed at commercially feasible conditions. While some catalysts have a sufficiently useful lifetime to allow the performance of alkylation, the rapid change in activity results in a change in product composition and also requires the periodic regeneration of the catalyst with the accompanying removal of the reaction zone from operation. It is very desirable to provide a continuous process for alkylation which is not subjected to periodic reaction zone stoppages or variation in the product stream composition.
In hydrocarbon processing, continuous catalytic processes commonly use transport reactors. In a transport reactor, the catalyst bed as a whole moves and is transported with a fluid phase. Thus, a transport reactor can be contrasted with a fixed bed catalytic reactor and with an ebulliated bed catalytic reactor. In a fixed bed reactor the catalyst particles do not move, and in an ebulliated bed reactor the catalyst particles are suspended in a fluid but the settling velocity of the catalyst particles balances the fluid upflow velocity so that the catalyst bed as a whole is not transported with the fluid phase. Although it is generally the case that the direction of catalyst flow through a transport reactor is upward, the direction may also be downward, horizontal, a direction that is intermediate between vertical and horizontal, or a combination of these directions.
When the direction of catalyst flow through a transport reactor is upward, the transport reactor is often called a riser-reactor. Riser-reactors are commonly used in hydrocarbon processing, such as fluidized catalytic cracking and more recently in motor fuel alkylation. In a common arrangement, a fluid hydrocarbon reactant engages a solid hydrocarbon conversion catalyst at the bottom of a riser-reactor and transports the catalyst in a fluidized state up the riser-reactor. During the ascent through the riserreactor, the catalyst promotes certain desired conversion reactions among the reactants in order to produce desired products. A stream of catalyst and hydrocarbon products, byproducts, and unreacted reactants if any discharges from the top of the riser-reactor into a separation zone. The hydrocarbons and the catalyst disengage in the separation zone, with the hydrocarbons being withdrawn overhead for recovery and the catalyst dropping by gravity to the bottom of the separation zone. Despite some deactivation that may have occurred to the catalyst in the riser-reactor, some of the catalyst that collects at the bottom of the separation zone may have enough residual activity that it can be reused in the riser-reactor without first being withdrawn from the separation zone for regeneration. Such still active catalyst is recirculated through a recirculation conduit from the bottom of the separation zone to the bottom of the riser-reactor, where the catalyst contacts reactants again.
Most commercial alkylation catalysts, however, require periodic regeneration of the catalyst with the accompanying removal of the catalyst from the reaction zone for regeneration. Depending on the particular catalyst and on the nature and degree of the deactivation, the periodic catalyst regeneration may be in the liquid phase or in the vapor phase. Liquid phase or “mild” regeneration comprises contacting the catalyst with a liquid phase hydrocarbon, which is commonly a feed hydrocarbon, such as isobutane, with dissolved hydrogen. Vapor phase or “severe” regeneration, on the other hand, comprises contacting the catalyst with hydrogen gas at a higher temperature and/or for a longer time than liquid phase regeneration. Vapor phase regeneration, which is also called “hydrogen stripping,” is a more intense regeneration than liquid phase regeneration. Whereas liquid phase regeneration helps to remove alkylate, light byproducts, and lightly sorbed contaminants from the catalyst, vapor phase regeneration helps to remove more strongly sorbed species, such as heavies which, if allowed to accumulate on the catalyst, would deactivate the catalyst and would cause the alkylate yield to decline. As used herein, the collective term “heavies” refers to oligomers having twelve or more carbon atoms. Because liquid phase regeneration may not remove these strongly sorbed oligomers, vapor phase regeneration is usually performed after a specified number, such as three or four, of liquid phase regenerations. But, in processes where the rate of catalyst deactivation or rate of yield loss is extremely rapid, vapor phase regenerations may be done either after each liquid phase regeneration or even instead of liquid phase regeneration. Thus, vapor phase regeneration can be a critical step in a continuous alkylation process, regardless of whether the alkylation process includes liquid phase regeneration.
In contrast to regeneration in the vapor phase, the alkylation reactor generally operates in at least partially liquid phase conditions, including supercritical conditions. Consequently, catalyst particles that are withdrawn from the alkylation reactor for regeneration contain entrained liquid hydrocarbons, both in the pores of the catalyst particles and in the interstitial volume between the catalyst particles. Although in theory this entrained hydrocarbon liquid could remain with the catalyst particles and be removed along with the strongly sorbed species during vapor phase regeneration, it is preferred as a practical matter to remove these liquid hydrocarbons prior to vapor phase regeneration in order to simplify the handling of the vapors that are employed in vapor phase regeneration and to exclude the need for separating liquids from the vapor phase regeneration gases. Thus, prior to vapor phase regeneration, the entrained liquid is removed from the catalyst in a process that is known as dewetting.
Subsequent to vapor phase regeneration, the catalyst particles must, of course, ultimately be returned to the alkylation reactor. But adding the vapor phase regenerated catalyst directly to the alkylation reactor, however, creates several problems. These same problems also arise when adding dry fresh catalyst as makeup directly to the alkylation reactor. In either case, directly contacting the catalyst with liquid hydrocarbons generates the heat of adsorption of the liquid hydrocarbons on the catalyst particles. If not removed from the alkylation reactor, this heat can cause side reactions that produce undesirable byproducts. Moreover, the released heat can vaporize hydrocarbons that are preferably maintained as liquids, not vapors, at alkylation conditions. Thus, the released heat necessitates the use of extra equipment to cool, condense, and recycle the vaporized hydrocarbons. In addition, the vaporization of hydrocarbons can cause pressure imbalances in vessels through which catalyst particles flow that can stop or reverse the direction of catalyst flow between the vessels.
Thus, a method is sought for wetting vapor phase regenerated or fresh catalyst particles with liquid hydrocarbons in a manner that does not cause undesirable side reactions, that does not require the use of additional condensers and other equipment for recycling hydrocarbon vapors, and that does not impede catalyst flow.
SUMMARY OF THE INVENTION
This invention is a process for alkylating an alkylation substrate with an alkylating agent that uses a particularly economical and effective method of wetting catalyst particles which are being introduced into an alkylation reactor which operates at least partially in the liquid phase. Prior to being added to the alkylation reactor, the catalyst particles are wetted with the alkylation substrate in a wetting zone. A vapor stream that is recovered from the wetting zone passes to the same recovery facilities that recover the product alkylate from other hydrocarbons in the alkylation reactor effluent. Routing the vapor stream to the product recovery facilities not only minimizes the equipment for recovery of any vaporized alkylation substrate from the wetting zone but in some embodiments also helps to balance the pressures of the wetting zone and the alkylation reactor, thereby ensuring steady catalyst flow from the wetting zone to the alkylation reactor. In addition, any vaporization of the liquid alkylation substrate in the wetting zone as a result of the wetting helps to remove the heat of adsorption that is generated by wetting the catalyst.
Thus, a primary objective of this invention is to provide a process for the alkylation of an alkylation substrate with an alkylating agent in the presence of a solid catalyst. A second objective of this invention is to provide a liquid phase alkylation process that uses solid catalyst particles and which minimizes the amount of necessary equipment. A third objective of this invention is to provide an alkylation process that introduces solid catalyst particles into a liquid phase alkylation reactor in a manner that avoids problems arising from the release of the heat of adsorption in the alkylation reactor.
Accordingly, in a broad embodiment, this invention is a process for the alkylation of an alkylation substrate with an alkylating agent. An alkylating agent and a first substrate stream comprising an alkylation substrate pass to a reaction zone. In the reaction zone, the alkylating agent alkylates the alkylation substrate to produce alkylate. The reaction occurs in the presence of catalyst particles having a first weight ratio of alkylation substrate per dry catalyst particles and at alkylation conditions that include at least a partial liquid phase. A reaction zone effluent stream comprising alkylate is withdrawn from the reaction zone. Catalyst particles having a second weight ratio of alkylation substrate per dry catalyst particles that is less than the first weight ratio pass to a wetting zone. A second substrate stream comprising the alkylation substrate also passes to the wetting zone. The first substrate stream or the second substrate stream comprises at least a portion of a recycle stream. In the wetting zone, alkylation substrate contacts catalyst particles having the second weight ratio at wetting conditions. The wetting conditions are sufficient to maintain at least a portion of the alkylation substrate that contacts the catalyst particles in a liquid phase. A wetting zone vapor stream comprising the alkylation substrate in the vapor phase is withdrawn from the wetting zone. Catalyst particles having a third weight ratio of alkylation substrate per dry catalyst particles that is greater than the second weight ratio are also withdrawn from the wetting zone. Catalyst particles having the third weight ratio and withdrawn from the wetting zone pass to the reaction zone. At least a portion of the wetting zone vapor stream and at least a portion of the reaction zone effluent stream pass to a product recovery zone. A product stream comprising alkylate and the recycle stream comprising the alkylation substrate are withdrawn from the product recovery zone. The product stream is recovered from the process.
In another embodiment, this invention is a process for the alkylation of an alkylation substrate with an alkylating agent. An alkylating agent and a first substrate stream comprising an alkylation substrate pass to a reaction zone. In the reaction zone, the alkylating agent alkylates the alkylation substrate to produce alkylate. The reaction occurs in the presence of catalyst particles having a first weight ratio of alkylation substrate per dry catalyst particles at alkylation conditions. The alkylation conditions include at least a partial liquid phase. Catalyst particles having a second weight ratio of alkylation substrate per dry catalyst particles that is not greater than the first weight ratio are withdrawn from the reaction zone. A reaction zone effluent stream comprising alkylate is also withdrawn from the reaction zone. Catalyst particles having the second weight ratio and withdrawn from the reaction zone pass to a dewetting zone. In the dewetting zone, at least a portion of the alkylation substrate is removed from the catalyst particles. Catalyst particles having a third weight ratio of alkylation substrate per dry catalyst particles that is less than the first weight ratio are withdrawn from the dewetting zone. A second substrate stream comprising the alkylation substrate passes to a wetting zone along with catalyst particles having the third weight ratio and withdrawn from the dewetting zone. The first substrate stream or the second substrate stream comprises at least a portion of a recycle stream. In the wetting zone, alkylation substrate contacts catalyst particles having the third weight ratio at wetting conditions. The wetting conditions are sufficient to maintain at least a portion of the alkylation substrate that contacts the catalyst particles in a liquid phase. A wetting zone vapor stream comprising the alkylation substrate in the vapor phase is withdrawn from the wetting zone. Catalyst particles having a fourth weight ratio of alkylation substrate per dry catalyst particles that is greater than the third weight ratio are also withdrawn from the wetting zone. Catalyst particles having the fourth weight ratio and which were withdrawn from the wetting zone pass to the reaction zone. At least a portion of the wetting zone vapor stream and at least a portion of the reaction zone effluent stream pass to a product recovery zone. A product stream comprising alkylate and the recycle stream comprising the alkylation substrate are withdrawn from the product recovery zone. The product stream is recovered from the process.
Other embodiments, purposes, and objectives will become clear from the ensuing description.
INFORMATION DISCLOSURE
U.S. Pat. No. 5,489,732 (Zhang et al.) discloses an alkylation process that uses a solid catalyst which is regenerated by a “mild,” low-temperature, liquid phase washing and by a “severe,” hot vapor phase hydrogen stripping operation.
The teachings of U.S. Pat. No. 5,489,732 are incorporated herein by reference.
The dispersion of powders in liquids, including wetting the powder in to the liquid, is discussed in the article entitled “Handling Powders (Dispersion),” written by Ralph D. Nelson, Jr., starting on page 1093 in Volume 19 of Kirk-Othmer Encyclopedia of Chemical Technology , Fourth Edition, edited by Jacqueline I. Kroschwitz, published by John Wiley and Sons, Inc., New York, in 1996, and also in Chapter 6 entitled “The Dispersion of Fine Particles in Liquid Media,” written by G. D. Parfitt and H. A. Barnes, starting on page 99 in Mixing in the Process Industries , Second Edition, edited by N. Hamby et al., published by Butterworth-Heinemann Ltd., Boston, in 1992.
Cooling by evaporating solvent during mixing of pastes and viscous materials is mentioned on page 19-24 of Perry's Chemical Engineers' Handbook , Sixth Edition, edited by R. H. Perry and D. W. Green, published by McGraw-Hill Book Company, New York, in 1984.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a process flow diagram of an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The alkylation substrate for this invention may be essentially any hydrocarbon which is retained as an easily flowable liquid phase material and which may be alkylated via solid catalyst at the conditions employed in the alkylation reactor. The alkylation substrate may be an aromatic hydrocarbon, if the objective is to produce such chemicals as ethylbenzene and cumene or to produce linear alkyl benzenes which are sulfonated to detergents. Although benzene is the principal aromatic of interest, aromatics such as alkyl-substituted benzenes, condensed ring systems generally, and alkylated derivatives thereof may be used. Examples of such aromatics are toluene, ethylbenzene, propylbenzene, and so forth; xylene, mesitylene, methylethylbenzene, and so on; naphthalene, anthracene, phenanthrene, methyinaphthalene, dimethyinaphthalene, and tetralin. More than one aromatic can be used. If, on the other hand, the objective is to produce motor fuels, then the alkylation substrate may be a paraffinic hydrocarbon, such as a branched paraffin having from 4 to 6 carbon atoms. Suitable paraffinic hydrocarbons are illustrated by 2-methylpropane (commonly called isobutane), 2-methylbutane (or isopentane), 2,3-dimethylbutane, 2-methylpentane, and 3-methylpentane.
The alkylation substrate is alkylated with an alkylating agent. If the objective is to produce chemicals such as ethylbenzene or cumene or to produce motor fuels, then the alkylating agent is typically an olefinic hydrocarbon containing from 2 to about 6 carbon atoms. Examples of such olefins include ethylene, propylene, 1-butene, cis-2-butene, trans-2-butene, and iso-butene. However, if the objective is to produce linear alkyl benzenes, then the alkylating agent can be an olefinic hydrocarbon having from about 2 to about 20 carbon atoms, and usually from about 10 to about 15 carbon atoms. More than one olefin may be used. The alkylating agent may be chosen also from a variety of compounds other than olefins including monohydric alcohols. Suitable alcohols include ethanol and methanol. For instance, methanol is widely described in the literature as being useful in the methylation of benzene and toluene.
The subject process can be performed using any solid, that is, heterogeneous, catalyst which is stable and has the required activity and selectivity for the desired reaction at the conditions needed to maintain liquid phase reactants in the alkylation reactor. A large number of catalysts have been proposed for the production of motor fuel by alkylation including nonzeolitic catalysts and various zeolitic catalysts. Suitable nonzeolitic catalysts include sulfated zirconia and tungstated zirconia. Among suitable zeolitic catalysts, U.S. Pat. No. 4,384,161, for example, describes the use of a large pore zeolite and a Lewis acid. The zeolites referred to include ZSM-4, ZSM-3, the faujasites including zeolite Y, and mordenite. The Lewis acids mentioned in this reference include boron trifluoride and aluminum chloride. The alkylation of isoparaffins using a somewhat similar catalyst system comprising a large pore crystalline molecular sieve such as a pillared silicate or an aluminophosphate or silicoaluminophosphate together with a gaseous Lewis acid is disclosed in U.S. Pat. No. 4,935,577. The use of these Lewis acids is not preferred in the subject process as they provide their own waste handling and safety problems. They also will probably require provisions for the circulation of the Lewis acid, which may complicate the process as shown by the teaching of the just cited U.S. Pat. No. 4,935,577. U.S. Pat. No. 5,157,200 describes an isoparaffin alkylation process using a catalyst comprising a crystalline transition alumina, preferably eta or gamma alumina, which has been treated with a Lewis acid under anhydrous conditions. Previously referred to U.S. Pat. No. 5,157,196 describes an isoparaffin alkylation process using a slurried solid catalyst, with the preferred catalyst being an acid washed silica which has been treated with antimony pentafluoride. Both of these last two references describe a number of prior art heterogeneous paraffin alkylation catalysts.
A preferred paraffin alkylation catalyst comprises a refractory inorganic oxide impregnated with a monovalent cation, especially an alkali metal cation or an alkaline earth metal cation, and whose bound surface hydroxyl groups have been at least partially reacted with a Friedel-Crafts metal halide. Analogs of these catalysts without the metal cations are described in U.S. Pat. Nos. 2,999,074 and 3,318,820 which describe preparation techniques which can be applied to the preferred catalysts. The preferred refractory oxide is alumina having a surface area greater than 50 m 2 /g, but the use of other oxides including titania, zirconia, silica, boria, and aluminum phosphate is contemplated. The preferred catalyst also contains a metal component active for olefin hydrogenation deposited on the inorganic oxide prior to reaction of the bound surface hydroxyl groups with the metal halides. This metal may be chosen from the group consisting of nickel, platinum, palladium, and ruthenium with the first three of these metals being preferred. The catalyst contains one or more monovalent metal or alkaline earth metal cations selected from the group consisting of lithium, sodium, potassium, cesium, silver, copper, beryllium, magnesium, calcium, and barium. Subsequent to the deposition of these metals and the controlled calcination of the composite, the composite is reacted with a Friedel-Crafts metal halide. The metal may be aluminum, zirconium, tin, tantalum, gallium, antimony, or boron. Suitable halides are the fluorides, chlorides, and bromides.
The presence of a highly active metal hydrogenation component on the catalyst will promote hydrogenation of the substrate olefin if both the olefin and hydrogen simultaneously contact the catalyst. This potential waste of the olefin and hydrogen can be avoided by careful design and operation of the process to avoid having both the olefin and hydrogen in simultaneous contact with the catalyst. This can be done by flushing the hydrogen or olefin from the catalyst before inserting it into a zone containing the other compound as described above.
Silicalites have been described as useful alkylation catalysts for the production of monoalkylbenzenes in U.S. Pat. No. 4,489,214 (J. R. Butler et al.) and as useful in methylating toluene to produce paraxylene in U.S. Pat. No. 4,444,989 (F. E. Herkes). The use of ZSM-5 zeolites in aromatic alkylation is described in U.S. Pat. No. 3,751,506. ZSM-5 zeolites that have been treated with one or more compounds or elements to improve their selectivity for paraselective alkylation of aromatic hydrocarbons are. described in U.S. Pat. No. 4,420,418. The use of zeolite L, zeolite omega, and zeolite beta as alkylation catalysts for the selective alkylation of benzene is described in U.S. Pat. No. 4,301,316. The use of a number of natural and synthetic zeolites including clinoptilolite and zeolite Y as alkylation catalysts is described in U.S. Pat. No. 3,251,897.
The catalyst may be in the form of any suitable shape and size that results in a solid catalyst which flows readily in both dry and wet states and which is readily fluidized at the moderate liquid flow rates employed in a transport reactor such as a riser-reactor. The catalyst can therefore be present as small irregular particles or as uniformly shaped particles. It is preferred that the catalyst is present as “microspheres” having an average diameter of from about 0.1 to about 2.0 mm and more preferably less than about 1.0 mm.
The term “wetting” as used herein refers to the formation of a liquid-solid interface in place of a gas-solid interface. In a wetting zone of the present invention, solid catalyst particles are wetted into a liquid comprising the alkylation substrate. Generally, the catalyst particles that enter the wetting zone have a weight ratio of alkylation substrate per dry catalyst particles that is less than the weight ratio of alkylation substrate per dry catalyst particles in the zone, such as the alkylation reactor or the alkylation reactor effluent separation zone, into which catalyst particles that leave the wetting zone pass. As used herein, the weight of dry catalyst particles is the weight of the catalyst particles on a volatile free basis, where the volatiles are determined by heating the catalyst particles to 900° C. (1652° F.). The weight ratio of aromatic substrate per dry catalyst particles that enter the wetting zone is generally from about 1:1000 to about 1:1 00.
Weight ratios of the aromatic substrate per dry catalyst particles of less than about 1:100 for the catalyst particles entering the wetting zone indicate that the pores of the catalyst particles are relatively dry in the sense that the pores at least partially contain a gas rather than the alkylation substrate. The particular gas that occupies the pores of the catalyst particles entering the wetting zone depends on the source of the entering catalyst particles and is not, therefore, an essential element of the present invention. The gas preferably has certain preferred characteristics, however. First, the gas should be capable of being displaced from the pores of the catalyst by the alkylation substrate. For example, when catalyst with gas sorbed within the pores is introduced on or under the surface of a reservoir or an accumulation of the alkylation substrate, the alkylation substrate effectively displaces, or desorbs, from the pores a substantial portion of the gas. By displacing a substantial portion of the gas it is meant that generally at least 50% but more typically at least 90% of the gas present within the pores is displaced from the pores of the catalyst. Second, the gas should not cause any undesired physical or chemical transformation of the catalyst. For example, the gas should not oxidize the catalytic metal if a reduced metal is desired, and the gas should not reduce the metal if an oxidized metal is desired. Third, the gas should be capable of being readily mixed with and separated from the alkylation substrate and the alkylate. Thus, where the alkylation substrate and the alkylate contain carbon and hydrogen, the gas is preferably not oxygen, which would produce a combustible or explosive mixture.
The catalyst particles that enter the wetting zone may originate from several possible sources. For example, fresh catalyst particles, which are being added as make-up to the alkylation process in order to compensate for catalyst particles that are lost or withdrawn from the process, may enter the wetting zone. Because fresh catalyst particles are often packaged and shipped under an inert atmosphere in order to preserve the select properties of the catalyst, the pores of the catalyst particles may thus contain an inert gas such as nitrogen. In another example, the entering catalyst particles may comprise catalyst that has been withdrawn from a hereinafter described dewetting zone, such as regenerated catalyst that has been used for alkylation reactions and has subsequently undergone vapor phase regeneration. Vapor phase or “severe” regeneration typically comprises contacting the catalyst with hydrogen gas at an elevated temperature and/or for an extended period of time. Vapor phase regeneration, which is also called “hydrogen stripping,” is a more intense regeneration than liquid phase or “mild” regeneration in that vapor phase regeneration helps to remove strongly sorbed species, such as the previously mentioned heavies, which if allowed to accumulate on the catalyst would deactivate the catalyst and would cause the alkylate yield to decline. Thus, the gas in the pores of the catalyst particles that enter the wetting zone may be hydrogen. Instead of, or in addition to, nitrogen or hydrogen, other gases may be present in the pores of the entering catalyst particles. Such other gases include light paraffins such as methane, ethane, propane; other inert gases such as helium, neon, or argon; and other noncombustible gases such as carbon dioxide. The pores of the catalyst particles that enter the wetting zone may even contain the alkylation substrate, which may result if the “severe” regeneration step comprises contacting the catalyst with a mixed vapor-liquid stream, such as a mixture of hydrogen and the alkylation substrate, rather than a vapor-only stream. However, if the pores of the catalyst particles entering the wetting zone do contain alkylation substrate because of this or any other reason, it is nevertheless a requirement of this invention that the entering catalyst particles have a weight ratio of substrate per dry catalyst particles that is less than the weight ratio of substrate per dry catalyst particles in the zone into which the catalyst particles leaving the wetting zone pass.
The wetting zone may comprise any suitable container for contacting the entering catalyst particles with the alkylation substrate. In its simplest form, the wetting zone comprises a vessel that defines a space for containing a reservoir of the liquid alkylation substrate, and a disengaging space above the liquid reservoir for disengaging the displaced gas from the liquid alkylation substrate. Although internals such as baffles, impactors, and screens within the wetting zone vessel are not necessary, such baffles and screens may be helpful for disengaging the displaced gas, which may form bubbles in the liquid or a stable froth on the surface of the liquid. Such phase separation devices are conventional and are within the knowledge of a person of ordinary skill in the art of liquid-gas phase separation. See, for example, pages 18-70 to 18-88 of Perry's Chemical Engineers' Handbook , Sixth Edition, edited by R. H. Perry and D. W. Green, published by McGraw-Hill Book Company, New York, in 1984.
The wetting zone typically operates at a temperature of from about 40 to about 150° F. (4 to 66° C.) and a pressure of from about 200 to about 600 psi(g) (1379 to 4137 kPa(g). Generally, the wetting zone temperature is within about 10° F. (5.6° C.) of the boiling point of the alkylation substrate at the wetting zone pressure. Some of the difference between the wetting zone temperature and the substrate boiling point is due at least in part to the presence of solid catalyst particles, gas, and other liquid components in the liquid phase of the wetting zone. These substances can suppress or elevate the boiling point of the liquid phase mixture relative to that of the alkylation substrate.
A vapor stream is withdrawn from the wetting zone, typically at a location sufficiently above the top surface of the liquid alkylation substrate so as to minimize any entrainment of liquid in the exiting vapor stream. The vapor stream that is withdrawn from the wetting zone typically comprises gas displaced from the pores of the catalyst particles, as well as alkylation substrate vapor. The concentration and the amount of alkylation substrate in the vapor stream depends on many factors that influence the operating conditions of the wetting zone, including the weight ratio of alkylation substrate per dry catalyst particles, the flow rate, and the temperature of the catalyst particles entering the wetting zone; the heat of adsorption of the alkylation substrate on the catalyst particles; the heat of vaporization of the alkylation substrate; the temperature of any make-up alkylation substrate to the wetting zone; and the loss or removal of any heat, such as by indirect heat exchange, from the wetting zone. Typically, the heat of adsorption of the alkylation substrate on the catalyst particles is at least 50% of the heat of vaporization of the alkylation substrate. Generally, the vapor stream will be saturated with the alkylation substrate because the temperature of the wetting zone is close to the boiling point of the alkylation substrate. The vapor stream that is withdrawn from the wetting zone passes to product recovery facilities which are described hereinafter. However, a portion of the vaporized alkylation substrate may be passed to a condenser located either inside or outside of the wetting zone, condensed, and recycled as liquid alkylation substrate to the wetting zone.
In addition to the vapor stream, solid catalyst particles wetted with the alkylation substrate are also withdrawn from the wetting zone. As a result of the wetting that occurs in the wetting zone, the catalyst particles leaving the wetting zone have a weight ratio of alkylation substrate per dry catalyst particles that is more than the weight ratio of alkylation substrate per dry catalyst particles entering the wetting zone. Because the preferred range of weight ratios of alkylation substrate per dry catalyst particles for the leaving catalyst particles depends on many factors including the nature of the catalyst particles and the alkylation substrate, it is helpful to describe the preferred range of weight ratios of alkylation substrate per dry catalyst particles in qualitative rather than quantitative terms. For purposes of this qualitative description, the following definitions are helpful. “Bound alkylation substrate” in the catalyst particles is that alkylation substrate which exerts a vapor pressure less than that of the pure aikylation substrate liquid at the given temperature. Alkylation substrate liquid may become bound by retention in small capillaries, by homogeneous solution throughout the catalyst particles, and by chemical sorption, known as chemisorption, on surfaces of the solid particles. The process by which the alkylation substrate becomes bound generates at least some heat of adsorption of the alkylation substrate and the catalyst particles. On the other hand, “unbound alkylation substrate” in the catalyst particles includes that alkylation substrate which exerts a vapor pressure equal to that of the pure alkylation substrate liquid at the given temperature. Unbound alkylation substrate liquid may become retained in large pores of the catalyst particles, and by physical sorption on the catalyst particles, but it is not sorbed chemically, that is, it is not chemisorbed, on the catalyst particles. Because the unbound alkylation substrate is not chemisorbed on the catalyst particles, the sorption, if any, of unbound alkylation substrate on the catalyst particles does not generate any heat of adsorption. Finally, “free alkylation substrate” is alkylation substrate that is not in the pores of the catalyst particles, but rather is alkylation substrate that is between the pores or is in the interstitial or void volume between the catalyst particles. Like unbound alkylation substrate, free alkylation substrate is not chemisorbed on the catalyst particles and the introduction of free alkylation substrate to a bed of particles does not generate any heat of adsorption.
Thus, the weight ratio of alkylation substrate per dry catalyst particles of the catalyst particles leaving the wetting zone is generally such that there is at least some bound alkylation substrate on the catalyst particles. To the extent that some bound alkylation substrate is present with the catalyst particles leaving the wetting zone, the heat of adsorption that is generated when the catalyst particles pass to the alkylation reactor or the separation zone is minimized. Accordingly, the heat that must be removed from the reactor or the separation zone is minimized. More preferably, the weight ratio of alkylation substrate per dry catalyst particles is such that there is at least some unbound alkylation substrate on the catalyst particles. Even more preferably, the weight ratio of alkylation substrate per dry catalyst particles is such that there is at least some free alkylation substrate with the catalyst particles leaving the wetting zone. Generally, as the amount of free alkylation substrate with the exiting catalyst particles increases, the outlet stream of the wetting zone tends to become more of a slurry, and so, rather than agglomerating in clumps, the catalyst particles tend to flow freely. The weight ratio of alkylation substrate per dry catalyst particles for the particles leaving the wetting zone is generally less than, but may be the same as or more than, the weight ratio of alkylation substrate per dry catalyst particles in the reactor or separation zone. Typically, the weight ratio of alkylation substrate per dry catalyst particles for the particles leaving the wetting zone is more than 1:2.
The catalyst particles withdrawn from the wetting zone usually enter a zone in which the catalyst particles have a weight ratio of alkylation substrate per dry catalyst particles that is more than the weight ratio of alkylation substrate per dry catalyst particles of the catalyst particles entering the wetting zones. This means that the zone into which the catalyst particles from the wetting zone pass generally operates at least partially in a liquid phase, and can be the alkylation reactor, or the separation zone that separates the alkylation reactor effluent, or both. Other than the weight ratio of alkylation substrate per dry catalyst particles, the operating conditions of the alkylation reactor and the separation zone are not critical to the present invention. Thus, the alkylation reactor can be any suitable reactor for reacting an alkylation substrate and an alkylating agent in the presence of a solid catalyst, and the separation zone can be any suitable separator for separating the alkylation reactor effluent into a stream comprising liquid and vapor components and a stream comprising the solid catalyst. U.S. Pat. No. 5,489,732 (Zhang et al.) discloses alkylation reactors and separation zones and their corresponding operating conditions that are suitable for this invention.
The stream that comprises the liquid and vapor components separated from the alkylation reactor effluent is passed to product recovery facilities which are conventional and need not, therefore, be described in detail herein. In brief, the product recovery facilities reject from the process components that are lighter than the alkylation substrate and/or components that are lighter than the alkylating agent, recycle to the alkylation reactor any unreacted alkylation substrate and/or alkylating agent, and recover the alkylate as product. In a process for the alkylation of isobutane with butenes, the product recovery facilities typically comprise a distillation column called an isostripper and another column called a depropanizer. The isostripper separates the entering liquids and vapors into an overhead stream comprising isobutane and lighter components, a sidecut stream comprising normal butanes which is rejected from the process, and a bottom stream comprising alkylate which is recovered as product. The overhead stream passes to the depropanizer, which rejects propane and lighter components and produces a stream comprising isobutane which is recycled to the alkylation reactor.
The catalyst particles that are separated from the alkylation reactor effluent may be passed to any suitable destination, and, in this invention's broadest terms, the destination is not a critical invention of the present invention. In other words, in this invention's broadest sense, there is no requirement that any of the catalyst particles that are separated from the alkylation reactor effluent be recycled to the wetting zone. However, in applying this invention to an alkylation process, it is within the scope of this invention that some of the catalyst particles withdrawn from the alkylation reactor are recycled to the wetting zone.
When the catalyst particles separated from the reactor effluent are recycled to the wetting zone, the catalyst particles are first passed to a zone, such as a drying zone or a vapor phase regeneration zone, where the weight ratio of alkylation substrate per dry catalyst particles of the catalyst particles is reduced to less than that in the zone into which the catalyst particles that exit the wetting zone pass. All that is required is that, prior to being reintroduced to the wetting zone, the weight ratio of the stream containing the catalyst particles is decreased somewhat compared to the weight ratio of the zone into which the catalyst particles are passed. This zone, in the most general terms, is called a dewetting zone. For general methods and equipment for drying solids, see, for example, pages 20-1 to 20-74 of Perry's Chemical Engineers' Handbook , Sixth Edition, edited by R. H. Perry and D. W. Green, published by McGraw-Hill Book Company, New York, in 1984.
Prior to being passed to a dewetting zone, such as a drying zone or a vapor phase regeneration zone as described in the previous paragraph, the catalyst particles separated from the reactor effluent may undergo liquid phase regeneration. Liquid phase, or “mild” regeneration typically comprises contacting the catalyst particles with liquid alkylation substrate containing dissolved hydrogen for an extended period of time and at a temperature that is lower than that for vapor phase regeneration. Liquid phase regeneration helps to remove alkylate, light byproducts, and lightly sorbed contaminants from the catalyst particles.
The FIGURE represents a preferred embodiment of the invention. The following description of the FIGURE is with respect to the alkylation of isobutane with mixed butene isomers, but this description is not intended to limit the scope of the invention as set forth in the claims. A liquid feed stream containing isobutane enters the process through a line 12 and combines with a liquid recycle stream also containing isobutane flowing through a line 46 , and a combined stream of feed and recycle isobutane flows through a line 14 to the alkylation reactor 10 . Another feed stream containing butene isomers enters the process through a line 16 and flows to the alkylation reactor 10 . Catalyst particles enter the alkylation reactor 10 through a line 34 . Within the alkylation reactor 10 , isobutane, which is present in a molar excess relative to the butene isomers, reacts with the butene isomers to produce C 8 alkylate. Oligomeric byproducts having more than eight carbon atoms also form, including heavies which deposit on the catalyst particles. The reaction takes place in the presence of the catalyst particles and at least partially in the liquid phase.
An alkylation reactor effluent stream containing liquid alkylate, excess liquid isobutane, and catalyst particles flows through a line 18 and enters a separation zone 20 , which is a quiescent zone where the catalyst particles disengage from the liquid hydrocarbons. A separator effluent stream comprising alkylate and isobutane flows through a line 36 , and a spent catalyst stream comprising catalyst particles with the heavy oligomeric deposits and isobutane liquid flows through a line 22 to a drying zone 24 . Although in theory the isobutane liquid could remain with the catalyst particles and be removed along with the heavy oligomeric deposits during vapor phase regeneration, the isobutane liquid is preferably removed prior to vapor phase regeneration in order to minimize the complexity of handling liquids in what would, except for the heavy oligomers, be a liquid-free, vapor phase regeneration process. Drying zone 24 removes some of the isobutane from the entering catalyst particles as isobutane vapor, which may be condensed by means not shown in the FIGURE and which is recycled to the alkylation reactor 10 through a line 21 , a line 46 , and the line 14 . After drying, catalyst particles flow from drying zone 24 through a line 26 to a vapor phase regeneration zone 28 . In vapor phase regeneration zone 28 , hot hydrogen gas enters through a line 27 and contacts and regenerates the catalyst particles by removing the heavy oligomers from the surface of the catalyst particles. Means that are not shown in the FIGURE separate the heavy oligomers from the hydrogen, and the heavy oligomers leave the process through a line 29 .
Regenerated catalyst particles flow to a wetting zone 30 through a line 32 . Line 32 may include a means such as a valve, which is not shown in the FIGURE, for allowing catalyst particle flow and for restricting gas flow between the vapor phase regeneration zone 28 and the wetting zone 30 . By such means the vapor phase regeneration zone 28 can operate at a pressure that is different from that of the wetting zone 30 and that of the separation zone 20 . The pressure of the vapor phase regeneration zone 28 is generally at least 5 psi (34.5 kPa), and preferably from 5 to 15 psi (34.5 to 103.4 kPa), greater than the pressure of the wetting zone 30 . Because of the means for restricting gas flow in the line 32 , fluctuations in the pressure of the vapor phase regeneration zone 28 generally do not propagate to the wetting zone 30 or to the separation zone 20 . Therefore, pressure fluctuations in the wetting zone 30 or the separation zone 20 are minimized.
In the wetting zone 30 , the entering catalyst particles are contacted with liquid isobutane. Some of the liquid isobutane in the wetting zone 30 is recycled via lines 23 and 35 from the product recovery facilities 40 as described hereinafter, and the remainder is makeup isobutane that enters through lines 33 and 35 . Fresh catalyst particles, which have nitrogen in their pores, may be added as makeup to the wetting zone 30 via a line 31 . Wetted catalyst particles and isobutane are withdrawn from the wetting zone 30 through a line 34 and are recycled to the alkylation reactor 10 . The weight ratio of isobutane per dry catalyst particles of the wetted catalyst particles in the line 34 is more than 1:2.
The wetting by the liquid isobutane displaces hydrogen from the pores of the regenerated catalyst particles and nitrogen from the pores of the fresh catalyst particles, if any. The wetting generates a heat of adsorption, which vaporizes a portion of the liquid isobutane in the wetting zone 30 . A vapor stream comprising hydrogen and vaporized isobutane flows from the wetting zone 30 through a line 38 , and combines with the previously-mentioned separator effluent stream in the line 36 . The combined stream thus contains alkylate and hydrogen, and in addition isobutane from both the separation zone 20 and the wetting zone 30 . The combined stream flows through a line 42 to product recovery facilities 40 , which recover the alkylate in a line 44 and which comprise means not shown in the FIGURE to condense at least a portion of the isobutane. Isobutane liquid recycles to the alkylation reactor 10 through lines 41 , 43 , 46 , and 14 . Some of the liquid isobutane 40 from the product recovery facilities is recycled to the wetting zone 30 also, via lines 41 , 23 , and 35 . It is expected, however, that the flow of recycle isobutane in the line 41 will generally exceed the requirement for the flow of isobutane to the wetting zone 30 , and hence some isobutane in the line 41 will flow to the alkylation reactor 10 . Means for recovering hydrogen from product recovery facilities 40 , and for recycling the recovered hydrogen to vapor phase regeneration zone 28 are not shown in the FIGURE.
In a particularly preferred variation on the embodiment shown in the FIGURE, the line 18 is eliminated, and the alkylation reactor 10 and the separator 20 are contained within a common vessel, which is referred to herein as a reaction-separator. One. example of such an arrangement is shown in FIG. 1 of the previously-mentioned U.S. Pat. No. 5,489,732, which employs a riser-reactor within a vessel which contains the separation zone and which also receives regenerated catalyst from a vapor phase regeneration zone. Such an arrangement can minimize the difference in pressure between the separator and the point at which the line 34 discharges wetted catalyst into the reactor-separator. In addition, in this particularly preferred variation the differences in pressure across the lines 36 and 38 are minimized. Thus, with these three pressure differences minimized, the wetting zone 30 operates at substantially the same pressure as the point at which the wetted catalyst particles enter the reactor-separator. In other words, the pressure of the wetting zone 30 is balanced with that of the reactor-separator. Accordingly, if the wetting zone 30 is located above the reactor-separator, catalyst particles can flow from the wetting zone 30 to the reactor-separator through the line 34 by gravity flow. Most importantly, however, the balancing of the pressures helps ensure that the pressure in the reactor-separator does not exceed the pressure in the wetting zone 30 to the extent that the flow of catalyst particles through the line 34 is stopped or, worse, reversed. A reversal of catalyst particle flow can result in unsatisfactory operations. This invention helps to prevent fluctuations in the pressure difference between the reactor-separator pressure and the wetting pressure from exceeding 50% of the average pressure difference between the reactor-separator pressure and the wetting pressure.
Numerous other variations on the flow scheme in the FIGURE are possible and are within the scope of the invention. First, rather than combining the wetting zone vapor stream in the line 38 with the separator effluent stream in the line 36 to form the combined stream in the line 42 , the streams in the lines 38 and 36 could each be routed separately to product recovery facilities 40 and the line 42 could be eliminated. In this variation, if the product recovery facilities 40 comprise a distillation column, and lines 36 and 38 are routed to the same distillation column, then preferably line 38 is routed to an upper portion of the column and line 36 is routed to a portion of the column below the upper portion. If lines 38 and 36 are separately routed to the product recovery facilities 40 , the possibilities arise that the pressure drops through the two separate lines will not be equal and/or that the pressures at each line's destination in product recovery facilities 40 may not be the same. Consequently, the previously-described balancing of the pressures between, on the one hand, the wetting zone 30 and, on the other hand, the alkylation reactor 10 may be lost. Therefore, this first variation might require additional instrumentation for measuring the pressures in the wetting zone 30 and the alkylation reactor 10 and for controlling the desired pressure difference between the two.
Two other variations on the flow scheme in the FIGURE involve the routing of the flow of catalyst particles between the catalyst-containing zones in the FIGURE. In the first of these two variations, some or all of the catalyst particles leaving the wetting zone 30 can flow to the separation zone 20 rather than to the alkylation reactor 10 . The separation zone 20 can be a separate vessel or can be combined with the alkylation reactor 10 in a common vessel, as described previously. If all of the catalyst particles from the wetting zone 30 flows to the separation zone 20 , then at least a portion of the catalyst particles from the separation zone 20 would flow to the alkylation reactor 10 , instead of all the catalyst particles from the separation zone 20 flowing to the drying zone 24 , as shown in the FIGURE. In a second variation involving the flow of the catalyst particles, some or all of the catalyst particles flowing in the line 22 can pass to a liquid phase or “mild” regeneration zone. In this variation, a portion of the catalyst particles that is withdrawn from the liquid phase regeneration zone may be passed directly to the alkylation reactor 10 , with the remainder passing to the drying zone 24 .
Transport of the catalyst particles from one catalyst-containing zone to another can be done by a variety of means, such as gravity flow, pneumatic lifting using a gas or a vapor for fluidizing and lifting, hydraulic lifting using a liquid for fluidizing and lifting, and mechanical conveying using buckets, belts, or other devices. One possible orientation of the zones in the FIGURE would be to locate the separation zone 20 , the drying zone 24 , the vapor phase regeneration zone 28 , and the wetting zone 30 above the alkylation reactor 10 . In this orientation, transporting the catalyst particles would comprise, first, hydraulic lifting upward in a riser in the alkylation reactor 10 to the separation zone 20 ; then, gravity flow downward from the separation zone 20 followed by hydraulic lifting upward using liquid isobutane in a lift line to the drying zone 24 ; and, finally, gravity flow from the drying zone 24 , through the vapor phase regeneration zone 28 , through the wetting zone 30 , and ultimately to the alkylation reactor 10 . Another possible orientation would be to place the separation zone 20 and the wetting zone 30 above the alkylation reactor 10 and to locate the drying zone 24 and the vapor phase regeneration zone 28 below the alkylation reactor 10 . In this alternate orientation, transporting the catalyst particles would comprise, first, hydraulic lifting upward in a riser in the alkylation reactor 10 to the separation zone 20 ; then, gravity flow downward from the separation zone 20 through the drying zone 24 and the vapor phase regeneration zone 28 ; then, pneumatic lifting upward using hydrogen or isobutane vapor in a lift line to the wetting zone 30 ; and, finally, gravity flow from the wetting zone 24 to the alkylation reactor 10 . Other orientations are also possible, and the orientation of these catalyst-containing zones is not an essential element of this invention. | A solid catalyst alkylation process that wets catalyst particles with the alkylation substrate prior to introducing the catalyst particles to a liquid phase alkylation reactor is disclosed. A vapor stream from the wetting step that comprises the alkylation substrate and a reactor effluent stream comprising product alkylate and excess alkylation substrate are both passed to the product recovery zone, which recovers the alkylate product and recycles the alkylation substrate. Routing the vapor stream and the reactor effluent stream together to the product recovery zone minimizes pressure imbalances, ensures steady catalyst flow, and minimizes equipment costs. This process is applicable to alkylation processes that produce motor fuels. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Patent Application No. 61/089,989, filed Aug. 19, 2008, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the collection of blood and medical specimens, for example, in a medical facility, such as a hospital.
2. Description of Related Art
In today's hospitals, mislabeling of specimen tubes, vials, or collection containers is a common problem that poses grave medical risk to a patient and potentially high liability to the institution. Despite best efforts at training and automation of the process with computers and barcodes, errors persist. The number of specimens collected and blood draws is quite high for a typical hospital. Error rates at or close to zero have been an unachievable goal.
Mislabeling errors can include: wrong patient name; missing label; mis-communicated order; outdated tube, vial, or container; unreadable, smudged, or bruised label; tube, vial, or container not labeled at bedside in accordance with applicable standards; and contamination while handling tube, vial, or container to add label. For the purpose of simplicity, hereinafter, the word “vial” will be utilized to describe the prior art in the present invention, and it is to be understood that “vial” means any specimen collection vessel deemed suitable and/or desirable by one skilled in the art for the collection of a specimen from a patient. Accordingly, “vial” is to be understood as being, without limitation, a vial, a tube, or a container.
Staff that attach labels to specimen vials in most modern hospitals can include: a floor nurse; a phlebotomist; a patient care technician; an emergency room nurse; an operating room nurse; a surgical floor nurse; and a lab technician.
The core problem has been identified to involve: failure to verify patient identity typically at the bedside; failure to use two forms of patient identity independent of a medical record number; and failure to verify that the patient identity matches the patient information on the printed label to be attached to the specimen vial.
Most hospitals use a wrist (or ankle) identification (ID) band to identify each patient with information that at minimum includes the patient's name and date of birth. Modern hospitals either use or are considering using a barcode to encode this and possibly other patient information on the ID band at registration to automate the capture of the patient's information without human error.
Although barcodes on ID bands work well after registration, some emergency room (ER) trauma patients are moved immediately to a bed where a specimen is drawn in anticipation of a medical doctor (MD) order and prior to full registration where the barcoded ID band is produced. These patients may use a handwritten ID band or an ID band without a barcode. Mistakes in getting the correct label onto the proper specimen vial are well documented. Unused full blood vials drawn in anticipation of an MD order are also at high risk of being labeled for the wrong patient as patients are moved with some frequency in the ER.
In the rest of the hospital, i.e., other than the ER, a typical, prior art flow diagram for collecting a specimen is shown in FIG. 1 . The many types of specimens that are routinely collected are shown in FIG. 2 .
With reference to FIG. 1 , a method of collecting a specimen (e.g., a blood specimen) in accordance with the prior art includes step 2 , where a suitable medical professional, e.g., a medical doctor (MD), a physician's assistant, etc., places an order to draw the blood specimen from a patient who is desirably already wearing a conventional ID band that includes at least the patient's name and date of birth, but which may not include any computer-readable code, such as, without limitation, a patient barcode.
After the order is placed in step 2 , the method advances to step 4 where the order to draw the blood specimen from the patient is entered into a computer in any suitable and/or desirable manner, e.g., without limitation, by a data entry person. Thereafter, the method advances to step 6 where barcode labels associated with the order are printed. These printed barcode labels may include one or more of the following: one or more order barcode labels, one or more patient barcode labels, and/or one or more vial barcode labels to be applied to one or more specimen vials that either will receive or have already received a specimen.
Thereafter, in step 8 , the barcode labels printed in step 4 are retrieved, perhaps from a printer that has also printed other, unrelated barcode labels. In step 10 , these retrieved barcode labels and the patient are brought together (e.g., in the patient's room) where, in step 12 , the specimen-taker determines whether the patient is wearing an ID band. If not, the method advances to step 14 where appropriate corrective action is taken to prepare an ID band for the patient and fasten it to the patient.
From either step 12 or step 14 , the method advances to step 16 where the specimen-taker manually compares information on the patient's ID band to like information on the printed barcode labels. This information desirably includes, among other things, a medical record number, the patient's name, and the patient's date of birth. If, in step 18 , the specimen-taker determines that the information on the patient's ID band does not match like information on the printed barcode labels, the method advances to step 20 where appropriate corrective action is taken to make the information on the patient's ID band and the like information on the printed barcode labels match.
From either step 18 or step 20 , the method advances to step 22 where the specimen-taker collects the specimen (in this example a blood specimen) in one or more specimen vials. In step 24 , the specimen-taker applies at least one of printed vial barcode labels to each specimen containing vial. In practice, the order of steps 22 and 24 may be reversed. Once each specimen vial contains a specimen and has one of the printed vial barcode labels applied thereto, the specimen vial is sent to the lab for analysis of the specimen.
In view of the prior art method of collecting a specimen described above being known to result in mislabeling of specimen vials, it would be desirable to provide a method and system that reduces or avoids such mislabeling of specimen vials.
SUMMARY OF THE INVENTION
Disclosed is a method of tracking a specimen acquired from a patient. The method comprises: (a) storing in a computer storage accessible by a standalone or networked computer a first machine-readable code present on an identification (ID) means worn by a patient; (b) storing in the computer storage a second machine-readable code associated with an order to obtain a specimen from the patient; (c) storing in the computer storage a third machine-readable code present on an identification (ID) means worn by a specimen-taker; (d) following steps (a)-(c), selecting from a plurality of specimen containers having machine-readable codes that are unique to each other preapplied thereto one specimen container including a fourth machine-readable code preapplied thereto; (e) in response to an electronic reading means reading and dispatching to a processor of the computer the first—fourth machine-readable codes present on the ID means worn by the patient, present on the order, present on the ID means worn by the specimen-taker, and present on the specimen container, respectively, and in response to the processor determining that the first machine-readable code and the second machine-readable code are related to the same patient, the processor causing said first—fourth machine-readable codes to be stored in the computer storage in a relational manner and the processor of the computer causing a signal to be generated to acquire a specimen from the patient and to place the acquired specimen in the container; and (f) responsive to the processor receiving a signal that the specimen has been placed in the container following step (e), the processor causing an indication thereof to be stored in the computer storage in a relational manner with said first—fourth machine-readable codes.
The method can further include: (g) in response to the electronic reading means reading and dispatching to the processor of the computer a fifth machine-readable code that is preapplied to another specimen container selected from the plurality of specimen containers, said processor causing the first, second, third, and fifth machine-readable codes to be stored in the computer storage in a relational manner; and (h) responsive to the processor receiving a signal that the other specimen has been placed in the other container following step (g), the processor causing an indication thereof to be stored in the computer storage in a relational manner with said first, second, third, and fifth machine-readable codes.
Each machine-readable code can be unique of the other machine-readable codes.
Step (f) can include the processor determining whether the signal of step (f) is received within a predetermined time interval of the processor generating the signal of step (e) and storing an indication thereof in the computer storage in a relational manner with said first—fourth machine-readable codes.
Each machine-readable code can comprise a unique barcode. The ID means worn by the patient can be a bracelet. The ID means worn by the specimen-taker can be a badge.
The first machine-readable code can comprise a barcode that encodes at least one of the following: a unique serial number; the patient's name; a registration number assigned to the patient; the patient's date of birth; the patient's sex; a code that signifies the type if ID means worn by the patient; and a check digit.
The fourth machine-readable code can comprise a barcode that encodes at least one of the following: a unique serial number; an expiration date; a color of a lid or cap that specifies the type of specimen the container is to be used for; human readable numbers and/or characters corresponding to one or more of the unique serial number, the expiration date, and the color of the lid; and a check digit.
The second machine-readable code can comprise a barcode that encodes at least one of the following: an order number; a type of specimen to be acquired; a volume of the specimen to be acquired; a time that the specimen is to be acquired; and a control number.
The electronic reading means can be an optical scanner that is communicatively coupled with the computer via a wired or wireless connection. The optical scanner can be a barcode scanner.
Also disclosed is a method of tracking a specimen acquired from a patient. The method comprises: (a) storing in a computer storage of a computer a first machine-readable code present on an identification (ID) means worn by a patient; (b) storing in the computer storage of the computer a second machine-readable code associated with an order to obtain a specimen from the patient; (c) storing in the computer storage of the computer a third machine-readable code present on an identification (ID) means worn by a specimen-taker; (d) following steps (a)-(c), selecting from a plurality of specimen containers having machine-readable codes that are unique to each other preapplied thereto one specimen container including a fourth machine-readable code preapplied thereto, wherein the fourth machine-readable code comprises a barcode that encodes a unique serial number and an expiration date of the container; (e) in response to receiving the fourth machine-readable code from an electronic reading means, a processor of the computer determining from the expiration date encoded in the fourth machine-readable code if the specimen container is out-of-date and, if so, causing an alert signal indicative of said out-of-date condition to be generated by or near the electronic reading means, otherwise, if the specimen container is not out-of-date, and in response to the processor determining that the first machine-readable code and the second machine-readable code are related to the same patient, the processor causing the first—fourth machine-readable codes to be stored in the computer storage in a relational manner and the processor causing a signal to be generated to acquire a specimen from the patient and to place the acquired specimen in the container; and (f) responsive to the processor receiving a signal that the specimen has been placed in the container following step (e), the processor causing an indication thereof to be stored in the computer storage in a relational manner with said first—fourth machine-readable codes.
The method can further include: (g) in response to receiving from the electronic reading means a fifth machine-readable code that is preapplied to another specimen container selected from the plurality of specimen containers, said processor causing the first, second, third, and fifth machine-readable codes to be stored in the computer storage in a relational manner; and (h) responsive to the processor receiving a signal that the other specimen has been placed in the other container following step (g), the processor causing an indication thereof to be stored in the computer storage in a relational manner with said first, second, third, and fifth machine-readable codes.
Each machine-readable code can be unique of the other machine-readable codes.
Step (f) can include the processor determining whether the signal of step (f) is received within a predetermined time interval of the processor generating the signal of step (e) and storing an indication thereof in the computer storage in a relational manner with said first—fourth machine-readable codes.
Each machine-readable code can comprise a unique barcode. The ID means worn by the patient can be a bracelet. The ID means worn by the specimen-taker can be a badge.
The first machine-readable code can comprise a barcode that encodes at least one of the following: a unique serial number; the patient's name; a registration number assigned to the patient; the patient's date of birth; the patient's sex; a code that signifies the type if ID means worn by the patient; and a check digit.
The fourth machine-readable code can comprise a barcode that encodes at least one of the following: a unique serial number; an expiration date; a color of a lid or cap that specifies the type of specimen the container is to be used for; human readable numbers and/or characters corresponding to one or more of the unique serial number, the expiration date, and the color of the lid; and a check digit.
The second machine-readable code can comprise a barcode that encodes at least one of the following: an order number; a type of specimen to be acquired; a volume of the specimen to be acquired; a time that the specimen is to be acquired; and a control number.
The electronic reading means can be an optical scanner that is communicatively coupled with the computer via a wired or wireless connection. The optical scanner can be a barcode scanner.
Lastly, disclosed is a system for tracking one or more specimens acquired from a patient, wherein a standalone or networked computer is in operative communication with a computer storage and an electronic reading means that is operative for reading unique machine-readable codes disposed on the following: an identification (ID) means worn by a patient, an order to obtain the one or more specimens from the patient, an identification (ID) means worn by a specimen-taker, and a plurality of specimen containers each for receiving one specimen from the patient.
The electronic reading means is also operative for dispatching said machine-readable codes to the processor which, in response to the machine-readable codes for the patient ID means and the order being related to the same patient, stores the machine-readable code for each specimen container to receive a specimen in the computer storage in a relational manner with the machine-readable codes for the patient ID means, the order, and the specimen-taker ID means, and generates a signal to acquire a specimen from the patient and to place the acquired specimen in the container.
The computer is responsive to a signal that a specimen that has been placed in each specimen container for storing an indication thereof in the computer storage in a relational manner with the machine-readable code for each specimen container that received the specimen stored in the computer storage. Each specimen container of the plurality of specimen containers has a machine-readable code preapplied thereon that is unique from the machine-readable code preapplied to any other of the specimen containers and the machine-readable codes disposed on the patient ID means, the order, and the specimen-taker ID means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of a prior art method for collecting a specimen;
FIG. 2 is a list of exemplary patient specimens that are routinely collected;
FIG. 3 is a block diagram of an exemplary computer that can be utilized to implement the present invention; and
FIG. 4 is a flow diagram of a method for collecting a specimen in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 3 , the present invention is embodied, at least in part, in a software program which executes on one or more standalone or networked computers 62 . Each computer 62 is coupled, either directly or via a wired or wireless computer network, to a local or remote computer storage 66 , such as RAM memory, FLASH memory, a Hard Disk Drive, etc., of the type known in the art. Each computer 62 can also include a media drive 70 , such as a CD-ROM drive, and the like, which can operate with a portable computer storage 72 , e.g., a CD-ROM, capable of storing computer software, data, and the like. Each computer 62 includes at least one microprocessor 64 or other such processing means that enables computer 62 to process and store data in computer storage 66 or computer storage 72 under the control of the software program, which operates under the control of a computer operating system, that controls the operation of computer 62 to process data, store data, and output data in human readable format (via print or visual display) in a manner known in the art. The software program can be stored in computer storage 66 , computer storage 72 , or some combination of computer storages 66 and 72 . The software program is able to configure and operate computer 62 in a manner to implement some or all of the present invention. Each computer 62 can include an input/output system 78 that can include, among other things, a keyboard 84 , a mouse 86 , and/or a display 88 . Computer 62 is exemplary of a computer that is capable of executing the software program of the present invention and is not to be construed as limiting the invention.
With reference to FIG. 4 and with continuing reference to FIG. 3 , a method of collecting a specimen in accordance with the present invention includes a step 32 where a suitable medical professional, e.g., a medical doctor, a physician's assistant, etc., places an order to draw the specimen, e.g., a blood specimen, from a patient who is desirably already wearing an ID band 92 that desirably includes a computer generated patient barcode number 92 ′ that is unique to the patient, i.e., no two patients currently in the medical facility are assigned the same patient barcode number. As used herein, “barcode number” may include an alpha, numeric, or alphanumeric sequence.
At or about the time the computer generates the patient barcode number 92 ′ on ID band 92 , the processor of the computer creates in the computer storage a database data structure where the patient's information, e.g., the patient's name and the patient's date of birth, are stored in a relational manner with the patient's barcode number. The patient's information can be entered in any suitable and/or desirable manner, e.g., without limitation, by order entry personnel, at or about the time the patient is accepted into the medical facility.
After the order is placed in step 32 , the method advances to step 34 where an order to draw the blood specimen from the patient is entered into the computer in any suitable and/or desirable manner, e.g., without limitation, by data entry personnel such as a lab clerk. At or about the time the order to draw the blood specimen is entered, the processor of the computer generates a unique order barcode number 94 ′ and stores this order barcode number 94 ′ in a relational manner in the database data structure where the patient's information and the patient's barcode number 92 ′ are stored in a relational manner. Desirably, no two orders currently in the medical facility are assigned the same order barcode 94 ′.
In step 36 , the computer, either automatically or under the control of the data entry person, generates a hard copy of the order 94 that includes the unique computer assigned order barcode 94 ′, some or all of the patient's information, and, optionally, the patient's barcode number 92 ′. The alpha, numeric, or alphanumeric sequence represented by each barcode number described herein may appear in conventional human readable form, i.e., letters, numbers, etc., next to each hardcopy of the barcode number to facilitate manual entry of the barcode number.
At this point in time, the computer storage includes the database data structure where the patient's information, the order barcode number 94 ′, and the patient's barcode number 92 ′ are stored in a relational manner. Because the combination of at least the patient's barcode number 92 ′ and the order barcode number 94 ′ are unique with respect to all other combinations of patient barcode numbers and order barcode numbers present in the medical facility, no other data structure having the same patient barcode number and order barcode number should exist in the computer storage.
In step 38 , the printed order 94 , including unique order barcode number and, desirably, some or all of the patient's information, along with suitable blood drawing supplies are brought to the patient (e.g., at the patient's bedside) where, in step 40 , the blood drawer (or blood-taker) determines whether the patient is wearing an ID band 92 that includes a unique patient barcode number 92 ′. To determine whether the patient's barcode number 92 ′ is unique, the barcode number on the ID band is input into the computer whereupon the processor compares said input patient barcode number 92 ′ to each other patient barcode number stored in data structures in the computer storage. If the patient is either not wearing an ID band or is wearing an ID band that the processor determines does not have a unique patient barcode number, an ID band having a unique patient barcode number is prepared for the patient and fastened to the patient in step 42 . The ID band can include, without limitation, a wrist band, an ankle band, and the like.
Following either step 40 or step 42 , the patient barcode 92 ′ on the patient's ID band 92 is input into the computer in step 44 . As used herein, “input into the computer” means that a barcode number is either manually input into the computer (e.g., without limitation, via a keyboard, a computer mouse, and/or any other suitable and/or desirable manual input means) or is read by a suitable barcode reading means, e.g., barcode reader 90 in FIG. 3 , that communicates the read barcode number to the processor of the computer which is in communication with the barcode reading means and which is operatively coupled to the computer storage. Each barcode number represents a machine-readable code that can be read by the suitable reading means, in this case barcode reading means 90 .
In steps 46 , 48 , and 50 the order barcode number 94 ′ on the order 94 is input into the computer, a badge barcode number 96 ′ present on a badge 96 of the blood drawer is input into the computer, and one or more barcode number(s) 98 ′ preapplied to specimen vial(s) 98 where the drawn blood is to be stored is/are input into the computer, respectively. Each barcode number input into the computer is stored at least temporarily by the processor in the computer storage. The order of input of barcode numbers into the computer in steps 44 , 46 , 48 and 50 is not to be construed as limiting the invention. Each barcode number (albeit, patient barcode number 92 ′, order barcode number 94 ′, blood drawer barcode number 96 ′, and vial barcode number 98 ′) is unique and, more specifically, each vial has a unique vial barcode number 98 ′ preapplied thereto.
In step 52 , the processor determines if a database data structure exists that includes the patient's barcode number 92 ′ input into the computer in step 44 and order barcode number 94 ′ input into the computer in step 46 . In other words, the processor determines if the patient's barcode number 92 ′ and the order barcode number 94 ′ are related to the same patient. If so, the processor causes the barcode number 96 ′ on the badge 96 of the blood drawer input into the computer in step 48 and each barcode number 98 ′ preapplied to a vial 98 that was input into the computer in step 50 to be stored in a relational manner in the database data structure with the patient's barcode number 92 ′ and the order barcode number 94 ′. Desirably, the barcode number 96 ′ on the badge 96 of the blood drawer input into the computer in step 48 and each vial barcode number 98 ′ preapplied to a vial 98 that was input into the computer in step 50 are stored in the same database data structure where the patient's barcode number 92 ′ and the order barcode number 94 ′ were previously stored in a relational manner. However, this is not to be construed as limiting the invention since it is envisioned that each vial barcode number 98 ′ can be stored in a separate database data structure in a relational manner with the patient barcode number 92 ′, the order barcode number 94 ′, and the blood drawer barcode number 96 ′ if desired. Thus, each database data structure can store one vial barcode number 98 ′ or more than one vial barcode number 98 ′ in a relational manner with the corresponding patient barcode number 92 ′, order barcode number 94 ′, and blood drawer barcode number 96 ′.
On the other hand, should the processor determine that the patient's barcode number 92 ′ and the order barcode number 94 ′ are not related to the same patient in the data structure where these barcodes were previously stored, the method advances from step 52 to step 54 where any discrepancy in the relationship between the patient's barcode number 92 ′ and the order barcode number 94 ′ in the data structure is corrected.
At this point in time, the computer storage includes the database data structure where the patient's information, the order barcode number 94 ′, the patient's barcode number 92 ′, the blood drawer's barcode number 96 ′, and each vial barcode number 98 ′ are stored in a relational manner.
Following either step 52 or 54 , the method advances to step 56 where the processor causes one or more suitable signals (audio, visual, or both) to be output that informs the blood drawer to draw the blood sample and send it to a lab for analysis. At or about the time the signal is output in step 56 , the processor starts a software or hardware timer that is utilized to determine that the blood draw is completed within a predetermined time after the signal is output in step 56 . When collection of the blood specimen in one specimen vial 98 or two or more specimen vials 98 is complete, the blood drawer causes an indication thereof to be input into the computer where the processor stores this indication in a relational manner with the patient's information, the order barcode number 94 ′, the patient's barcode number 92 ′, the blood drawer's barcode number 96 ′, and each vial barcode number 98 ′.
The processor compares the time between when the signal is output in step 56 and the time when the blood drawer causes the indication that the collection of the blood specimen is complete to be input into the computer (i.e., the specimen collection time) to the predetermined time. The specimen collection time is desirably stored in a relational manner in the same database data structure where the patient's information, the order barcode number 94 ′, the patient's barcode number 92 ′, the blood drawer's barcode number 96 ′, and each vial barcode number 98 ′ are stored in a relational manner. Thus, upon completion of the blood draw, a complete record of the blood drawing event resides in a relational manner in the database data structure stored in the computer storage. If the specimen collection time exceeds the predetermined time, the processor can optionally cause a suitable signal to be output that informs the blood drawer of this fact.
The lab receiving each vial 98 containing a blood sample has all of the order and “label” information stored in the database data structure that is linked to the vial barcode number 98 ′ preprinted on each vial and can process the order with confidence without producing any further paperwork or labels.
Prior to executing the method shown in FIG. 4 , at least the patient barcode number 92 ′, the order barcode number 94 ′, and the blood drawer barcode number 96 ′ are stored in the computer storage. As discussed above, the relationship between the patient barcode number 92 ′, the order barcode number 94 ′, the blood drawer barcode number 96 ′, and each vial barcode number 98 ′ can be stored in the database data structure that is stored in the computer storage. For example, in step 52 of the method shown in FIG. 4 , in response to barcode reader 90 reading and dispatching to a processor of the computer the patient barcode number 92 ′, the order barcode number 94 ′, the blood drawer barcode number 96 ′, and the barcode number 98 ′ of each vial utilized to collect a sample, and in response to the processor determining that the patient barcode number 92 ′ and the order barcode number 94 ′ are related to the same patient, the processor stores the patient barcode number 92 ′, the order barcode number 94 ′, the blood drawer barcode number 96 ′, and each specimen vial barcode number 98 ′ to be stored in a relational manner in a database data structure that exists in the computer storage. The storage of these barcode numbers in a relational manner in a database data structure stored on the computer storage occurs only after it has been established that the patient barcode number 92 ′ and the order barcode number 94 ′ are related to the same patient. In the method described above, the relationship of the patient barcode number 92 ′ and the order barcode number 94 ′ to the same patient was made by way of these barcodes being stored in a relational manner in the database data structure stored in the computer storage. Thereafter, when the blood drawer barcode number 96 ′ and each specimen vial barcode number 98 is input into the computer, these latter barcode numbers 96 ′ and 98 ′ are stored in a relational manner in the same database data structure as the patient barcode number 92 ′ and the order barcode number 94 ′. However, this is not to be construed as limiting the invention since the determination that the patient barcode number 92 ′ and the order barcode number 94 ′ are related to the same patient can be made outside of the database data structure whereupon the database data structure is created that relates to various barcode numbers 92 ′, 94 ′, 96 ′, and 98 ′ in a relational manner at the time these barcode numbers are input into the computer in steps 44 - 50 .
Desirably, the barcode number 96 ′ of the blood drawer (or specimen-taker) is stored in the computer storage prior to performing the steps of the method shown in FIG. 4 for security purposes and/or quality control purposes. Thus, if a specimen-taker is not qualified or is not authorized to acquire a particular specimen from a patient, the processor can cause a suitable error signal to be generated when the specimen-taker's badge barcode number 96 ′ is input in step 48 .
As noted above, each barcode comprises a unique machine-readable code. The ID band worn by each patient can be in the form of a wrist or ankle bracelet. The badge of the blood drawer (or blood-taker) comprises an ID means that is worn by the blood drawer.
The patient barcode number 92 ′ is desirably a machine-readable code that encodes one or more of the following: a unique serial number; the patient's name; a registration number assigned to the patient; the patient's date of birth; the patient's sex; a code that signifies the type of ID means worn by the patient (ankle or wrist bracelet); and a check digit.
Each vial barcode number 98 ′ is desirably a machine-readable code that encodes one or more of the following: a unique serial number; an expiration date; a color of a lid or cap that specifies the type of specimen the container is to be used for; human readable numbers and/or characters corresponding to one or more digits of the unique serial number, the expiration date, and a check digit.
The order barcode number 94 ′ is desirably a machine-readable code that encodes one or more of the following: an order number; a type of specimen to be acquired; a volume of the specimen to be acquired; a time when the specimen is to be acquired; and a control number.
The barcode reading means 90 comprises an electronic reading means in the form of an optical barcode scanner that is communicatively coupled with the processor of the computer via a wired or wireless connection.
As can be seen, the present invention provides a means of achieving a failsafe, zero defect process for identifying and processing patient specimen samples. It has the additional benefit of eliminating the cost of vial labels (since the vials have preprinted vial barcodes already attached thereto), associated printers, and staff labor in dealing with the vial labels.
The invention has been described with reference to the preferred embodiment. Obvious modifications and alterations will occur to those of ordinary skill in the art upon reading and understanding the preceding detailed description. For example, the specimen collection system described above can be implemented in any suitable and/or desirable manner utilizing one or more standalone or networked computers and local or remote computer storage, all connected by a wired network, a wireless network, or some combination of a wired and wireless network. Moreover, while the invention has been described with reference to the drawing of a blood specimen, this is not to be construed as limiting the invention since it is envisioned that the invention can be utilized in connection with the acquisition of any type of biological specimen, such as, without limitation, each specimen type shown in FIG. 2 . It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | In a method of tracking a specimen acquired from a patient, machine-readable codes present on a patient identification (ID), an order to obtain a specimen from the patient, and on a specimen-taker ID means, respectively, are stored in a computer storage. A specimen container having a fourth machine-readable code preapplied thereto is selected from a plurality of specimen containers having unique machine-readable codes preapplied thereto. In response to a processor determining that the first and second machine-readable codes are related to the same patient, the processor causes the first—fourth machine-readable codes to be relationally stored in the computer storage. Responsive to the processor receiving a signal that a specimen has been placed in the selected specimen container, the processor causes an indication thereof to be stored in the computer storage in a relational manner with the first—fourth machine-readable codes. | 6 |
This is a divisional of U.S. patent application Ser. No. 176,197, filed Aug. 7, 1980 by the application now U.S. Pat. No. 4,374,804, issued Feb. 22, 1983.
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to sludge treatment and in particular to sludge treatment methods to produce a composted material for agricultural and other similar uses. Specifically, the invention relates to a controlled sludge treatent method that eliminates objectionable odors and provides a useable composted product.
Sewage sludge accumulates at a rapid rate and in areas of large population the disposal becomes a problem. This is particularly so because the raw sludge from the sewage treatment plants has a distinct objectionable and disagreeable odor. The method of this invention provides a means for handling that sludge, eliminating the objectionable odor, and producing a useable product that makes the method economically feasible.
The method described herein is for an ordinary unit. It is to be understood that the method may be used in structures in a range of sizes to handle a range of volumes, or the method may be used in structures as a plurality of similar sized units to handle the total volume of sludge generated.
In the prior art sludge was disposed of by merely dumping it with a result of complaints about the disagreeable and objectional odor. Also, the raw sludge was not readily suitable for direct application to form land, flower beds, and similar uses in its untreated state.
Field treatment in the prior art has been tried in order to obtain a compost material, but this still had the problem of the disagreeable and objectionable odors.
Some treatment methods tried a digester means in order to capture certain gases that were useable, but this did not fully treat the sludge for agricultural use.
The present method of this invention overcomes the aforementioned problems of the prior art. The present invention thoroughly premixes the sludge with carbonaceous material and conveys it to a silo where it is spread evenly over the interior area in a layering manner by a movable distribution means. A timed interval moves the mixture through the silo in a specified period as more layers are added at the top and an equivalent volume (less the amount consumed in the composting process) is removed from the bottom by movable pick-up means.
The partially treated mixture is then conveyed to a second silo and spread, moved at a timed interval, and removed in a similar manner and packaged or bulkhandled for distribution to the user.
In both silos a forced air system passes air through the mixture mass. In the first silo to promote aerobic bacteria action for the composting and in the second silo to complete the process which eliminates the objectionable odors.
It is, therefore, an object of the invention to provide a controlled sludge composting method which will prepare raw sewage sludge for safe disposal and agricultural type uses.
It is another object of the invention to provide a controlled sludge composting method that removes objectionable disagreeable odors from the sludge in its final composted form.
It is also an object of the invention to provide a controlled sludge composting method that uses carbonaceous material as a mixture with the sludge to obtain a composted product.
It is still another object of the invention to provide a controlled sludge composting method that uses forced air to promote aerobic bacteria action in producing the composted end product.
It is yet another object of the invention to provide a controlled sludge composting method that uses forced air to complete the sludge treatment to eliminate disagreeable objectionable odors.
Further objects and advantages of the invention will become more apparent in the light of the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic layout of a controlled sludge composting system;
FIG. 2 is a diagramatic layout of the process of a controlled sludge compositing method;
FIG. 3 is a partial pictorial view of a silo for a controlled sludge composting method, showing distribution means of the silo;
FIG. 4 is a partial pictorial view of a silo for a controlled sludge composting method, showing a removal means at the bottom of the silo.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings and particularly to FIG. 1, a method for controlled sludge composting system is shown at 10.
The controlled sludge composting method 10 consists of a sludge supply means 12, a composting agent storage means 14, a mixing means 16, at least one first silo means 18, at least one second silo means 20, and associated conveying means, distribution means, retrieval means, discharge means, and control means to be described hereinafter in relation to the sludge supply means 12, composting agent storage means 14, mixing means 16, and first and second silo means 18 and 20 respectively.
As sludge is received from waste treatment plants, by truck, conveyor, or other means, it is deposited in the sludge supply means 12. The sludge supply means 12 can be in the form of a tank, hopper, or other suitable container to store the sludge for compounding with other ingredients as described hereinafter.
In a like manner, composting agents being received for the controlled sludge treatment method 10 are stored in the composting agent storage means 14 for later compounding with the aforementioned sludge.
Sludge from the sludge supply means 12 is transported via associated conveying means 22 to the mixing means 16, and composting agents from the composting agents storage means 14 are transported via associated conveying means 24 to the mixing means 16.
The sludge and the composting agent are thoroughly mixed in the mixing means 16 and then conveyed via conveying means 26 to first silo means 18.
The composting agent is primarily wood chips, reduced to a dimension approximately three-eighth of an inch across. Longer chips are not desirable as at the conclusion of the process it may be necessary to screen out larger particles that have not been assimilated into the final compost product by the process. The wood chips may also be in the form of sawdust. The wood chips, as will be described later, are added as a carbonaceous ingredient for the composting process. In addition to wood chips or sawdust, other materials may be added for the purpose, such as ground sugar cane stalks, corn stalks, and corn cobs, ground leaves, peanut hulls, shredded paper in cut bits, and other types of carbonaceous material.
The first silo 18 is the main composting means for the process. As noted, the controlled sludge composting method contains at least one first silo 18. For large volume production, the first silo 18 may be built as a twin silo as later described herein. Also, there may be a plurality of first silos 18 if the volume of sludge to be composted warrants such a facility. The method will be described for one first silo 18, with occasional reference to the plurality of first silos 18 where necessary.
As the mixed sludge and composting agent enters the first silo 18 as a compound it is spread evenly over the total cross sectional area of the first silo 18. The even distribution is accomplished by a traveling type carrier means with a superimposed conveyor means thereon. FIG. 3 shows a partial pictorial view of first silo 18 with the roof portion of the structure cut away to show the traveling type carrier distributor means 28 with a superimposed conveyor means 30 thereon.
The traveling type carrier distributor means 28 consists of at least a pair of transverse support members 32, suitably connected together by bracing and strut members 34 and having a wheeled truck means 36 at each support location at the ends of transverse support members 32. The wheeled truck means 36 ride on and are supported by rails 38 suitably affixed to the first silo 18 structure. A pair of wheeled carriages 40, rigidly connected together centrally by strut structure 42, rides on rails 44 on the top side of transverse support members 32. Power means, not shown, provides power to move the wheeled truck means 36 longitudinally along rails 38. At the same time, power means, not shown, provides power to move the wheeled carriages 40 along the rails 44 on transverse support members 32.
The superimposed conveyor means 30 consists of first distribution conveyor means 46 which runs from a first swivel connection, at the discharge point of conveying means 26 leading into to first silo 18, to a second swivel connection at the center of a second distribution conveyor means 48 which is mounted on the top most side of strut structure 42. The second distribution conveyor means 48 has discharge ends at each end thereof, for further discharge as hereinafter described, to a pair of third distribution conveyor means 50 which are mounted on the top most side of wheeled carriages 40. The third distribution conveyor means 50 have discharge ends at each end thereof, for further discharge as hereinafter described.
The mixed sludge and composting agent that is conveyed by conveying means 26, is discharged into first silo 18 by depositing the mixture on to the first distribution conveyor means 46 which transports the mixture to and deposits it on to the second distribution conveyor means 48. By suitable control means, the second distribution conveyor means 48 may be operated to discharge at either end thereof. In whichever direction it is programmed for or for which the controls are set manually, the second distribution conveyor means 48 which delivers to and deposits the mixture on to one of the third distribution conveyor means 50, may also be operated to discharge at either end thereof. In whichever direction it is programmed for or for which the controls are set manually, the third distribution conveyor means 50 delivers to and deposits the mixture into the first silo 18 by gravity flow 52.
By operation of the wheeled trucks 36 and the wheeled carriages 40 the gravity flow 52 can be distributed over the entire area of the interior of the first silo 18. This is done by control of the direction of the second and third distribution conveyor means 48 and 50 respectively so that the final discharge for gravity flow 52 may be at either end of the third distribution conveyor means 50. The matrix of gravity flow 52 points, established by the combination of second and third distribution conveyor means 48 and 50 directional movements and the concurrent transverse and longitudinal movments of wheeled carriages 40 and wheeled trucks 36 assures the even distribution and load of first silo 18. The control of the aforesaid directional movements, transverse movements, and longitudinal movements may be manual or programmed for automatic distribution.
Hereinbefore it was noted that first silo 18 (and similarly for second silo 20) may be individual silos, twin silos, or a plurality of adjacent silos. In FIG. 3 a center transverse wall 54 in first silo 18 indicates the structure for a twin silo arrangement. For a plurality of silos, adjacent structures would be formed in the longitudinal direction.
It is to be noted and understood that such twin silo arrangement and such plurality of silos is within scope and intent of this invention. It is to be further understood that the separate or single standing of silo structures is equally within the scope and intent of this invention.
Where twin silos or a plurality of adjacent silos is used, the traveling type carrier distribution means 28 with a superimposed conveyor means 30 thereon may be used. Such a dual use for twin silos is illustrated in FIG. 3 and the rails 38 could be extended for a plurality of adjacent silos.
As described hereinbefore, the even matrix-like distribution of gravity flow 52 points is important for the proper composting of the mixture of sludge and the composting agent. The evenly distributed layers move downward evenly, as hereinafter described, for the removal or retrieval of the composed materials. The movement is over a calculated and controlled period of time so that even distribution is important, should it not be an even distribution over the first silo 18 interior area, portions of the mixture may not be fully or properly composted at the end of the calculated and controlled period of time.
In FIG. 1 the traveling type carrier distribution means 28 is shown schematically, the details are shown in FIG. 3.
Note in FIG. 1 that sloping side walls are shown for the first silo 18 and the second silo 20. It is to be understood that straight or sloped walls for the silos 18 and 20 are within the scope and intent of the invention. Sloped walls are desirable to eliminate or reduce the possibilities of the mixture of materials bridging across the silo interior.
Rectangular shaped silos, square being one form, are most efficient for the top distributing mechanism and the bottom removal mechanism, however, it is to be understood that any other configuration is within the scope and intent of this invention.
Arrows in the conveying means 22, 24, and 26 as well as in other conveying means of materials, gases, and air subsequently described herein indicated the directional flow involved. Arrows to the first silo 18 indicate the flow of materials being composted, enters at the top, evenly layered as hereinbefore described, and moves downward. A similar downward movement occurs in second silo 20.
At the time when the first silo is full and the composting process is in operation, the passage of the mixture will take 14 days to move from the top to the bottom for removal. This time controlled movement is based on the depth of the layers put in each day at the top and the amount taken out at the bottom. A controlling factor is the height of the material in the first silo 18 through which air can be forced to facilitate the bacterial action. If too high the air cannot be forced through, if too low the temperature cannot be properly controlled on the interior and control over the composting process is lost. Ideally, a height of material, evenly distributed at each deposit time as hereinbefore described, is about 33 feet.
At 33 feet the air can be forced through the mixture and the temperature can be adequately controlled at specific levels. At top three feet of the material, the level where it has most recently been added, the controlled temperature range is 50° to 60° C. Below this three feet is a high temperature zone where the controlled temperature is 80° C., the depth of the high temperature zone is 10 feet. Below the high temperature zone is a controlled temperature of 40° C. that is 20 feet in depth. Thus a total of 33 feet.
Referring to FIG. 1, these three zones are designated as A, B, and C, respectively, with the temperatures shown for each. Air is forced in over the entire cross-sectional area.
The cited depths for each zone and the temperatures have been found to be the optimum arrangement for the time period provided. It is to be understood that a variation from these depths, temperatures, and time period, that in combination accomplishes an equivalent composting of the sludge mixture, is within the scope and intent of this invention.
In order to control the temperatures in the zones as indicated, thermocouples 56 are affixed in the interior of the first silo 18 at a plurality of levels, six levels are shown in FIG. 1. Thermocouples 56 are also affixed at these levels but at a plurality of different cross sectional points 58 to obtain a mattrix of temperature readings at each level in the mixture being composted. Two such cross sectional points 58 are illustrated in FIG. 1.
The thermocouples 56 at points 58 are connected to a plurality of temperature readout dials 60 at a suitable control station. Only one temperature readout dial 60 of the plurality is shown in FIG. 1 for purposes of clarity.
In addition to the thermocouples 56 in the mixture being composted, thermocouples 62 and 64 are also located in the exhaust duct area and the fresh air intake area, respectively, and connected to similar readout dials 60. With the temperature information from the readout dials 60, the temperatures in Zones A, B, and C can be controlled manually or programmed for automatic control.
In a like manner, the CO 2 content of the incoming fresh air 66, and of the exhausted gases 68 is transmitted to readout dials 70 at the control station. Only one CO 2 readout dial 70 is shown for clarity. With the CO 2 information the bacteria activity in the mixture being composted can be ascertained.
In a similar manner, the moisture content 72 of the incoming mixture to the moisture content 74 of the silo, the incoming air to the silo and of the composted mixture leaving the first silo 18 is measured the moisture content 76 transmitted to readout dials 78 at the control station. Only one readout dial 78 is shown for clarity. With the moisture content data the composting progress can be ascertained.
It is to be understood that other means of readout recording instead of the dials 60, 70, and 78 may be used, such as pen recording charts, multiple readings on a readout means, and other such arrangements are within the scope and intent of this invention.
As the composted material reaches the point where it is to be removed or retrieved, that is, at the bottom of first silo 18, it may be removed by various means. The present invention provides two alternatives. A single directional screw means and a dual directional screw means.
In FIG. 1 the dual directional screw means 80 is shown and in FIG. 4 the single directional screw means 82 is shown. The dual directional screw means 80 is best suited for huge first silos 18 where the transverse dimension is very large. The single directional screw means 82 is best suited for smaller first silos 18 where the transverse dimension is moderate, about half or less of what a huge first silo 18 might be.
The dual directional screw means 80 will be described first: Twin or dual directional screw means 80 with opposite (or left and right) advancing spiral blades, respectively, revolve so as to "cut off" and transport a layer of composted material; that has reached the bottom of first silo 18, from the outside wall area of first silo 18 toward the center line of the first silo 18. The inboard ends of the dual directional screw means 80 are shielded or covered by a center deflecting structure 84. As the dual directional screw means 80 transport the composted material toward the center the composted material is thereby dumped or deposited into and on to the discharge conveying means 86. The discharge conveying means 86 has hopper or elongated longitudinal funnel-like chutes for each screw means that lead to a longitudinal conveying means (shown but not individually numbered). The discharge conveying means 86 then transports the composted material deposited on it to an exterior point for further distribution as hereinafter described.
The single directional screw means 82 shown in FIG. 4 has but one screw means with the blades advancing in one direction which "cuts off" and transports a layer of composted material, that has reached the bottom of first silo 18, from one side wall to the opposite wall in accordance with the direction of the advancing blade. As the transported material reaches the end of the screw it is likewise dumped into a hopper or elongated longitudinal funnel-like chute that leads to a longitudinal conveying means 88 along one wall only. The longitudinal conveying means 88 then transports the composted material deposited on it to an exterior point for further distribution (as for the dual directional screw means 80) and as hereinafter described.
Both the dual directional screw means 80 and the single directional screw means 82 operate on a rack and pinion system. The rack and pinion means system 90 for the dual directional screw means 80 moves the screw means 80 along the bottom of the composted material in the first silo 18 to cut or shove off a layer of the composted material by the rack and pinion means 90. As the layer is cut off and transported away as perviously described the composted material above settles into the area where composted material was removed. As layers are cut out and removed, space is provided at the top for the next layer of material to be added. The amount of material removed is controlled, along with the amount then added at the top to maintain the 14 day cycle of passage through the first silo 18.
In FIG. 4 the rack 92 and the pinion 94 on each side of the screw means 82 operates for the single directional screw means 82 in the same manner as the rack and pinion system 90 operates for the dual directional screw means 80. Both systems are operated by power means, the arrangement can be partially seen in FIG. 4, to cause the screw means 80 and 82 to move longitudinally along side rails 96 as seen in FIG. 4.
As noted previously, air is forced up through the mixture mass in the first silo 18 to activate the composting process. The system is shown in FIG. 1 where the air intake system 98 brings in fresh air at inlet 100, sends it through a heat exchanger 102 for preheating, then through a manifold means 104 for discharge through a bed of gravel or stone-like material 106 and thence upward, through the mixture being composted, over the entire area, over the entire area.
As the gases 108 are exhausted by exhaust means 110, the heated gas is piped down through the heat exchanger 102 to heat incoming air. It is to be noted that some of the gases have combustible qualities and may be used for heating purposes as well.
Several alternatives exist for disposing of the exhaust gases after passing through the heat exchanger 102. A portion can be mixed with fresh air and used to force air through the second silo 20, in the same arrangement as described for the first silo 18. A portion can be shunted 112 through piles of composted material that may be in storage to absorb odors or be mixed with fresh air or shunted through aeration tanks 114 to remove odors, either means serving as a filter. Or a portion can be shunted through charcoal filters 116 to remove odors before being exhausted to atmosphere.
As the composted material is removed by the discharge conveying means 86 and 88 it may be moved in two directions. It may be discharged through a hopper means 118 in bulk directly to transport means 120, such as highway trucks, rail cars, and the like for direct transport to areas such as farms. It is to be noted that at this point some odor is still involved and the bulk handling disposal must take this into consideration. Or, the composted material may be transported via conveyor means 122 to the second silo means 20.
In silo means 20 the principle operation is to remove the remaining odor, dry the material and prepare it for shipping, either in bulk or by bagging.
The operation of silo means 20 and time of passage therethrough is exactly like silo means 18, except that the plurality of thermocouples 56 is not as extensive. The details are not shown for silo means 20, but the arrangement is similar and an additional air supply may be received from the air intake system 98.
As the air passes through the composted material in silo means 20 it is essentially a slow cure. As it is discharged from the silo means 20 it may be shipped in bulk 124 or transported to a bagging station 126 for bagging or otherwise containerizing the composted material for shipment.
Regarding the control of the temperature, the temperature, based on the data received at temperature dials 60, is maintained by varying the air volume and pressure as dictated by the recorded temperatures, carbon dioxide, and moisture content, the latter two based on CO 2 dials 70 and moisture content dials 78 respectively.
The mix of the sludge and the composting agent must be adjusted so that the resulting mix has a 30 to 1 carbon-nitrogen ratio.
The CO 2 concentration as monitored on the CO 2 readout dials 70 is an indication of microbe activity, it is recorded and monitored carefully in the exhaust as hereinbefore described.
It is to be noted that the air to be passed through the composting mass is not a steady blowing of air. It may be intermittent, based on monitoring of both the CO 2 level and the temperature recordings. Manifold means 104 covers the entire area.
It is to be understood that more than one traveling type carrier distributor 28 with a superimposed conveyor means 30 may be used on the rails 38 when a plurality of adjacent silo means 18 or 20 are used. Also, it is to be understood that more than one dual directional screw means 80 or single directional screw means 82 may be used on the same side rails when operating under a plurality of adjacent silo means 18 or 20. Such variations are within the scope and intent of the present invention.
FIG. 2 represents in chart form the process of controlled composting of sludge as hereinbefore described.
As can be readily understood from the foregoing description of the invention, the present structure can be configured in different modes to provide the ability to compost sludge.
Accordingly, modifications and variations to which the invention is susceptible may be practiced without departing from the scope and intent of the appended claims. | The invention is a method for composting sludge to a useable state. The method of the system eliminates the usual objectionable odors. The method consists of a thorough mixing of the sludge with carbonaceous material, layering the mixture in a silo and moving it through the silo on a timed interval basis, forcing air through the mixture in the silo to promote the composting action by an aerobic bacteria process, periodically withdrawing the treated material in a manner compatible with the timed interval basis, further layering the composted material in a second silo having a forced air means to complete the treatment process, and withdrawing the final treated material for packaged or for bulk distribution to users. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of gas valves. More specifically the present invention relates to the field of gas valves that are commonly used in homes and control the flow of gas to standard cooking appliances.
BACKGROUND OF THE INVENTION
[0002] Modernly, it is common practice among suppliers of stoves for commercial and home use to provide the cooking unit with a safety shutoff system that uses a thermoelectric solenoid that interrupts the flow of flammable gas when the flame has been extinguished. This gas valve is common in the industry, and is very user friendly in its operation. The user presses the control knob in, which overrides the solenoid spring allowing the gas to flow to the burner, at which time the flammable gas is ignited causing an emf current flow that energizes the solenoid, and keeps the gas supply flowing. When the flame is extinguished, the current stops, and the solenoid de-energizes, cutting off the flow of flammable gas.
[0003] The current designs of gas valves force the flammable gas to flow from the rear of the valve towards the front of the valve, which has the consequence of lengthening the control know, and therefore the offset to the front of the appliance.
[0004] Another well-known shortcoming of these valves, hereinafter known as standard valves, is that they are frequently awkward to install, because of the locating dimensions of the inlet and the exhaust. In commonly known constructions, either the distance from the gas-conducting valve assembly tube to the front plate of an appliance is relatively large or these constructions are built relatively high.
DESCRIPTION OF THE PRIOR ART
[0005] U.S. Pat. No. 6,234,189 B1 by Koch, discloses a “Gas Valve with Thermoelectric Safety Shutoff”. The standard construction is disclosed and described. The major difference is that the inlet, and inlet attach features are towards the rear of the gas valve, and the exhaust is more towards the front (bottom located) of the gas valve. Although the basic design is similar, the resultant size of the valve is increased. Additionally and more specifically, the flow of the flammable gas of the described patent is reversed from the present invention.
OBJECTS OF THE INVENTION
[0006] It is a present object of the invention to provide an improved gas valve the overcomes the existing disadvantages of the current designs, by shortening the distance from the inlet to the front of the appliance, therefore shrinking the overall size of the appliance.
SUMMARY OF THE INVENTION
[0007] The following description is provided to enable a person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor for carrying out his invention. Various modifications, however, will be readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide for an improved adjustable gas pressure regulator.
[0008] The task is to construct a gas valve incorporating thermoelectric security device, in which both of the previously described large locating dimensions must be reduced.
[0009] The standard valves have the inlet, and hence the gas flowing from the area of the thermoelectric security device, which has a magnetic insert (solenoid) that is open when the flame is ignited. When the valve is open, the gas flows axially into the valve plug, through the valve plug, and then through either a hole drilled at a 90° angle to the valve plug or a slot. The gas will then flow into the outlet of the valve. The outlet, or exhaust directs the gas to flow into a gas line and then to a burner attached to the cooking appliance.
[0010] The present invention reverses the inlet and outlet and hence the direction of the gas flow through the gas valve. The gas flow path then enters the inlet of the valve and is directed into the valve plug and when the magnet valve (or solenoid) is in the open position, the gas passes through the axially located hole in the valve plug through the valve plug, and then through the gas outlet of the valve body.
DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 a shows a standard construction, where the gas valve is in the closed position.
[0012] [0012]FIG. 1 b shows the same valve as described in FIG. 1 a in its open position.
[0013] [0013]FIG. 2 shows a gas valve in which the distance from gas inlet of the valve to the valve plate is small, but the installation height is relatively large. FIG. 2 a shows a valve in the closed position, while FIG. 2 b shows the same valve in the open position.
[0014] [0014]FIG. 3 shows the new development of a gas valve. FIG. 3 a shows an open position, FIG. 3 b shows a closed position
DETAILED DESCRIPTION
[0015] With respect to FIG. 3, the gas valve body ( 1 ) is shown being provided with a gas inlet ( 10 ) and a gas outlet ( 16 ). The in flowing gas flow is restricted by the mantle surface ( 17 a ) of the valve plug ( 17 ). The gas valve body ( 1 ) is connected to the gas conducting gas supply tube ( 4 ), with elastic washers ( 7 , 9 ), and held in place by a screw ( 5 ) that is firmly threaded into the gas inlet ( 10 ) of the gas valve body ( 1 ). FIG. 3 a shows the gas valve assembly ( 100 ) in a closed position.
[0016] The gas valve body ( 1 ) has a receiver hole ( 102 ) bored into the gas valve body ( 1 ) for the magnet insert ( 13 ). The receiver hole ( 102 ) communicates with the gas outlet ( 16 ). The magnet insert ( 13 ) has a pressure spring ( 14 ) which biases a valve disk ( 12 ) against a valve seat ( 11 ) located in the gas valve body ( 1 ). The valve disk ( 12 ) is slidably mounted on a spindle ( 24 ). The gas valve plug ( 17 ) has an axial spindle ( 18 ) that is mounted in the gas valve plug ( 17 ). The spindle ( 18 ) is assembled with a pressure plate ( 20 ) that contains an O-ring( 19 ). The O-ring ( 19 ) seals against the inner offset hole ( 19 a ) of the gas valve plug ( 17 ), preventing leakage of gas through the inner offset hole ( 19 a ). The axial spindle ( 18 ) is generally connected to the valve spindle ( 23 ) on the opposite side. A pressure plate ( 20 ) is biased against the O-ring ( 19 ), by a pressure spring ( 21 ), thereby making a gas-tight seal in the valve plug ( 17 ). The pressure spring ( 21 ) is assembled between the pressure plate ( 20 ) and the valve spindle ( 23 ). The magnetic insert ( 13 ), the pressure spring ( 14 ), and the valve disk ( 12 ) comprise a magnetic solenoid, common in the art. The solenoid is energized by current generated by the heat of combustion of the flammable gas (thermocurrent).
[0017] The valve spindle ( 23 ) is assembled with a driver pin ( 22 ) that drives the valve plug ( 17 ). The valve plug ( 17 ) is provided with a slot ( 31 ). When the slot ( 31 ) is rotated from the closed position to the open position, the gas inlet ( 10 ) will communicate with the slot ( 31 ) allowing the gas to pass through. This driver pin ( 22 ), in turn, meshes with an indentation ( 22 a ) of the valve flange ( 32 ) and thus prevents gas entering the gas valve plug ( 17 ) unless a gas valve knob ( 3 ) is axially pressed in at the same time the gas valve plug ( 17 ) is rotated to an orientation where the gas can enter. The activation is both axial and as provided by the indentation in the valve flange ( 32 ) and is activated by the gas valve knob ( 3 ) that is attached to the valve spindle ( 23 ) located in front of the front plate of the cooking appliance.
[0018] If the valve plate ( 24 ) is opened by pressing in the gas valve knob ( 3 ), the gas still cannot flow through the valve seat ( 11 ), if the gas valve knob ( 3 ) is not also rotated, since the gas valve plug ( 17 ) still remains in a closed position, orientated away from a gas inlet hole ( 25 ). The gas inlet hole ( 25 ) is bored at 90° to the central axis of the gas valve body ( 1 ). Only after simultaneous pushing in and rotating of the valve spindle ( 23 ) by means of the gas valve knob ( 3 ), can gas flow through the gas valve assembly ( 100 ) as shown in FIG. 3 b.
[0019] The valve spindle ( 23 ) is held in an open position by turning the valve plug ( 17 ) in conjunction with a driver pin ( 22 ), provided that the thermocouple (not shown) which is mounted in the hole ( 15 ) of the assembly nut ( 33 ) has generated sufficient thermocurrent to hold the magnet ( 13 ) (solenoid) in an open (energized) position. Only after an interval of about 5 seconds can the gas valve knob ( 3 ) be released and the valve plate ( 24 ) of the magnet insert remain in the open position.
[0020] If the flame of the burner goes out and the thermocouple cools off, the conduction of thermocurrent is interrupted, and the valve plate ( 24 ) in the magnet insert ( 13 ) is pressed against the seat ( 11 ) of the gas valve body ( 1 ) by the pressure spring ( 14 ), so that despite the open position of the valve plug ( 17 ), no additional gas can penetrate through to the gas valve outlet ( 15 ), even though the gas valve knob ( 3 ) still indicates that the gas valve assembly ( 100 ) is in an open position. | This invention reveals an improved gas valve with a thermoelectric security device that has a shortened distance from the gas inlet to the front of an appliance, enabling the overall size of the appliance to be smaller than normal for this type of device.
The current invention achieves this goal by reversing the gas inlet and outlet and hence the gas flow through the gas valve. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. Ser. No. 11/858,921 filed on Sep. 21, 2007, now U.S. Pat. No. 7,556,730, and claims priority benefits to Chinese Patent Application No. 200610062687.7, filed on Sep. 21, 2006. The contents of all of these specifications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field biochemical engineering, and particularly to a method for cleaning a reclaimed water reuse device.
2. Description of the Related Art
The most frequently used methods of physical cleaning include backwash and aeration. These methods need to be performed frequently and thus may influence the filtering process. During backwash, permeation through the membrane is stopped momentarily. Air or water flows through the membranes in a reverse direction to physically dislodge solids off of the membranes. During aeration, bubbles are produced in the tank water below the membranes. As the bubbles rise, they agitate or scrub the membranes and thereby dislodge some solids while creating an air lift effect and circulation of the tank water to carry the solids away from the membranes. The physical cleaning requires a large amount of aeration and energy, long cleaning time, and features comparatively poor cleaning quality.
Chemical cleaning is typically performed by removing membrane modules from the MBRs, and then immersing the membrane modules into a chemical solution. The chemical cleaning process may be complex and time-consuming.
SUMMARY OF THE INVENTION
In view of the above-described problems, it is one objective of the invention to provide a method for cleaning a reclaimed water reuse device that is simple, effective, and features good cleaning quality.
To achieve the above objective, in accordance with one aspect of the present invention, there is provided a method for cleaning a reclaimed water reuse device of the invention comprising: (a) detecting an operating signal of the clean water supply device, (b) enabling the first aeration device or the backwash device according to the operating signal, so as to perform backwash on the membrane module, and (c) completing the wash back and restoring to a normal operating state.
In certain classes of this embodiment, the reclaimed water reuse device further comprises a contaminated-soil backflow device, a second aeration device and a control module.
In certain classes of this embodiment, the method for cleaning a reclaimed water reuse device further comprises setting a timing period and enabling the contaminated-soil backflow device when the timing period is up.
In certain classes of this embodiment, the step of setting a timing period and enabling the contaminated-soil backflow device as the timing period is up comprises (a) starting and entering an operating state by the reclaimed water reuse device, (b) setting the timing period, and (c) alternately enabling the contaminated-soil backflow device and the first aeration device and the second aeration device.
In certain classes of this embodiment, clean water supply device comprises a clean water supply pipe, a self-priming pump, an electromagnetic valve, and a pressure gauge.
In certain classes of this embodiment, the step of enabling the first aeration device or the backwash device according to the operating signal, so as to perform backwash on the membrane module comprises (a) setting a pressure threshold and a frequency threshold; (b) receiving a pressure signal from the pressure gauge by the control module, the pressure signal indicating a self-priming pressure of the self-priming pump; (c) comparing the pressure threshold with the self-priming pressure; and (d) if the self-priming pressure exceeds the pressure threshold, detecting whether the frequency at which the self-priming pressure of the self-priming pump exceeds the pressure threshold is greater than the frequency threshold.
In certain classes of this embodiment, the step of enabling the first aeration device or the backwash device according to the operating signal, so as to perform backwash on the membrane module further comprises (a) if the frequency at which the self-priming pressure of the self-priming pump exceeds the pressure threshold is greater than the frequency threshold, performing chemical backwash of the membrane module, and (b) if the frequency at which the self-priming pressure of the self-priming pump exceeds the pressure threshold is less than the frequency threshold, enabling the first aeration device and the backwash device to perform physical backwash of the membrane module.
Advantages of the invention include:
(a) cleaning and regeneration of the membrane module in the membrane filtering pool can be accomplished without removing the membrane module from the membrane filtering pool, which greatly simplifies an operating process;
(b) while the membrane module is cleaned and regenerated, the activity in the biological reaction tank will not be affected (namely, a seamless operation between cleaning and normal operation is implemented), and the MBR can be restored to normal operation in a relatively short amount time;
(c) since the invention integrates the first aeration device with the backwash device, it is easy to apply physical (aeration) backwash, chemical backwash, or a combination thereof, to facilitate complete cleaning, and to regenerate the membrane module to a great extent; therefore, the invention features simple operation and good cleaning efficiency;
(d) space separated by the separating plate forms a membrane filtering pool, which makes it applicable to all types of water processing systems such as normal active contaminated-soil processing device, oxidation ditch processing device, contact oxidation processing device, and so on, in a cost-effective and simple manner;
(e) the contaminated-soil backflow device is connected to the inlet-drainage device, so that the high concentration contaminated soil in the membrane filtering pool is able to flow back, which reduces the concentration of the contaminated soil, mitigates pollution of the membrane module caused by the high concentration of contaminated soil, and further improves applicability and reliability of the invention; and lastly
(f) the control module controls operating states of all devices, and thus facilitates automation of operation and standardization or MBR devices, improves operation efficiency, and makes the invention applicable to large-scale production.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described hereinafter with reference to accompanying drawings, in which:
FIG. 1 is a schematic diagram of a reclaimed water reuse device according to one embodiment the invention;
FIG. 2 is a block diagram of a reclaimed water reuse device according to one embodiment of the invention;
FIG. 3 is a partial enlarged view of grooves at the top of the separating plate 5 ;
FIG. 4 is a high-level flowchart diagram illustrating a method for cleaning of a reclaimed water reuse device according to one embodiment of the invention; and
FIG. 5 is a detailed flowchart diagram illustrating a method for cleaning of a reclaimed water reuse device according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Detailed description will be given below in conjunction with accompany drawings.
As shown in FIGS. 1 and 2 , a reclaimed water reuse device of the invention comprises a biological reaction tank 1 , a membrane module 2 , a water pool 3 , a membrane filtering pool 4 , a control module 6 , an inlet-drainage device 11 , a clean water supply device 21 , an outlet device 31 , a first aeration device 22 , a second aeration device 12 , a backwash device 23 , and a contaminated-soil backflow device 41 .
The membrane module 2 is disposed in the membrane filtering pool 4 .
A separating plate 5 is disposed in the biological reaction tank 1 , and separates the membrane filtering pool 4 from the biological reaction tank 1 . Water in the biological reaction tank 1 overflows a top of the separating plate 5 and pours into the membrane filtering pool 4 . The ratio between the volume of the biological reaction tank 1 and that of the membrane filtering pool 4 is between 1:1 and 10:1, and more particularly, the ratio is 3:1.
A groove 51 is disposed at the top of the separating plate 5 . In this embodiment, the groove 51 is tooth-shaped.
The inlet-drainage device 11 comprises an inlet pipe 111 , a drainage pipe 112 , and a plurality of electromagnetic valves M 0 and M 1 . The electromagnetic valve M 0 is disposed in the inlet pipe 111 , and the electromagnetic valve M 1 is disposed in the drainage pipe 112 .
The outlet device 31 drains water from the water pool 3 . The outlet device 31 comprises an outlet pipe 311 , a clean water pump 312 , and an electromagnetic valve M 9 . The clean water pump 312 and the electromagnetic valve M 9 are attached to the outlet pipe 311 .
The clean water supply device 21 comprises a clean water supply pipe 211 , a self-priming pump 212 , an electromagnetic valve M 8 , a manual valve H 8 , and a pressure gauge P. The clean water supply pipe 211 connects the water pool 3 to the membrane module 2 . The self-priming pump 212 , the electromagnetic valve M 8 , the manual valve H 8 , and the pressure gauge P are connected to the clean water supply pipe 211 and disposed between the membrane module 2 and the water pool 3 . The pressure gauge P detects self-priming pressure of the self-priming pump 212 , and transfers the pressure signal to the control module 6 .
The first aeration device 22 aerates the membrane module 2 , and comprises a first aeration pipe 221 , an electromagnetic valve M 5 and a manual valve H 5 . The electromagnetic valve M 5 and the manual valve H 5 are connected to the first aeration pipe 221 . The first aeration pipe 221 extends to the bottom of the membrane module 2 .
The second aeration device 12 aerates the biological reaction tank 1 , and comprises a second aeration pipe 121 , an electromagnetic valve M 3 and a manual valve H 3 . The electromagnetic valve M 3 and the manual valve H 3 are connected to the second aeration pipe 121 . The second aeration pipe 121 extends to the bottom of the biological reaction tank 1 .
The aeration pipe 221 and the second aeration pipe 121 have a common entrance.
The backwash device 23 washes back the membrane filtering pool 4 and connects the outlet device 31 to the membrane module 2 .
The backwash device 23 comprises a backwash pipe 231 , a first backwash supporting pipe 232 , a second backwash supporting pipe 233 , electromagnetic valves M 6 and M 7 , and a manual valve H 6 .
One end of the backwash pipe 231 is connected to the outlet pipe 311 , and the other end of the backwash pipe 231 is a common end of the first backwash supporting pipe 232 and the second backwash supporting pipe 233 . The first backwash supporting pipe 232 is, at its other end, disposed in the membrane filtering pool 4 . The second backwash supporting pipe 233 and the clean water supply pipe 211 are connected to the membrane module 2
The electromagnetic valve M 6 is connected to the first backwash supporting pipe 232 , and the electromagnetic valve M 7 is connected to the second backwash supporting pipe 233 .
The contaminated-soil backflow device 41 is disposed in the membrane filtering pool 4 , and is connected to the inlet-drainage device 11 and the biological reaction tank 1 .
The contaminated-soil backflow device 41 comprises a backflow pipe 411 , a first backflow supporting pipe 412 , a second backflow supporting pipe 413 , a backflow pump 414 , and electromagnetic valves M 2 and M 4 .
The backflow pump 414 is disposed at the bottom of the membrane filtering pool 4 , and connected to one end of the backflow pipe 411 . The other end of the backflow pipe 411 is a common end of the first backflow supporting pipe 412 and the second backflow supporting pipe 413 . The first backflow supporting pipe 412 terminates at the top of the biological reaction tank 1 , and the second backflow supporting pipe 413 is connected to the outlet pipe 112 .
The electromagnetic valve M 4 is connected to the first backflow supporting pipe 412 , and the electromagnetic valve M 2 is connected to the second backflow supporting pipe 413 .
As shown in FIG. 2 , the control module 6 controls operation of the inlet-drainage device 11 , the clean water supply device 21 , the outlet device 31 , the first aeration device 22 , the backwash device 23 , the contaminated-soil backflow device 41 , and the clean water supply device 21 according to preset data and/or signal received from the clean water supply device 21 . The preset data comprises a timing period T 0 , a delay time T 1 , a pressure threshold F 1 , a frequency threshold f 1 , and so on. The operating signal of the clean water supply device 21 comprises a pressure signal of the pressure gauge P, etc. Based on the pressure signal, the control module 6 detects the operating state of the membrane module 2 , and correspondingly performs physical or chemical backwash of the membrane module 2 .
Referring to FIG. 2 , the control module 6 directly controls operating states of the electromagnetic valves M 0 . . . M 9 , the self-priming pump 212 , the clean water pump 312 , and the backflow pump 414 .
As the reclaimed water reuse device of the invention is in a normal operating state, the backflow pump 414 , the self-priming pump 212 , the clean water pump 312 , and the electromagnetic valves M 4 , M 3 , M 5 , M 8 and M 9 are enabled; the other valves are disabled. Manual valves H 3 , H 5 and H 6 may be manually adjusted to change gas flux and water flux. During normal operation, contaminated water flows in via the inlet pipe 111 , after biological processing and being filtered by the membrane module 2 in the membrane filtering pool 4 , clean water is generated.
As shown in FIG. 4 , a method for cleaning a reclaimed water reuse device comprises the following steps:
i. The reclaimed water reuse device is enabled, and enters a normal operating state; ii. A timing period T 0 is set, and saved in the control module 6 ; iii. As the timing period T 0 is up, the reclaimed water reuse device is disabled; after a delay time T 1 , the control module 6 enables the contaminated-soil backflow device 41 , so that contaminated soil deposited at the bottom of the membrane filtering pool 4 flows back to a front portion of the biological reaction tank 1 ; iv. The control module 6 detects an operating signal of the clean water supply device 21 , and enables the first aeration device 22 or/and the backwash device 23 according to the operating signal, so as to perform physical or chemical backwash of the membrane module 2 ; and v. After the backwash is completed, the reclaimed water reuse device restores to a normal operating state under the control of the control module 6 , and the process returns to step iii.
As shown in FIG. 5 , a detailed method for cleaning a reclaimed water reuse device comprises the following steps:
1. The reclaimed water reuse device is enabled, and enters a normal operating state; 2. A timing period T 0 is set, and saved in the control module 6 ; 3. The control module 6 detects whether the timing period is up, if the timing period is not up, the process proceeds to step 4, otherwise the process proceeds to step 9; 4. If the timing period is up, the control module 6 detects whether contaminated-soil backflow is enabled. In this embodiment, the control module 6 detects whether contaminated-soil backflow is enabled by checking the signal from the backwash pump 414 , or an operating history saved in the control module 6 . If the contaminated-soil backflow is enabled, the process proceeds to step 5, otherwise the process proceeds to step 6; 5. After a deposit time T 1 , the control module 6 stops the contaminated-soil backflow and starts aeration. In this embodiment, the control module 6 switches on the electromagnetic valve M 5 in the first aeration device 22 and the electromagnetic valve M 3 in the second aeration device 12 , so that gas is led to the bottom of the membrane module 2 and the biological reaction tank 1 via the first aeration pipe 221 and the second aeration pipe 121 , respectively; 6. The control module 6 detects whether aeration is enabled. In this embodiment, the control module 6 detects whether aeration is enabled by checking states of the electromagnetic valve M 5 and the electromagnetic valve M 3 . If the aeration is enabled, the process proceeds to step 7, otherwise the process proceeds to step 8; 7. The control module 6 stops the aeration, and enables the contaminated-soil backflow after the deposit time T 1 ; 8. The control module 6 enables the contaminated-soil backflow after the deposit time T 1 ; 9. The control module 6 sets a pressure threshold F 1 and a frequency threshold f 1 . In this embodiment, the pressure threshold F 1 is between +0.04 and −0.04 MPa with respect to the standard pressure of 760 mmHg (101,325 Pa). 10. The control module 6 receives a pressure signal from the pressure gauge P, the pressure gauge indicating self-priming pressure of the self-priming pump 212 ; 11. The control module 6 detects whether the self-priming pressure is greater than the pressure threshold F 1 . If the self-priming pressure is greater than the pressure threshold F 1 , the process proceeds to step 12, otherwise the process returns to step 3; 12. The control module 6 detects whether a frequency at which the self-priming pressure of the self-priming pump 212 exceeds the pressure threshold F 1 is greater than the frequency threshold f 1 . If the frequency at which the self-priming pressure of the self-priming pump 212 exceeds the pressure threshold F 1 is greater than the frequency threshold f 1 , the process proceeds to step 13, otherwise the process proceeds to step 14. In this embodiment, the frequency at which the self-priming pressure of the self-priming pump 212 exceeds the pressure threshold F 1 is equal to 1/(the amount of time the self-priming pressure of the self-priming pump 212 exceeds the pressure threshold F 1 during this time interval−the amount of time the self-priming pressure of the self-priming pump 212 exceeds the pressure threshold F 1 during the immediately preceding time interval); 13. the control module 6 exits the normal operating state, and performs chemical backwash on the membrane module 2 ; 14. The control module 6 exits the normal operating state, and enables the first aeration device 22 and the backwash device 23 , so as to perform physical backwash on the membrane module 2 ; and 15. Under the control of the control module 6 , the reclaimed water reuse device is restored to its normal operating state, and then the process returns to step 3.
The above steps 4-7 alternately enable contaminated-soil backflow and aeration. The above steps 10-14 implement combination of the physical backwash and the chemical backwash. The membrane module 2 is not required to be taken out of the membrane filtering pool 4 for cleaning. All of this contributes to a good cleaning efficiency.
A detailed process of the physical backwash is as follows: the control module 6 enables the electromagnetic valves M 5 and M 7 and the clean water pump 312 , the clean water pump 312 pours filtered water into a membrane tube and a membrane hole in the membrane module 2 , so as to perform backwash thereon. Meanwhile, blowing aeration is performed at the bottom of the membrane module 2 , and contaminant deposited on an upper surface of the membrane module 2 is cleaned. The entire process lasts for 2-10 minutes.
A detailed process of the chemical backwash is as follows: cleaning chemical agent such as acid, alkali, oxidant (sodium hypochlorite) and so on is added to the water pool 3 , and let the biological reaction tank 1 and the membrane filtering pool 4 stands for 5-15 minutes. In this embodiment, the soaking time is 10 minutes. The control module 6 enables the electromagnetic valve M 1 to drain clean water from the upper portion of the biological reaction tank 1 . And then disables the electromagnetic valve M 1 .
The control module 6 enables the contaminated-soil backflow pump 414 and the electromagnetic valve M 4 , so that active contaminated soil in the membrane filtering pool 4 flows back to the biological reaction tank 1 .
The control module 6 disables the electromagnetic valve M 4 and enables the electromagnetic valve M 2 after the backflow is completed, so as to discharge clean water in the upper portion of the membrane filtering pool 4 to outside via the contaminated-soil backflow pump 414 .
The control module 6 disables the contaminated-soil backflow pump 414 after the membrane filtering pool 4 is evacuated.
The control module 6 enables the clean water pump 312 and the electromagnetic valve M 6 , and allows the cleaning chemical agent to flow into the membrane filtering pool 4 , so as to immerse the membrane module 2 .
The control module 6 disables the electromagnetic valve M 6 after the cleaning chemical agent immerses the membrane module 2 , enables the electromagnetic valves M 5 and M 7 , and performs chemical backwash on the membrane module 2 . Meanwhile, a membrane surface is scrubbed via aeration.
The control module 6 disables the electromagnetic valves M 5 and M 7 and the clean water pump 312 , enables the contaminated-soil backflow pump 414 and the electromagnetic valve M 2 , so as to evacuate the cleaning chemical agent in the membrane filtering pool 4 , and then disables the contaminated-soil backflow pump 414 and the electromagnetic valve M 2 .
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A method for cleaning a reclaimed water reuse device, the reclaimed water reuse device comprising a clean water supply device, a first aeration device, a backwash device and a membrane module, the method comprising detecting an operating signal of the clean water supply device; enabling the first aeration device or the backwash device according to the operating signal, so as to perform backwash of the membrane module; and completing washing back and restoring to a normal operating state. | 2 |
CLAIM OF PRIORITY
[0001] This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application entitled PLASMA DISPLAY PANEL filed with the Korean Industrial Property Office on 17 Dec. 2002 and there duly assigned Serial No. 2002-0080804, and an application entitled PLASMA DISPLAY PANEL filed with the Korean Industrial Property Office on Jan. 15, 2003 and there duly assigned Serial No. 2003-0002682.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to a plasma display panel and, more particularly, to barrier ribs of a plasma display panel.
[0004] 2. Related Art
[0005] A plasma display panel (PDP) typically includes barrier ribs that define discharge cells. The two main types of barrier ribs are closed barrier ribs and open barrier ribs. The open barrier ribs are generally formed in a stripe configuration. Since discharge cells formed between such stripe-type barrier ribs are in communication (i.e., the discharge cells between each pair of adjacent barrier ribs are in communication), exhaust of the PDP and sealing of discharge gas within the PDP are relatively easily performed during manufacture.
[0006] With the closed barrier ribs, on the other hand, the discharge cells are not in communication. That is, the barrier ribs are formed into individual units having a quadrilateral, hexagonal, or other shape. With the closed barrier ribs, the discharge cells are separately formed for each pixel, and phosphor material is formed over all inner surfaces of barrier ribs that form each pixel.
[0007] In the first PDPs that utilized such closed barrier ribs, a gap formed between a distal end of the barrier ribs and the substrate opposing the substrate on which the barrier ribs are formed was used as an exhaust path. The gap was formed by adjusting the height of the barrier ribs or by forming depressions at predetermined locations of distal end areas of the barrier ribs. However, because of the minimal size of the gap, the resulting exhaust resistance necessitated the use of a significant amount of time to exhaust the PDP. This reduced overall manufacturing efficiency.
[0008] Various configurations have been disclosed to overcome these problems. For example, Japanese Laid-Open Patent No. Heisei 4-274141 discloses a structure in which open stripe-type barrier ribs and closed lattice-type barrier ribs are combined to reduce exhaust resistance. However, with such a combinational structure, the process of forming each barrier rib on the substrate during PDP manufacture is complicated. With this structure, productivity is reduced to such an extent that mass production is made difficult.
[0009] Japanese Laid-Open Patent No. Heisei 2002-83545 discloses a PDP in which closed barrier ribs are formed using a material that has a heat shrink property. The barrier ribs are formed having areas of lesser height that function as exhaust paths to thereby form a mesh-type structure of the exhaust paths. Although it is claimed that such a barrier rib structure reduces exhaust resistance during the exhaust process, in practice, there is a limited number of paths through which exhaust may occur as a result of the mesh configuration. This may result in insufficient exhaust of the PDP.
SUMMARY OF THE INVENTION
[0010] The present invention provides a plasma display panel including barrier ribs that maximize exhaust efficiency.
[0011] More particularly, the present invention provides a plasma display panel including barrier ribs that enable improvements in brightness through the efficient use of discharge cells.
[0012] In one embodiment, the present invention provides a plasma display panel including a first substrate, a second substrate mounted opposing the first substrate with a predetermined gap therebetween to thereby form a vacuum assembly, and barrier ribs formed between the first substrate and the second substrate, the barrier ribs defining discharge cells. Radial exhaust paths are formed in the barrier ribs for each of the discharge cells.
[0013] The discharge cells are formed in a closed configuration by the barrier ribs, and the discharge cells are arranged in a lattice pattern or a delta pattern.
[0014] In another embodiment, the present invention is a plasma display panel including a first substrate, a second substrate mounted opposing the first substrate with a predetermined gap therebetween to thereby form a vacuum assembly, and barrier ribs formed on the second substrate and extending a predetermined distance in a direction toward the first substrate, the barrier ribs defining discharge cells. A plan view of the barrier ribs is such that, if imaginary lines are formed bisecting distal end surfaces of the barrier ribs, the imaginary lines form a plurality of multilateral shapes that encompass each of the discharge cells to thereby form the discharge cells into the multilateral shapes. Also, if a radius of a first inscribed circle drawn in areas of the barrier ribs corresponding to corner portions of the multilateral shapes of the discharge cells is R, and a radius of a second inscribed circle drawn in areas corresponding to predetermined points between the corner portions of the multilateral shapes of the discharge cells is r, the following condition is satisfied:
R>r.
[0015] Alternatively, the barrier ribs may be formed so as to satisfy the following condition:
R>2r.
[0016] The barrier ribs are made of a material that has a heat shrink property, and widths of the distal end surfaces of the barrier ribs vary, in a continuous manner or in stages, along a direction in which the barrier ribs are formed.
[0017] Further, exhaust paths are formed in the barrier ribs such that one of the exhaust paths is formed in areas of the barrier ribs corresponding to each side of the multilateral discharge cells. The exhaust paths are formed in the distal ends of the barrier ribs.
[0018] The plasma display panel further includes sub exhaust paths formed in areas of the barrier ribs where corner portions of the multilateral shapes of the discharge cells converge. The sub exhaust paths are realized by exhaust grooves formed in the barrier ribs.
[0019] In another embodiment, the present invention is a plasma display panel including a first substrate, a second substrate mounted opposing the first substrate with a predetermined gap therebetween to thereby form a vacuum assembly, and barrier ribs formed on the second substrate and extending a predetermined distance in a direction toward the first substrate, the barrier ribs defining discharge cells. A plan view of the barrier ribs is such that, if imaginary lines are formed bisecting distal end surfaces of the barrier ribs, the imaginary lines form a plurality of multilateral shapes that encompass each of the discharge cells to thereby form the discharge cells into the multilateral shapes.
[0020] Also, the height of the barrier ribs, measured from where they are formed on the second substrate to the distal end of the same, is greater at areas corresponding to corner portions of the multilateral shapes of the discharge cells than at areas between the corner portions of the multilateral shapes of the discharge cells.
[0021] The height of the barrier ribs is at a maximum at areas corresponding to the corner portions of the multilateral shapes of the discharge cells, and the height of the barrier ribs is at a minimum at predetermined points between the corner portions of the multilateral shapes of the discharge cells.
[0022] A width of the distal ends of the barrier ribs at areas corresponding to the corner portions of the multilateral shapes of the discharge cells is greater than the width of the distal ends of the barrier ribs at areas between the corner portions of the multilateral shapes of the discharge cells.
[0023] Further, the heights of the barrier ribs vary in a continuous manner starting from where the heights are maximum and decreasing until reaching the minimum heights.
[0024] The present invention is more specifically described in the following paragraphs by reference to the drawings attached only by way of example. Other advantages and features will become apparent from following description and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
[0026] [0026]FIG. 1 is a partial exploded perspective view of a plasma display panel according to a first embodiment of the present invention;
[0027] [0027]FIG. 2 is a plan view showing a structure of barrier ribs of FIG. 1;
[0028] [0028]FIGS. 3A and 3B are sectional views taken along lines A-A and B-B of FIG. 2;
[0029] [0029]FIG. 4 is a plan view showing a structure of barrier ribs according to a second embodiment of the present invention;
[0030] [0030]FIGS. 5, 6, and 7 are plan views showing a structure of barrier ribs according to a third embodiment of the present invention;
[0031] [0031]FIG. 8 is a partial exploded perspective view of a plasma display panel according to a fourth embodiment of the present invention;
[0032] [0032]FIG. 9 is an enlarged perspective view of a sub exhaust path of FIG. 8; and
[0033] [0033]FIG. 10 is a partial plan view of a plasma display panel according to a fifth embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[0035] [0035]FIG. 1 is a partial exploded perspective view of a plasma display panel according to a first embodiment of the present invention, FIG. 2 is a plan view showing a structure of barrier ribs of FIG. 1, and FIGS. 3A and 3B are sectional views taken along lines A-A and B-B of FIG. 2.
[0036] With reference to the drawings, the plasma display panel (PDP) according to the first embodiment of the present invention includes a first substrate 10 and a second substrate 12 opposing one another with a predetermined gap therebetween. A vacuum assembly is formed by the combination of the first substrate 10 and the second substrate 12 .
[0037] Address electrodes 14 are formed in a predetermined pattern (e.g., a stripe pattern) and at predetermined intervals on the second substrate 12 . A first dielectric layer 16 is formed on the second substrate 12 and covers the address electrodes 14 . Further, barrier ribs 18 are formed on the first dielectric layer 16 and in a predetermined pattern to define a plurality of discharge cells 17 .
[0038] In the first embodiment, the barrier ribs 18 are made of a glass material having a low melting point. Regarding a plan view formation of the barrier ribs 18 , with reference to FIGS. 1 and 2, in a state where imaginary lines L are formed bisecting distal end surfaces of the barrier ribs 18 , the imaginary lines L form a plurality of multilateral shapes that encompass each of the discharge cells 17 . In the first embodiment, the imaginary lines L are formed into a plurality of quadrilateral shapes.
[0039] The barrier ribs 18 include row sections 18 a extending in a direction substantially perpendicular to the direction in which the address electrodes 14 are formed, and column sections 18 b extending in a direction substantially parallel to the direction in which the address electrodes 14 are formed. Areas where the row sections 18 a and the column sections 18 b intersect, that is, areas of the barrier ribs 18 between four adjacent discharge cells 17 , occupy a greater space than other areas of the barrier ribs 18 . The formation of the barrier ribs 18 , and, in particular, the relative widths of the barrier ribs 18 , will be described in greater detail below.
[0040] As an example, areas of the barrier ribs 18 between four adjacent discharge cells 17 are the greatest among all areas of the barrier ribs 18 , while areas of the barrier ribs 18 corresponding to centers of long sides and short sides of adjacent discharge cells 17 are the smallest among all areas of the barrier ribs 18 . In particular, a radius R of a first inscribed circle C 1 (see FIG. 2) drawn in one of the areas of the barrier ribs 18 between four adjacent discharge cells 17 is greater than a radius r of a second inscribed circle C 2 (see FIG. 2) drawn in areas corresponding to the center of the long sides and short sides of adjacent discharge cells 17 . That is, these radii R and r satisfy the condition R>r, and more preferably satisfy the condition R>2r.
[0041] With reference to FIGS. 3A and 3B, areas where the second inscribed circles C 2 are drawn, that is, areas of the barrier ribs 18 corresponding to centers of the long sides and short sides of adjacent discharge cells 17 with the smallest widths, have a height H1 that is the smallest among all areas of the barrier ribs 18 , while areas of the barrier ribs 18 between four adjacent discharge cells 17 have a height H2 that is the greatest among all areas of the barrier ribs 18 .
[0042] With this configuration, gaps of predetermined dimensions are formed between the first substrate 10 and the distal ends of the row sections 18 a and the column sections 18 b of the barrier ribs 18 by the difference in the heights H1 and H2. Preferably, the difference in the heights H1 and H2 is between 5 and 10 μm. These gaps function as exhaust paths P through which air inside the PDP travels when forming a vacuum in the same during manufacture. As a result, radial paths P are provided for each of the discharge cells 17 . In the first embodiment, four exhaust paths P are provided for each discharge cell 17 .
[0043] The barrier ribs 18 are formed by a sandblast process, which is commonly used in the manufacture of PDPs. If a minimum width of the barrier ribs 18 that can be formed using the sandblast process is m, the radius r of the second inscribed circle C 2 described above satisfies the condition:
2r>m.
[0044] Further, with reference to FIG. 2, the width of the row sections 18 a and the column sections 18 b of the barrier ribs 18 may be continuously (i.e., not abruptly and not in steps) made larger as the distance from their centers (where the inscribed circles C 2 are formed) is increased. Also, with reference to FIGS. 3A and 3B, the heights of the row sections 18 a and the column sections 18 b may be continuously reduced starting from areas thereof where the heights are H2 and moving toward areas thereof where the heights are H1.
[0045] The barrier ribs 18 structured as described above are produced according to the following manufacturing method of the present invention.
[0046] First, in a state where the address electrodes 14 and the first dielectric layer 16 are formed on the second substrate 12 , a barrier rib material layer of a predetermined thickness is realized through a paste, which is formed by uniformly mixing a vehicle and a glass powder having a low melting point, and the barrier rib material layer is formed on the first dielectric layer 16 using a screen printing method or a laminate method. The glass powder of a low melting point may be made, for example, of a material containing 50˜60 wt % of Pbo, 5˜10 wt % of B 2 O 3 , 10˜20 wt % of SiO 2 , 15˜25 wt % of Al 2 O 2 , and 5% or less of CaO.
[0047] Following the drying of the barrier rib material layer, a photosensitive dry film is formed or a resist material is deposited. Then, using a photolithography process that includes exposure and development, a cut mask is formed in a lattice pattern corresponding to the desired shape of barrier ribs. The dimensions of the mask pattern are set to be greater than the desired dimensions of the barrier ribs since thermal contraction of the barrier rib material layer occurs.
[0048] Next, using a sandblast process, non-masked portions of the barrier rib material layer are removed until the dielectric layer is exposed. Heating and baking are then performed to thereby complete the formation of the barrier ribs.
[0049] The cut mask has a pattern corresponding to the various shapes of the barrier ribs 18 as described above.
[0050] Red, green, and blue phosphor layers 20 R, 20 G, and 20 B (see FIG. 1) are deposited on areas of the first dielectric layer 16 positioned within the discharge cells 17 and on inner surfaces of the barrier ribs 18 within the discharge cells 17 to thereby form corresponding pixels (i.e., R, G, and B pixels). In the first embodiment, the discharge cells 17 are arranged in a lattice pattern wherein each of the discharge cells is individually formed in fully closed units by the barrier ribs 18 .
[0051] Further, formed on a surface of the first substrate 10 , opposing the second substrate 12 , are discharge sustain electrodes 22 that include common electrodes 22 a , scanning electrodes 22 b , and bus electrodes 22 c formed on each of the common electrodes 22 a and the scanning electrodes 22 b The common electrodes 22 a and the scanning electrodes 22 b are made of a transparent material, such as indium tin oxide (ITO), and the bus electrodes 22 c are made of a conductive material, such as silver (Ag) or gold (Au).
[0052] The discharge sustain electrodes 22 are formed in a direction substantially perpendicular to the direction in which the address electrodes 14 are formed. A second dielectric layer 24 is formed on the first substrate 10 covering the discharge sustain electrodes 22 , and a protective layer made of MgO is formed over the second dielectric layer 24 . The protective layer 26 acts to protect the discharge sustain electrodes 22 , and functions also to aid discharge by emitting secondary electrons.
[0053] In the PDP having the closed barrier rib structure as described above, there are provided radial exhaust paths P for each of the discharge cells 17 such that exhaust efficiency is significantly improved over the prior art.
[0054] [0054]FIG. 4 is a plan view showing the structure of barrier ribs according to a second embodiment of the present invention. Barrier ribs 28 according to the second embodiment have the basic structure of the barrier ribs of the first embodiment. However, row sections 28 a of the barrier ribs 28 that define discharge cells 27 are positioned differently. In particular, the row sections 28 a of the barrier ribs 28 of adjacent discharge cells 27 (i.e., adjacent in a direction in which the row sections 28 a are formed) are offset and not aligned as in the first embodiment. As a result, the discharge cells 27 defined by the barrier ribs 28 are arranged in a delta pattern.
[0055] [0055]FIGS. 5, 6, and 7 are plan views showing the structure of barrier ribs according to a third embodiment of the present invention. FIG. 5 shows a structure in which imaginary lines L bisecting distal end surfaces of barrier ribs 38 are formed into a plurality of hexagonal shapes. Stated differently, the barrier ribs 38 are formed to define a plurality of discharge cells 37 such that the discharge cells 37 are formed as individual, closed units in the shape of a hexagon or a similar form. As a result of this configuration, the discharge cells 37 may be arranged in a delta configuration.
[0056] In the third embodiment, areas of the barrier ribs 38 between any three, mutually adjacent discharge cells 37 occupy the largest area and have the greatest height when compared to other areas of the barrier ribs 38 , that is, main sections 38 a of the barrier ribs 38 . This results in the formation of exhaust paths in the main sections 38 a of the barrier ribs 38 . Since there is a larger number of exhaust paths for each of the discharge cells 37 than in the first embodiment, an even greater improvement in exhaust efficiency is realized.
[0057] The basic configuration of FIGS. 5, 6 and 7 shows the barrier ribs 38 defining the discharge cells 37 such that the discharge cells 37 are formed as closed, 12-sided individual units. As shown in FIG. 6, the twelve sides forming each of the discharge cells 37 are substantially equal in length, and the barrier ribs 38 are placed in relation to one another such that the main sections 38 a between adjacent discharge cells 37 have a width that increases as the distance from the center of the main sections 38 a increases.
[0058] In FIG. 7, the twelve sides forming each of the discharge cells 37 are not equal in length. That is, the sides that form the main sections 38 a are longer than the sides in areas where three, mutually adjacent discharge cells 37 converge. Therefore, the widths of the barrier ribs 38 along the main sections 38 a remain constant.
[0059] [0059]FIG. 8 is a partial exploded perspective view of a plasma display panel according to a fourth embodiment of the present invention. Like reference numerals will be used for elements of the fourth embodiment identical to those of the first embodiment.
[0060] The PDP of the fourth embodiment of the present invention utilizes the same basic structure as the PDP of the first embodiment. However, sub exhaust paths 40 are formed at areas where the row sections 18 a and the column sections 18 b intersect, that is, at areas of the barrier ribs 18 between four adjacent discharge cells 17 .
[0061] The sub exhaust paths 40 are formed to enable communication between adjacent discharge cells 17 to thereby improve the exhaust process. With reference also to FIG. 9, the sub exhaust paths 40 are realized by forming exhaust grooves in the barrier ribs 18 . The sub exhaust paths 40 may be formed in a simple manner using an etching process. As an example, the exhaust grooves may be formed to a width of 10˜100 μm and a depth of 10˜130 μm.
[0062] With the PDP of the fourth embodiment, in addition to the radial exhaust paths formed by the particular configuration of the row sections 18 a and the column sections 18 b of the barrier ribs 18 as described with reference to the first embodiment, the sub exhaust paths 40 act to even further improve exhaust efficiency.
[0063] [0063]FIG. 10 is a partial plan view of a plasma display panel according to a fifth embodiment of the present invention. In the fifth embodiment, sub exhaust paths 50 are formed on barrier ribs 48 in the case where the barrier ribs 48 are formed to realize a delta pattern of discharge cells. Although the sub exhaust paths 50 are formed at each corner area between adjacent discharge cells, it is also possible to form the sub exhaust paths 50 at other selective locations.
[0064] While the present invention has been illustrated by the description of embodiment thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the special details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the sprit and scope of the general inventive concept. | A plasma display panel includes a first substrate, a second substrate mounted opposing the first substrate with a predetermined gap therebetween to thereby form a vacuum assembly, and barrier ribs formed between the first substrate and the second substrate, the barrier ribs defining discharge cells. The barrier ribs are formed so as to provide radial exhaust paths for each of the discharge cells. Moreover, the barrier ribs are configured dimensioned and arranged so as to maximize the exhaust efficiency of the plasma display panel. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a stapler.
2. Description of the Prior Art
A conventional stapler is provided with too many parts to be assembled easily in spite of its simple function of stapling an object to be stapled. Accordingly, it is impossible to justify the production cost of most conventional staplers. Also, the cost of miniaturizing the dimensions of conventional staplers is another limitation upon production.
A novel miniature stapler provided according to the present invention is free of the above-mentioned conventional defects. Furthermore, such defects are not so great even when the stapler is produced in a medium size or a large size. Accordingly, it is easy to obtain efficiency in mass production of a stapler and to keep costs down regardless of the size of the stapler.
SUMMARY OF THE INVENTION
The present invention provides an improved construction of a stapler.
A conventional mechanism is advantageously improved for absorbing the stress created when closing the gap between the front end portion of a projecting frame of an intermediate layer and a guide body of an upper layer and another gap existing between the front end portion of said frame and a lower base. Consequently, an independent member for absorbing the stress is not required. Thus, the construction of the frame and the frame cover of the stapler may be relatively miniaturized.
In the above-mentioned improvement, all members for absorbing the stress are made by partially punching out of a basic material used for the above-mentioned members constituting the stapler and are engaged with the other mechanisms having conventional mechanical action.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view showing various members according to the present invention.
FIG. 2 is a cross-sectional view of the construction of a closed stapler in use according to the present invention.
FIG. 3 is a cross-sectional view of the construction of an open stapler according to the present invention.
FIG. 4 is an exploded perspective view wherein the present invention is applied to a stapler provided with a frame cover.
FIG. 5 is a side elevational view of an assembly of the parts shown in FIG. 4.
FIG. 6 is a partial sectional view of the guide body, as shown in FIG. 1 or FIG. 4, wherein a connector is shown for firmly connecting a driver embedded thereinto.
FIG. 7 is a cross-sectional view taken along line A--A' in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a mechanism for absorbing the elastic stress of a stapler.
As is known, the members constituting a stapler necessitate the existence of gap P (FIG. 2 and FIG. 5) preliminarily in relation to the front end portion of a staple magazine III provided with a feeder for feeding staples by partially punching the same. By applying an impact to a guide body I, a staple is driven through a gap Q (FIG. 2 and FIG. 5) to a base II downward in relation to the front end portion of the staple magazine III. Therefore, a spring body in the form of a coil or a panel has been conventionally fixed, in most cases, to the base II and the guide body I which act in combination as a mechanism for absorbing the elastic stress. Also, the guide body I and the base II form the above-mentioned gaps P and Q and are fixed to an upper surface and a bottom surface, respectively, of the staple magazine III prior to the use of the stapler.
In order to eliminate the above-mentioned conventional members for absorbing the elastic stress, according to the present invention, two (2) elastic pieces a 1 ,a 2 on the upper surface of the guide body I and also another elastic piece a 3 on a bottom of the base II are integrally formed with the guide body I and the base II, respectively, by partially punching out parts thereof.
Furthermore, in such a type of a stapler necessitating a frame cover IV (FIG. 4) for securing a spring for energizing a feeding force to a feeder of the staples, it is suitable to form an elastic piece a 4 formed by partially punching out the wall portions of the staple magazine III and the frame cover IV and also to punch out another two (2) elastic pieces a 5 and a 6 , respectively.
Hereinafter, embodiment (1) will be described in detail with reference to the drawings of the present invention.
FIG. 1 is a perspective view of an assembly of a stapler in which the means for absorbing the elastic stress according to the present invention is shown. The guide body I is molded from a hard plastic material with elastic properties.
Edges 2, 3, 4 depending from an upper surface 1 of the guide body I can be seen in front and on both sides, thereof, respectively. A driver 7 on the guide body I is stably secured downward through a connector built within a wall formed behind the edge 2. A hook 5 for a conventional spring 23 having the elastic effect mentioned hereunder is fixed in relation to the above-mentioned edge 2.
When the base II is formed as illustrated in FIG. 1 by employing the same material as that of the guide body I or, alternatively, by employing a metal panel, the length l thereof is almost the same as that of the above-mentioned guide body I and the width w thereof is conventionally designed to be less than a corresponding width of the guide body I.
The base II is provided with an anvil 12 for a staple 24. An end portion 7' of the above-mentioned driver 7 cooperates with the anvil. The base II is further provided with a horizontal axis 10 through a hinge (not shown) about which the guide body I is rotatable by means of a manual operation at the rear end portion of the base II. For this purpose, latch holes 6 are perforated in the guide body I.
A stop 12 is formed by cutting open a section in a side wall 9 of the base II. Convex or concave portions 14 in the form of a frame for reinforcing physically the bottom surface of the base II are also formed in the base II.
The staple magazine III has such a width w' and a length l' sufficient to enter into the base II in a conventional manner. The staple magazine III is also provided with a horizontal axis 18 for a hinge (not shown) movable into a latching position by means of the holes 11 perforated along the horizontal axis 10 in the base II. The staple magazine III is further provided with a groove 15 into which the end portion 7' of the above-mentioned driver 7 may enter in front of a wall 16. A magazine follower 20 of the staple magazine III is arranged to contact a bottom 17 in order to allow sliding in of a plurality of staples 24 (FIG. 2) arranged in the bottom 17 of the staple magazine III in the back and forth direction by means of the elasticity of the spring 23.
Edges 21 of the magazine follower 20 engage with both grooves 19 cut into the side wall of the staple magazine III.
In the above construction of a stapler, a hook 22 of the magazine follower 20, a stop 20' of the staple magazine III, and a stop 12 of the base II engage with each other. The spring 23, elastically pulling said magazine follower 20, is latched between the hook 5 of the guide body I and the hook 22 on the end of the magazine follower 20.
The mechanism for absorbing the elastic stress according to the present invention with respect to the above-mentioned assembly will be described as set forth hereinunder.
Both of the front end portions X, Y of two (2) elastic pieces a 1 ,a 2 are in the shape of a board with a rectangular cross-section and are formed integrally with the guide body I by partially punching out and bending suitable portions of an upper surface at the front portion of the guide body I. These punched out portions X and Y are inclined downward in order to touch the top surfaces X' and Y' of both side walls of the staple magazine III, and thus the staple magazine is pushed down prior to use of the stapler (FIG. 2).
On the other hand, a third elastic piece a 3 in the shape of a board with a rectangular cross-section is formed integrally with the base II by partially punching out and bending an enclosed portion of the bottom surface of the base II. The elastic piece a 3 is inclined upwards in the direction of the horizontal axis 10 and is disposed so that an end portion Z may touch an external bottom surface Z' at the rear portion of the bottom 17 of the staple magazine III. Thus, the staple magazine III prior to use is open in the forward direction with a suitable gap existing in relation to the guide body I (FIG. 2).
In other words, the driver 7 prior to use may form gap P (FIG. 2) so as to be always positioned above a groove 15 in staple magazine III in which said driver 7 may contact a staple 24 when it is descending. Also prior to use, the staple magazine III and the base II form inevitably the open gap Q (FIG. 2).
FIG. 3 exemplifies a degree of the opening between the gaps P and Q in the above-mentioned construction when the guide body I is manually opened upwardly.
Furthermore, in another embodiment not shown, the pieces a 1 and a 2 are respectively inclined upward at the central portions of the top surfaces of X' and Y' of the staple magazine III. At the same time, another piece a 3 is bent downward (not illustrated) at the rear portion of the bottom 17 of the same staple magazine III. Each of the pieces thus formed has been subjected to a test by contacting them against the corresponding portions of the guide body I and the base II; and the result showed the equivalency of the effect of the invention in this case, too.
Therefore, it is noted that such a mere change in design also belongs to the technical principles of the present invention.
Next, another embodiment (2) according to the present invention will be described with reference to the drawings which show a type of structure provided with a frame cover IV (FIG. 4).
The front end portion X 1 of an elastic piece a 4 is in the shape of a board made by partially punching out and bending the staple magazine III in FIG. 4 at the rear portion of the bottom surface thereof in like manner as the above-mentioned first embodiment (1) is formed. The front end portion X 1 is inclined downward so as to touch an upper surface of the base X 2 .
Next, in order to form other elastic pieces a 5 ,a 6 on the frame cover IV, a pair of rectangular bottom surfaces of hollow small boxes 25 are preliminarily formed integrally with cover members in the direction from the front end portion of the frame cover IV to the rear position thereof.
Each bottom surface (not illustrated) of the boxes 25 is bent by partially punching them out so as to form the two (2) elastic pieces a 5 ,a 6 .
Each of the pieces a 5 ,a 6 is formed to be inclined upwards. Furthermore, each of the front end portions Z 1 ,Z 2 is also constituted so as to touch a ceiling (not illustrated) within the guide body I, so that the same gaps P,Q (FIG. 5), as in the case of the first embodiment (1), may be formed. Accordingly, the guide body I and the staple magazine III may respectively be opened with a suitable gap existing in relation to the base II.
The effect with respect to each of the elastic stress pieces a 1 through a 6 formed as above according to the present invention will concisely be described as set forth hereinafter.
At the time of manual operation of the first embodiment (1) shown in FIGS. 1-3, the guide body I and the staple magazine III are pushed down against the pieces a 1 ,a 2 and a 3 when the guide body I is pushed down; and, accordingly, the gaps P,Q just prior to stapling are forcibly narrowed. Each of the plurality of staples 24 inserted in a conventional manner in the stapler is acted upon individually by the driver 7. At the same time, the driver 7 passes through the groove 15. In this case, the staple magazine III pushes down staples 24 on an object to be stapled (not illustrated), one by one, as the object is arranged on the anvil 13 of base II.
Also, in the case of the second embodiment (2), it is clear now that the above-mentioned operation can be equally carried out.
Thus, in order to reduce more and more the cost in production as one of the inevitable favorable effects of the present invention, the following structure is supplementally fixed to the guide body I.
That is to say, as shown in FIG. 6, because the above-mentioned driver 7 is pushed into the connector of the guide body I in order to be secured thereto when assembling the stapler, a conventional means for securing the driver 7 to the side wall of a body formed by punching out and bending a portion thereof into the shape of an L can be eliminated according to the present invention.
In this embodiment, shown in FIG. 6, a sectional face 27 on the front end portion of the guide body I is molded to be thick. Furthermore, the guide body I is composed of an embedded connector 26 for the driver 7 with an inverse check element which does not slip down the groove 15.
Thus, elimination or reduction of the labor necessary for the securing operation of the driver is an advantageous result obtained by the present invention.
FIG. 7 shows a cross-sectional view taken along line A--A' in FIG. 6 in the above-mentioned case. Element 28 in FIG. 7 is an inverse checking portion of the connector 26; element 29 is a nail portion for the connector 26; and element 30 is a cap for inserting the driver 7.
According to the present invention, any independent members are not necessary to be supplementally fixed as a mechanism for absorbing the elastic stress. In the prior art, it is impossible to obtain an equal advantage for a conventional stapler by miniaturizing the constructions of both a frame and a frame cover.
Another effect of the present invention provides considerable efficiency and reduced cost in the mass production of staplers because the number of members needed for absorbing the elastic stress can be manufactured by punching out the base materials of each stapler routinely. | The present invention relates to a construction of a stapler having a base, a staple magazine hinged to the base, a magazine follower arranged in the staple magazine, and a guide body positioned over the staple magazine and hinged to the base. The stapler is characterized by two novel elements. At least one first punched-out element extends between the guide body and a top surface of the staple magazine in order to absorb elastic stress created between the guide body and the staple magazine when the stapler is operated. At least one second punched-out element extends between the base and a bottom surface of the staple magazine in order to absorb elastic stress created between the base and the staple magazine when the stapler is operated. | 1 |
BACKGROUND
[0001] The invention relates generally to a system and method of securing a wellhead connector to casing of a wellhead assembly that has been damaged by a storm or other similarly destructive event. In particular, the invention relates to a system and method of installing a wellhead connector to the casing of a well having casing and production tubing, which extends from the sea floor to a surface wellhead.
[0002] Surface wellheads are a common feature of oil production. A production tree is attached to the wellhead to control the flow of oil and/or gas produced by the well. The oil and/or gas from the well passes through production tubing to a production tree. The production tree, in turn, may be coupled to a platform that couples the oil and gas to a pipeline for transfer to a processing facility.
[0003] A violent storm, such as a hurricane, can damage wells located on land, as well as offshore. For example, a storm can damage an offshore platform, the production tubing, and/or the production tree of a well by pulling the production tubing from its platform. Furthermore, tidal forces from a storm can blow over a production tree, damaging both the production tree and the production tubing.
[0004] Previous efforts at securing wells damaged by storms have been time-consuming and ineffective. These efforts have included installing devices using numerous loose bolts. However, installing these loose bolts is time-consuming and the bolts may be lost or misplaced, adding to the installation time. This is even more problematic for subsea well heads.
[0005] Therefore, a more efficient technique is desired for securing a well damaged by a storm or any other catastrophic event. In particular, a technique is desired that would enable a well to be secured quickly and securely.
BRIEF DESCRIPTION
[0006] A technique is provided for securing a well damaged by a storm or similar catastrophic event. The techniques utilizes a casing head assembly that may secured to the casing of the damaged well by tightening a plurality of set screws to drive slips into the casing. Before installing the casing head assembly, the casing of the damaged well is prepared for receiving the casing head assembly. For example, any valves secured to the well may be removed and the casing and production tubing of the well may be cut so that the production tubing extends a relatively-short defined distance from the end of the casing. Some preparation of the casing head assembly may also be performed, such as cleaning and coating surfaces.
[0007] Once the casing, production tubing, and the casing head assembly are ready, a portion of the casing head assembly, a casing head, may be installed onto the casing. As the casing head is lowered into position on the casing, the control line of the downhole safety valve of the well is fed into an inner bore of the casing head and then out of the casing head via a control line port through the side of the casing head. Once the casing head is in position on the casing, the casing head set screws may be tightened to secure the casing head to the casing.
[0008] The casing head assembly may also comprise a tubing hanger. The tubing hanger may be installed in the casing head after the casing head is secured to the casing. Tubing head set screws may then be tightened to activate the tubing hanger to secure the production tubing to the casing head.
[0009] In addition, the casing head assembly may also comprise a latch-lock connector that may be secured to the casing head. The latch-lock connector may be stabbed into the casing head and rotated approximately one-quarter turn. This locks the latch-lock connector to the casing head. A corrosion cap may then be secured to the latch-lock connector to cover the production tubing.
DRAWINGS
[0010] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0011] FIG. 1 is an elevation view of a casing head assembly secured by set screws to the casing of a damaged production assembly, in accordance with an exemplary embodiment of the present technique;
[0012] FIG. 2 is a cross-sectional view of the casing head assembly taken along the longitudinal axis of the casing head assembly of FIG. 1 , in accordance with an exemplary embodiment of the present technique;
[0013] FIG. 3 is a block diagram of a method for securing a wellhead using a casing head assembly that is securable to casing using set screws, in accordance with an exemplary embodiment of the present technique;
[0014] FIG. 4 is a cross-sectional view of the casing head secured to casing using set screws, in accordance with an exemplary embodiment of the present technique;
[0015] FIG. 5 is a cross-sectional view of a tubing hanger secured to the casing head using set screws, in accordance with an exemplary embodiment of the present technique;
[0016] FIG. 6 is a cross-sectional view of a latch-lock connector and corrosion cap secured to the casing head, in accordance with an exemplary embodiment of the present technique; and
[0017] FIG. 7 is a cross-sectional view of a casing head adapted to receive a control line from the well at an angle of forty-five degrees, in accordance with an alternative exemplary embodiment of the present technique.
DETAILED DESCRIPTION
[0018] Referring now to FIG. 1 , the present invention will be described as it might be applied in conjunction with an exemplary technique, in this case a casing head assembly for securing a damaged wellhead, as represented generally by reference numeral 20 . The casing head assembly 20 is adapted to attach to the end of a string of casing 22 extending from a well bore. In a normal well in production, a production valve assembly would extend above a well head secured to the casing 22 . In addition, production tubing would extend from the well within the casing and through the production valves to transport oil and/or gas to a surface platform, subsea manifold, or other location. In this embodiment, the casing head assembly 20 has been adapted to secure the innermost of several casing strings, as well as production tubing extending from the well to prevent any fluids therein from leaking into the surrounding waters. However, the casing head assembly 20 may be adapted to secure additional casing strings other than the innermost casing string of a well. For this, additional casing heads with larger diameters may be attached to the casing head assembly.
[0019] In the illustrated embodiment, the casing head assembly 20 comprises a casing head 24 , a latch-lock connector 26 , a corrosion cap 28 , and a vent valve 30 . The casing head 24 is adapted to attach to the casing 22 and secure the production tubing extending from the casing 22 . The latch-lock connector 26 is adapted to connect to the casing head 24 to enable the corrosion cap 28 to be secured to the casing head 24 . One end of the latch-lock connector 26 is adapted to secure to the casing head by being stabbed into the casing head 24 and then being turned one-quarter of a turn. The opposite end of the latch-lock connector 26 is adapted to receive and secure the corrosion cap 28 . The corrosion cap 28 has one end that is adapted to be secured by the latch-lock connector 26 . The opposite end of the corrosion cap 28 is configured with the vent valve 30 to enable any gasses that leak into the corrosion cap 28 to be vented. For example, the vent valve 30 may prevent an explosive concentration of gases from building up within the corrosion cap 28 .
[0020] The casing head 24 has a series of casing head set screws, or dogs 32 , spaced circumferentially around the lower end of the casing head 24 . As will be discussed in more detail below, within the casing head 24 are slips that bite into the casing 22 when the casing head set screws 32 are tightened. These slips grip the casing 22 and secure the casing head 24 to the casing 22 . In this embodiment, the casing head 24 has six casing head set screws 32 . A family of casing heads may be established to correspond to various standard casing sizes. In addition, the outer diameters of the casing heads 24 are established to correspond to a larger standard casing size. Thus, if addition to the inner casing string, a larger casing string is desired to be secured, a smaller casing head may be inserted into a larger casing head in a wedding cake arrangement.
[0021] The casing head 24 also has a control line tie-in 34 that enables external access to a control line extending from the well within the casing 22 . The control line tie-in and control line enable pressure to be applied to the well to set a downhole safety valve. The control line is fed to the control line tie-in 34 through a port through the casing head 24 . The port is angled at an acute angle relative to an axial inner bore within the casing head to make it easier for the control line to be fed through the casing head 24 . In addition, the illustrated embodiment of the casing head has a valve to enable fluid to be removed from within the casing through an annulus formed between the casing and the production tubing.
[0022] The casing head 24 also has a series of tubing hanger set screws, or dogs 38 , that are spaced circumferentially around an upper portion of the casing head 24 . The tubing hanger set screws 38 are oriented to activate a tubing hanger within the casing head 24 . As will be discussed in more detail below, the tubing hanger is positioned so that the production tubing extends through the tubing hanger within the casing head When activated, the tubing hanger expands outward to engage the casing head 24 and inward to engage the production tubing. This secures the production tubing to the casing head 24 . In the illustrated embodiment, the casing head 24 has six tubing hanger set screws 38 .
[0023] Referring generally to FIG. 2 , a cross-sectional view of the casing head assembly 20 is presented. In addition, the production tubing 40 and control line 42 may be seen in this view. The casing 22 and production tubing 40 are cut in a wedding cake arrangement with the production tubing 40 extending a desired distance above the casing 22 .
[0024] As noted above, slips 44 are used to secure the casing head 24 to the casing 22 . As the casing head set screws 32 are tightened into the casing head 24 , the casing head set screws 32 drive the slips 44 downward. This downward motion causes the slips 44 to bite into the casing 22 , thereby gripping the casing 22 and securing the casing head 24 to the casing 22 .
[0025] The casing head assembly 20 also utilizes a pack-off seal 46 that forms a seal between the casing head 24 and the casing 22 . In this embodiment, the casing 22 is cut and prepared to facilitate the formation of a seal with the pack-off seal 46 . The casing head 24 is adapted to receive the pack-off seal 46 and hold it in position so that the seal is made when the casing head 24 is lowered onto the casing 22 . The casing head 24 also has a test port 47 . Hydraulic pressure may be applied to casing head 24 through the test port 47 to verify that the casing head 24 is securely attached to the casing 22 .
[0026] The casing head 24 has a valve port 48 that extends from an inner bore 50 of the casing head 24 to the exterior. In this embodiment, the valve port 48 is threaded to enable an annulus valve 36 to connect to the casing head 24 . The valve port 48 enables the casing 22 to be drained through the casing head 24 . The annulus valve 36 enables the drainage of the casing 22 to be controlled.
[0027] The casing head 24 also has a control line port 52 that extends through a side of the casing head 24 to the inner bore 50 of the casing head. The control line port 52 is oriented at an acute angle relative to a central axis 54 of the casing head assembly 20 . For example, the control line port 52 may be angled at an angle of forty-five degrees or sixty degrees relative to the central axis 54 . Insertion of the control line 42 through the control line port 52 is eased markedly by having the control line port 52 oriented at an acute angle, rather than a ninety degree angle. In the illustrated embodiment, the control line port 52 is oriented at an angle of sixty degrees.
[0028] A tubing hanger 56 is used to secure the production tubing 40 to the casing head 24 . The tubing hanger 56 has two semi-circular half-pieces that are secured to each other by screws. The two half-pieces of the tubing hanger 56 may be separated to facilitate placing the tubing hanger 56 around the production tubing 40 . Once located around the production tubing 40 , the two pieces of the tubing hanger 56 may be joined. In addition, each of the two tubing hanger pieces has an upper portion 58 and a lower portion 60 held together by screws 62 . The tubing hanger 56 also has a rubber packer 64 .
[0029] The tubing hanger 56 sits in a landing in the casing head 24 . The top of the upper portion 58 of the tubing hanger has a beveled surface. When the tubing hanger set screws 38 are tightened they drive against the beveled surface of the tubing hanger 56 , which drives the upper portion 58 of the tubing hanger 56 downward toward the lower portion 60 . This causes the rubber packing 64 to be expanded outward toward the casing head 24 and inward toward the production tubing 40 . This secures the production tubing 40 to the casing head 24 .
[0030] In the illustrated embodiment, the casing head 24 has a female threaded connector 66 and the latch-lock connector 26 has a corresponding male threaded connector 68 . The female threaded connector 66 and the male threaded connector 68 form a high-strength connection. The connectors 66 , 68 are adapted to be stabbed together and then rotated approximately one-quarter turn to make-up the connection. In this embodiment, a quadruple helix thread form is used by the connectors 66 , 68 . The threads interlock as they are rotated relative to each other.
[0031] In the illustrated embodiment, the vent valve 30 is located at the highest point of the corrosion cap 28 to prevent as little build-up of gas as possible within the corrosion cap 28 . The vent valve 30 may utilize a check valve or some other type of pressure-relieving valve.
[0032] Referring generally to FIG. 3 , a method of securing a damaged well using the casing head assembly 20 is presented, and represented generally by reference numeral 70 . Initially, the casing 22 is prepared for receiving the casing head assembly, represented generally by block 72 . If the well has a “Christmas tree” or similar production valves, these must be cut from the end of the casing. Preferably, the end of the casing 22 is cut to provide a desirable surface for forming a seal. In addition, the outer diameter of the end of the casing 22 should be beveled. In addition, it is preferable that the casing is cut so that a straight portion of casing is presented to the casing head assembly 20 . As noted above, the production tubing 40 and casing 22 are cut in a wedding cake arrangement with the production tubing 40 cut to extend a defined distance from the end of the casing 22 . In addition, if there is more than one string of casing in the well, the inner casing is cut so that it extends from the other strings of casing to provide an adequate surface to receive the casing head 24 . In addition, if it is desired to secure the ends of other strings of casing, they should also be cut in this wedding cake arrangement to enable these strings of casing to receive additional casing head sections.
[0033] Some preparation of the casing head assembly 20 may also be performed, as represented generally by block 74 . For example, the casing head assembly 20 may be cleaned and a coat of light grease may be applied to all moving parts. Various dimension checks may also be preformed.
[0034] Once the casing 22 , production tubing 40 , and casing head assembly 20 are ready, the casing head 24 may be installed onto the casing 22 , as represented generally by block 76 . A lifting device may be used to lower the casing head 24 to the casing 22 . The control line 42 is fed into the inner bore 50 of the casing head 24 and though the control line port 52 as the casing head 24 is lowered into position. Once the casing head 24 is in position on the casing, the casing head set screws 32 may be tightened. Preferably, the casing head set screws 32 are tightened in an alternating crisscross manner in increments until a desired torque is reached. In addition, the casing head 24 may be pulled to ensure that the casing head 24 is secured to the casing 22 . For example, a 10,000 lbf pull may be applied to the casing head 24 to ensure that the casing head 24 is properly gripping the casing 22 . The casing head set screws 32 may be re-tightened to the desired torque after the test pull.
[0035] In this embodiment of the method, the tubing hanger 56 is installed in the casing head 24 after the casing head 24 is secured to the casing 22 , as represented generally by block 78 . Initially, the two halves of the tubing hanger 56 are separated. The two half-pieces are then wrapped around the production tubing 40 and secured together with screws. The tubing hanger 56 is then lowered into the casing head toward a landing shoulder within the casing head 24 . Preferably, the annulus valve 36 is open during this process. The tubing head set screws 38 are then tightened in an alternating crisscross manner in increments until a desired torque is reached.
[0036] In the illustrated embodiment, the latch-lock connector 26 is secured to the casing head 24 after the tubing hanger 56 is activated within the casing head 24 , as represented generally by block 80 . The latch-lock connector 26 is stabbed into the casing head 24 and rotated approximately one-quarter turn. This brings all of the threads of the connectors 66 , 68 into engagement.
[0037] The corrosion cap 28 is then secured to the latch-lock connector 26 over the production tubing 40 , as represented generally by block 82 . The production tubing 40 is thereby covered so that any leakage from inside the production tubing is contained within the corrosion cap 28 . If the vent valve 30 is separate from the corrosion cap 28 it would now be installed. Thus, the casing 22 and production tubing 40 are secured and prevented from leaking into the surrounding waters. In addition, access to the control line 42 of the well is provided.
[0038] Referring generally to FIG. 4 , the process of installing the casing head 24 to the casing 22 is presented. The casing head 24 is lowered into position on the casing 22 , as represented by arrow 84 . The pack-off seal 46 is seated on the end of the casing 22 , forming a seal between the casing head 24 and the casing 22 . Once in position, the casing head set screws 32 are tightened, as represented by arrows 86 . Tightening the casing head set screws 32 causes the casing head set screws 32 to drive the slips 44 downward, biting into the casing 22 . This biting action of the slips 44 grips the casing 22 to the casing head 24 , securing the casing head 24 to the casing 22 .
[0039] Referring generally to FIG. 5 , the process of installing the tubing hanger 56 within the casing head 24 is presented. As discussed above, in this embodiment, the tubing hanger 56 is composed of two half-pieces that are joined together around the production tubing 40 . The tubing hanger set screws 38 are then tightened, as represented by arrow 88 . This causes the upper portion 58 of the tubing hanger 56 to be driven downward toward the lower portion 60 of the tubing hanger 56 .
[0040] Referring generally to FIG. 6 , the process of securing the latch-lock connector 26 and the corrosion cap 28 to the casing head 24 is presented. The latch-lock connector 26 is stabbed into the casing head 24 , as represented generally by arrow 90 . The latch-lock connector 26 is then rotated clockwise approximately one-quarter turn, or ninety degrees, to secure the latch-lock connector 26 and the corrosion cap 28 to the casing head 24 , as represented by arrow 92 .
[0041] Referring generally to FIG. 7 , an alternative embodiment of a casing head assembly is presented, and represented generally by reference numeral 94 . In this embodiment, the casing head 96 has a control line port 98 that is angled at an angle of forty-five degrees relative to the central axis 54 of the casing head 24 , rather than sixty degrees as in the previous embodiment.
[0042] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A technique is provided for securing a subsea well that has had some of its components damaged as a result of a storm or other catastrophic event. The techniques utilizes a casing head assembly that may secured to the casing of the damaged well by tightening a plurality of set screws to drive slips into the casing. The casing head assembly may also comprise a tubing hanger. Tubing head set screws may then be tightened to activate the tubing hanger to secure the production tubing to the casing head. The casing head assembly may also comprise a latch-lock connector that may be secured to the casing head by stabbing the latch-lock connector into the casing head and rotating the connector approximately one-quarter turn. A corrosion cap may then be secured to the latch-lock connector to cover the end of the production tubing. | 4 |
FIELD OF THE INVENTION
The present invention relates to a clasp for fixing an electrical wire to a pin type insulator and to a method of attaching an electrical wire to a pin type insulator by means of the clay.
BACKGROUND OF THE INVENTION
Insulators are used on utility poles and towers to prevent electricity flowing through wires, frequently at a very high voltage, from being discharged to the ground or other wires.
A typical pin type insulator is fixed to a pole or tower crosspiece and has an upper saddle portion on which the wire rests. Till now, most commonly a wire has been attached to its insulator by manually winding and twisting a small diameter wire around the electrical wire and the saddle portion.
Such method and means of attachment is unsatisfactory for four reasons:
(1) it is difficult for a workman who must also climb or be hoisted to live wires in a crane bucket, to effect the tricky winding of the small diameter wire, using a tool with a six-foot insulated pole;
(2) it is time-consuming;
(3) such means of attachment does not prevent the electrical wire from slipping away over the insulator in the event that the wire is severed, for example, by a falling tree, in a windy storm, such being possible because the utility poles or towers are usually quite far apart from each other, resulting in relatively heavy lengths or suspended wire between insulators, and thus, if a wire is broken, its weight will tend to pull downwardly and across an insulator against the wound small diameter wire; and
(4) tie-wires are known to cause radio interference of the AM band.
OBJECTS OF THE INVENTION
In view of the above, it is a first object of the present invention to provide a clasp and method for fixing a wire to an insulator which obviates the above-mentioned disadvantages.
It is another object of the present invention to provide a clasp and method of the character described, which is simple in design and includes easy steps to install on an insulator.
It is a further object of the present invention to provide a clasp of the character described, which is non-costly to manufacture.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the present invention are realized according to a preferred embodiment by a clasp comprised of a clamp made of rigid but bendable material and a gripper element. The clamp has a flat, upper portion and a means at each end adapted to positively grasp the saddle portion of an insulator, as will be explained. The clamp is adapted to be positioned directly over the insulator and clamped to the same. Within the clamp is a wire-gripping element which is made of a yieldably-deformable material, such as a suitable elastomer. The element consists of a main body portion including a generally flat upper surface. The undersurface of the body portion has a lengthwise-extending first groove. Both sides of the gripper element are preferably formed with an attachment means to attach the gripper element to the clamp. Both sides of the gripper element further have lengthwise-extending first walls projecting preferably slightly outwardly. These first walls each merge with the body portion. Second downwardly-extending walls also project from the body portion.
The inner lower extremity of each second wall has a lengthwise-extending second groove.
During fixation, the two second walls are deformed inwardly from their initial configuration to a fully-permanent folded configuration, where the three grooves define a bore of a circular cross-section, adapted to firmly grip an electrical wire therein. Such deformation of the second walls is assisted by the initially straight first walls which abut against the lower surface of the clamp. Simultaneously, the clamp is rigidly fastened to the insulator.
It is within the scope of the present invention to achieve such attachment of an electrical wire to an insulator saddle portion by having recourse to a handtool connected to an arrangement of mechanical parts adapted to perform a series of steps.
The mechanical parts are comprised of a pair of spacedapart legs joined together by a lengthwise yoke member, the latter being in turn attached to an expansible ram mechanism.
Each leg has a lowermost first hook means adapted to grip the lower edge of an insulator and further has a second hook means adapted to catch and lift an electrical wire extending over the saddle portion of the insulator.
Secured to the expansible ram mechanism is a press means adapted to push downwardly against the clamp and cause the lifting action of the second hook means and the locking action of the first hook means.
The method of securing the electrical wire to its insulator may therefore be briefly indicated as follows:
(a) the gripper element is attached to the clamp by its attachment means;
(b) the clasp is attached manually directed to the press means of the tool and positioned over the insulator saddle portion, with the first and second hook means under the insulator and the electrical wire, respectively;
(c) the ram is actuated to lift the hook means and cause the press means to exert downward pressure on the clamp and gripper element, until the clasp holds the electrical wire and is securely fastened to the insulator; and
(d) the tool is removed.
BRIEF DESCRIPTION OF THE DRAWINGS
The above will be more clearly understood by having referral to the preferred embodiments of the invention, illustrated by way of the accompanying drawings, in which:
FIG. 1 is a perspective view of a clasp according to the invention, prior to installation, also showing an insulator and a segment of an electric wire or cable;
FIG. 2 is an end view of a clamp and one embodiment of a gripper element for a given wire size;
FIG. 3 is a cross-sectional view of another embodiment of a gripper element for a smaller wire size;
FIGS. 4 and 4a are views of half-clasps, half the upper portion of an insulator and half of the first and second embodiments of the gripper, respectively; the grippers being in fully-closed configuration;
FIG. 5 is a lateral elevation of an insulator, a segment of electrical wire to be attached thereto, and of the tool and clasp positioned over the insulator;
FIGS. 6 is an end view at right angle to and corresponding to FIG. 5; and
FIGS. 7 to 9 are further sequential end views illustrating the method used to effect installation of the clasp.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring firstly to FIG. 1, there is shown a typical, conventional insulator 1, made out of an electrically-insulating material, such as porcelain. Insulator 1 is formed with a lower skirt portion 2, of generally frustum shape, including a pair of concentric base portions 3, 4, the smaller of which is rigidly attached to a support post 5, the latter being in turn attached to a cross-piece 6 (as seen in FIG. 5) of a utility pole or tower (not shown). The upper portion of insulator 1 has the general shape of a transverse saddle including a central arcuate cradle 7 and jutting parts 8.
The saddle is adapted to support a lengthwise-extending electrically-charged wire or cable 9.
FIGS. 1, 2, and 4 show a clamp 10 according to the invention. It is preferably made from an extrusion of aluminum cut to length and machined. It includes a flat portion 10' merging with downwardly-curved portions 10" at both its ends. Each portion 10" is bent horizontally inwardly at its lower end to define a flange 11, having an innermost semi-circular recess 12. Portion 10", flanges 11, and recesses 12 constitute the grasp means. Each recess 12 has a central notch 12a. Clamp 10 has a lengthwise-extending exterior ridge 13 at each merging of arcuate portions 10" with flat portion 10'. The interior surface of clamp 10 is provided with a pair of lengthwise-extending L-shape flanges 14, which are more closely spaced than ridges 13.
A wire gripper element 15 is adapted to be used complementarily with clamp 10. Element 15 is made of yieldably-deformable, essentially, electrically-partly-conducting elastomeric material, such as rubber with a carbon content. The initial shape of element 15 is preferably formed by an extrusion process after which a piece of desired length may be easily cut.
Element 15 has a main body portion 15', the top surface of which has a pair of transversely-spaced L-shape furrows 16, as clearly shown in FIGS. 2 and 3. Furrows 16 constitute an attachment means adapted to receive flanges 14, so that the gripper element 15 can be secured to clamp 10, as shown.
Each furrow 16 defines a contiguous angularly-outwardly-projecting first wall 17. Walls 17 merge with body portion 15'.
Also merging with body portion 15' are a pair of second walls 18. Each of the latter is located below each adjacent first wall 17 and generally in alignment therewith.
The middle of the undersurface of body portion 15' is formed with a lengthwise-extending first groove 19, in the general cross-sectional shape of a semi-circle. Groove 19 is flanked on each side by a V-shaped notch 19a.
The lower inner extremities of both second walls 18 are provided with a second groove 20 in the general shape of a quarter-circle.
The gripper 15a of the second embodiment is similar, except as to dimensions, including a smaller groove 19' and grooves 20' and a thicker portion 15".
It will be clear from a perusal of FIGS. 2, 3, 4, and 4a that the two walls 18 are adapted to be bent inwardly from an initial configuration, shown in FIGS. 2 and 3, to a permanently-bent installed configuration, as in FIGS. 4 and 4a. In the latter configuration, the first groove 19 or 19' and the two second grooves 20 or 20' form a bore 21, 22, respectively, of circular cross-section and of a size to grippingly, frictionally retain a wire 9. The latter may, of course, be of varying diameter, as suggested in the figures. The outer surface of curvature of the exterior of both second walls 18 is identical to the arc of curvature of the arcuate cradle 7 on both sides of the latter, as shown.
Referring now to FIGS. 5 to 9 inclusive, the method of using clamp 10 and gripper element 15 is illustrated, along with a tool used to carry out the method.
FIGS. 5 and 6 show power means consisting of a spring-return cylinder and piston ram 23, which is securely attached to a hand-held handle 24 by a universal connector 24a. Handle 24 is held by an operator in a crane bucket or the like (not shown). Expansion force, such as hydraulic pressure, can be delivered to ram 23 through a tube running within or along handle 24 with operating levers on the latter.
Ram 23 is made integral with a transverse, horizontal yoke member 25. Each of the opposite ends of yoke 25 carries a downwardly-projecting leg 26. The lower ends of legs 26 carry an inwardly-oriented hook 27, constituting a first hook means, as clearly shown in FIG. 5. Hooks 27 are adapted to catch the bottom edge of the skirt 2 of insulator 1.
Intermediate the upper and lower ends of legs 26 are transversly- outwardly-bent portions 26' having lowermost hook rests 28, the latter constituting a second hook means.
Immediately below hook rests 28, each leg 26 may be made with an enlarged hollow portion 26". Portions 26" are internally threaded so that the complementarily-threaded upper ends of the lower portions of legs 26 can be length-adjusted by screwing such lower portions of the legs into portions 26". Thus, the distance between hooks 27 and 28 of each leg 26 may be adjusted to suit different sizes of insulators.
Completing the tool is a press means comprised of a rigid press plate 29, having a flat mid-area 30, which is rigidly secured to the remote end of ram piston rod 31, the latter being adapted for vertical movement, as suggested by the arrows 32 in FIG. 6. Mid-area 30 is merged on both its sides with transversely- outwardly-downwardly-projecting portions 33, in turn merging with endmost transversely- outwardly-projecting shoulders 34.
Shoulders 34 are adapted to contact and press against the respective ridges 13 of clamp 10.
Press plate 29 incorporates, at both ends, guiding and clasp-retaining flange 35, with an outwardly-flared lower end 35'.
The clasp is installed as follows:
(a) gripper element 15 or 15a is attached to clamp 10 by sliding flanges 14 into furrows 16 until the element 15 is directly underneath top wall 10' or clamp 10;
(b) the clamp 10 is pressed against press plate 29 and retained by guiding and retaining flange 35;
(c) using handle 24, gripper element 15 or 15a is carried to and positioned over cable 9 with flanges 11 of the clamp 10 resting on the respective jutting parts 8 of insulator 1, and, thus, as seen in FIG. 6, the electrical wire 9 partially engages between the two second walls 18 of gripper 15 and yoke 25 then extends lengthwise of wire 9 and legs 26 project down on each side of insulator 1 with lower and upper hooks 27, 28 ready to upwardly engage the bottom edge of wire 9 firstly and insulator 1 secondly;
(d) the piston rod 31 of ram 23 is actuated downwardly, thus lifting ram 23 and resulting in two things: hook rests 28 engage and lift wire 9, so that it clears the necessary space between it and the cradle 7 to allow insertion therein of the two second walls 18 of gripper 15; and hooks 27 engage insulator 2;
(e) piston rod 31 is further actuated, as in FIGS. 8 and 9, thereby exerting downward force against clamp 10 and gripper element 15 with wire 9 firmly held above cradle 7 of insulator 1; press plate 29 pushes against clamp 10 by its shoulders 34 acting on ridges 13 and as such action continues (see FIG. 8), second walls 18 are forced to follow the contour of cradle 7 and bend inwardly under wire 9, such being obtained because each wall 18 is initially aligned with its associated wall 17 (see FIG. 2) which effectively transmits a pushing force; then first walls 17 are gradually splayed outwardly, relieving unwanted force from being exerted upwardly against the distal ends of portion 10', notches 19a permitting this closure, (the final shape of gripper 15 is shown in FIGS. 9, 4, and 4a); and occuring simultaneously with the deformation of gripper element 15 is the movement of flanges 11 around and underneath jutting parts 8 due to the bendable quality of clamp 10 at its weakest central portion, whereby recesses 12 finally are locked under jutting parts 8, as suggested by the dashed line 36 in FIG. 1, and because the downward push is exerted on the spaced ridges 13, flat portion 10' is bent and, therefore, the fully-installed configuration of clamp 10 includes a slightly-convex shape 10'a of flat portion 10' (see FIGS. 4 and 4a) to more firmly retain clamp 10 on insulator 1; and
(f) ram 23 is operated in reverse direction to clear hooks 27 and 28 from skirt 2 and wire 9; and ram 23 is withdrawn.
Either notch 12 is used for the insertion of a tool (not shown), which serves to pry away clamp 10 in case the clasp needs replacement. | A clasp for fixing an electrical wire to an insulator having a saddle portion and a method of doing so. The clasp includes a resilient but bendable clamp, having attached to its inner surface a wire gripper element, made of a semi-conductor elastomeric material. The method of fixation involves the use of a power device associated with mechanical parts adapted to carry out a series of simple steps, including the steps of lifting the electrical wire into the gripper, and applying pressure to close the gripper around the wire while simultaneously securing the clamp to the saddle portion of the insulator. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/295675 filed in the United States Patent Office on Jun. 4, 2001.
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates generally to condensation cure moldmaking compositions that produce useful, curable molds and/or coatings that can be sprayed, trowled or poured, and to a method of making said molds. More particularly, the present invention relates to the use of hindered amine siloxanes to create a desirable thixotropy and cure rate in said moldmaking applications as compared to current technologies.
2. Discussion of the Related Art
Curable silicone coating compositions are well known. U.S. Pat. No. 4,460,712 describes rapid cure compositions including aminofunctional silicone compositions or silicones having alkyl radicals bearing one or more amino groups that produce curable foams and coatings. The reactive silicon group is a polyorganosiloxane that is combined with an amino functional polymer to form a silicone foam, but does not disclose or teach enhancement of thixotropic character or moldmaking.
Silicone based condensation curing mechanisms are well known to those skilled in the art, and generally involve reactions between reactants such as silanol (Si—OH) and siliconhydride (Si—H) groups; between silanol and hydrolyzable or condensable silyl groups, such as Si—OC(O)CH 3 or Si—NR 2 , etc.; between a hydrolyzable or condensable group and a polyhydric species, such as polyamines, polyalcohols, and the like. One example of this cure system is the reaction between two polymers, one may be organic and the other may be a siloxane polymer, bearing hydrolyzable or condensable groups attached directly to silicon atom(s).
Divalent tin compounds are the most preferred condensation catalysts as described in U.S. Pat. No. 4,954,565. As taught in the art, when said condensation catalysts are used, they are added in an amount preferably from 0.01 to 20 weight parts, more preferably from 0.1 to 5 weight parts, per 100 weight parts of the silicon modified organic polymer.
Typically, silicone compositions used for moldmaking are very flowable exhibiting Newtonian-like character. Block and glove molding are the two most popular types of moldmaking in the industry. A master, or an original, is placed in a container and the catalyzed silicone is then poured over the part. The silicone is then allowed to cure after which time the original part is removed. The silicone mold is then used for reproduction of the original part. For large parts, use of the above discussed condensation cure related art for this process has severe limitations. Typically an additive for the silicone is used to make the material thixotropic, or non-flowable, so that the large part can be sprayed with the silicone or to allow for the material to be trowled onto the original.
The present invention addresses deficiencies in the current art including: undesirable changes to the cure profile, residue on the surface of the reproductions and lack of thixotropic character preventing the use of very thick layers to prepare the mold.
The present invention represents several significant advances in the art. Even though the art teaches means for producing curable silicone compositions, it does not disclose compositions with high thixotropic character or an application of the same to moldmaking.
Accordingly, it is the object of the present invention to provide a means for reducing the minimum volume of material necessary to cure silicon molds, as well as, a method wherein the curing cycle is substantially reduced.
Additional objects and advantages of the present invention are apparent from the specification, which follows.
SUMMARY OF THE INVENTION
According to the present invention, the foregoing and additional objects are obtained by providing a trowlable or sprayable condensation curable silicone moldmaking composition with thixotropic character that cures to a stable silicone mold.
BRIEF DESCRIPTION OF THE DRAWINGS
No drawings are included.
DETAILED DESCRIPTION
Although there are several embodiments that encompass the elements of the claimed invention, those shown by the written description herein represent the preferred embodiments of the present invention and are exemplary thereof and are not intended by the inventors to constitute a limitation of the same.
The present invention is a silicon compound having the formula R 3 SiOQ n SiR 3 ,
wherein:
R is a monovalent hydrocarbon radical,
Q is a siloxane having one or more radicals bearing one or more amino groups, and n is 1-500.
In a preferred embodiment, R is CH 3 ,
Q is
and n is 1.
The present invention relates to a composition comprising, in combination a base and a catalyst:
A. the blend of a base, hereinafter component (A):
1. a silanol terminated polydimethylsiloxane;
2. an extending filler;
3. a reinforcing filler; and
4. a trimethyl siloxy terminated polydimethylsiloxane; and
B. the reaction product of a composition, hereinafter component (B):
1. an organometallic condensation catalyst;
2. an alkoxy silane;
3. a trimethylsilyl terminated polydimethylsiloxane; and
4. a cyclosiloxane piperidine.
In a preferred embodiment, the extending filler is alpha quartz and the reinforcing filler is amorphous silica. Also, in a preferred embodiment, the organometallic condensation catalyst is an organometallic tin compound; preferably a beta-diketonate tin compound or an alkyl tin carboxylate. The alkoxy silane is a di-, tri- or tetra alkoxy silane, preferably ethyl silicate.
The resulting compound (C) hindered amine siloxane is an organo silicon resin essentially of R 3 SiOQ n SiR 3 , wherein R represents a monovalent hydrocarbon radical, such as methyl, ethyl, butyl, propyl and the like, and Q is a siloxane having alkyl radicals bearing one or more amino groups.
In the most preferred practice of this invention, component (A) is synthesized by mixing, at a minimum, about 35 to about 70 weight parts of a silanol terminated polydimethylsiloxane, about 20 to about 40 weight parts. alpha quartz, about 10 to about 20 weight parts amorphous silica and sufficient trimethyl siloxy terminated polydimethylsiloxane to create a homogenous solution; and component (B) is synthesized by mixing about 1 weight part dibutyl tin dilaurate, about 5 weight parts ethyl silicate, about 12 weight parts trimethylsiyl terminated polydimethylsiloxane and about 2 weight parts of a cyclosiloxane piperidine.
The present invention is in the field of condensation cure chemistries wherein the curable silicone composition is comprised of the following:
(a) a di-silanol stopped linear polydimethylsiloxane having a viscosity ranging from about 3,000 to about 100,000 centipoise at 25C;
(b) a finely divided filler or mixtures thereof;
(c) a methyl stopped polydimethylsiloxane having a viscosity ranging from about 10 to about 400 centipoise at 25C;
(d) a methyl stopped polydimethylsiloxane having a viscosity ranging from about 400 to about 1000 centipoise at 25C; and
(e) a hindered amine siloxane.
The present invention further provides for a curable silicone composition for making casting molds comprising:
(a) a silanol stopped hydrogen stopped polydimethylsiloxane having a viscosity ranging from about 3,000 to about 100,000 centipoise at 25C;
(b) a fumed silica having a surface area varying from 50 to 325 m 2 /g;
(c) a precipitated silica wherein said precipitated silica has been treated with hexamethyldisilazane and wherein said hexamethyldisilazane treated precipitated silica has a surface area ranging from about 50 to 225 m 2 /g;
(d) a methyl stopped polydimethylsiloxane having a viscosity ranging from about 10 to 1000 centipoise at 25C;
(e) a hindered amine siloxane.
The present invention further provides for a silicone composition for making casting molds comprising:
(a) a curable silicone composition, and
(b) a hindered amine siloxane
By hindered amine siloxane it is meant herein a polyorganosiloxane substituted with at least one alkyl radical bearing at least one amino group. Said alkyl radical is bonded to a silicon atom by a Si—C bond. The term hindered amine siloxane as used herein is intended to encompass silicones having alkyl radicals bearing one or more amino group.
The present invention uses a catalyst to effect the reaction between the polymer and a crosslinking compound. The preferred catalyst is an organometallic catalyst. The organometallic catalysts are organotin compounds of carboxylic acids having from 2 to 20 carbon atom(s) and organotin halides. Specific examples of such organotin compounds suitable for the present invention are diorganotin dicarboxylates, in particular dibutyltin dilaurate and also including dibutyltindiacetate, dibutyltinbisneodecanoate, stannous octaote, stannous oxide, dibutyl tin dichloride and dibutyltinbis acetylacetonoate. However, other tin catalysts can also be utilized, such as a member selected from the class consisting of diacylstannoxane, acylhydroxystannoxane, monomethoxyacylstannanes, dihalostannoxane or halohydroxystannoxane.
EXAMPLES
The following examples are presented to further illustrate the compositions of this invention, but are not to be construed as limiting the invention, which is delineated in the appended claims. In the following examples, if not otherwise noted, compound (A) and compound (B) are synthesized according to the preferred practice as stated herein and the aforesaid cyclosiloxane piperidine used was Uvasil™ although commercially available substitutes are incorporated by reference.
EXAMPLE 1
Reaction of compound (A) and compound (B) with 0 weight parts of the cyclosiloxane piperidine produced flowable material of greater than 4 inches (Boeing flow jig) and having a cure cycle of 395 minutes.
EXAMPLE 2
Reaction of compound (A) and compound (B) with 2 weight parts of the cyclosiloxane piperidine (Uvasil™ 299HM-Great Lakes Chemical) produced non-flowable material of approximately 0.15″ and having a cure cycle of 25 minutes.
EXAMPLE 3
Reaction of compound (A) and compound (B) with 1 weight part of the cyclosiloxane piperidine (Uvasil™ 299HM-Great Lakes Chemical) produced non-flowable material of approximately 0.25″ and having a cure cycle of 38 minutes.
EXAMPLE 4
Reaction of compound (A) and compound (B) with 0.5 weight parts of the cyclosiloxane piperidine (Uvasil™ 299HM-Great Lakes Chemical) produced non-flowable material of approximately 0.40″ and having a cure cycle of 57 minutes.
EXAMPLE 5
Reaction of compound (A) and compound (B) with 1 weight part of the cyclosiloxane piperidine (Uvasil™ 299LM-Great Lakes Chemical) produced non-flowable material of approximately 0.30″ and having a cure cycle of 41 minutes.
The present invention provides a unique, useful, and reliable means for decreasing undesirable changes to the cure profile and residue on contact surfaces; and increasing thixotropic character of hindered amine siloxanes for moldmaking. Many improvements, modifications, and additions will be apparent to the skilled artisan without departing from the spirit and scope of the present invention as described herein. | The present invention relates generally to condensation cure moldmaking compositions that produce useful, curable molds and/or coatings that can be sprayed, trowled or poured, and to a method of making said molds. More particularly, the present invention relates to the use of hindered amine siloxanes to create a desirable thixotropy and cure rate in said moldmaking applications as compared to current technologies. | 2 |
FIELD OF THE INVENTION
The invention relates to a device for detecting the operation of a valve, such as a safety valve, and more precisely to a device permitting the monitoring of the correct operation of a safety valve.
BACKGROUND OF THE INVENTION
Safety valves are devices commonly used in installations utilizing various apparatus for the storage and handling of fluids. When a high level of reliability is required of such installations, for example in the case of nuclear power stations, it is indispensable to make certain of the correct operation of all components, particularly the safety valves. It is therefore appropriate to install on these valves devices detecting their operation.
Detection devices of this kind may comprise a detection means which is displaced at the same time as the movable portion of the valve carrying the valve closure means.
It is then possible to detect the displacement of the movable part of the valve, or else the closure or opening of the latter, by monitoring the displacements or the position of the movable detection means.
However, these extremely simple devices, which are also extremely reliable because they follow the displacements of the movable part of the valve, with which they are generally in direct contact, are not entirely satisfactory because they require the fitting to the valve of detection means which are liable to hinder the correct operation of the valve itself and consequently entail a reduction of the reliability of the valve.
SUMMARY OF THE INVENTION
The aim of the invention is therefore to propose a device for the detection of the operation of a valve, comprising a movable detection member connected kinematically to a movable part fastened to the closure member of the valve, the detection member being in direct contact with the said movable part, and a displacement and/or position detector for monitoring the displacements and/or the position of the detection member, this detection device making it possible to avoid any hindrance to the correct operation of the valve.
To this end, the detection member comprises at least one part having a predetermined breaking point making it possible to interrupt the kinematic connection between the valve and the detection member, through the breaking of that part, in the event of the jamming of the detection member.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to enable the invention to be more clearly understood, a description will now be given, by way of example, with reference to the accompanying drawings, of two different embodiments of a device according to the invention, applied to a safety valve.
FIG. 1 is a view in section through a vertical plane of an hydraulically controlled valve provided with a detection device corresponding to a first embodiment of the invention.
FIG. 2 is a view on a larger scale of the portion of the device shown in FIG. 1 where the detection device according to the invention is disposed.
FIG. 3 is an view in section through a vertical plane of a hydraulically controlled valve provided with a device according to a second embodiment the portion of the device shown in the invention.
FIG. 4 is a view on a larger scale of part of FIG. 3 where the detection device according to the invention is disposed.
DETAILED DESCRIPTION
FIG. 1 shows a safety valve of conventional general design. This valve comprises an inlet aperture 1, an outlet aperture 2, a fixed seat 3, and a closure member 4 which comes to bear against the seat 3 in order to close the valve, and which moves away from the seat 3 in order to open it. The closure member 4 is connected by a rod 5 to a piston 6, whose front face 7 is subjected to the action of a fluid controlling the opening and closing of the valve. The rod 5 and the piston 6 constitute the movable part of the valve.
The detection device 9 according to the invention is mounted on the valve in such a manner as to detect the displacements or the relative position of the movable part with respect to the fixed part or body 8 of the valve. It can in fact be seen that the open or closed state of the valve is directly linked to the relative position of the movable part 5, 6 with respect to the valve body 8.
The detection device 9 can be seen in greater detail in FIG. 2. This detection device comprises a a casing 12 composed of a sleeve fixed on the valve body 8 at the level of an opening 14 passing through the valve body.
A rod 15 is mounted for translation inside the casing 12, and is guided by means of a centering and support member 16 for its translatory movement in the direction of the axis of the opening 14, inside the valve body 8.
The junction portion between the rod 5 and the piston 6 of the movable part of the valve has a frusto-conical outer surface 18, and the front end of the rod 15 is held bearing against this frusto-conical surface 18 by a spring 19 bearing against the sleeve 12 fastened to the valve body 8.
The front part of the rod 15 is provided with a predetermined breaking point 20. The rod 15 is connected kinematically to the movable part of the valve, because the displacements of the valve in the direction of its axis 21 are transmitted by the frusto-conical surface 18 to the rod 15, which is biased against this frusto-conical surface by the spring 19.
The displacements of the rod 15 are controlled with the aid of a displacement transducer consisting essentially of a ferrite member 26 fastened to the end of the rod 15 remote from the end in contact with the surface 18, and of two windings 24 and 25 constituting the primary and secondary windings of a differential transformer type displacement transducer.
A displacement transducer of this kind is of known design and need not be described in detail. The windings 24 and 25 are connected by conductors 27 to an electronic device which at its output transmits signals representing the position or the displacements of the ferrite member 26, and therefore of the rod 15 and of the movable part of the valve.
In the event of the jamming of the detection member consisting of the rod 15, the stresses applied by the movable part of the valve to this rod will cause it to break at the predetermined breaking point 20, so that the kinematic connection between the movable part of the valve and the detection member is interrupted. The valve therefore continues to work normally.
In FIG. 3, elements corresponding to the elements shown in FIG. 1 are given the same references. It can be seen that the detection device is composed of an assembly comprising a movable finger 30 and a displacement detection arrangement 31.
Referring to FIG. 4, it can be seen that the finger 30 is mounted for translatory movement in the axial direction, i.e., the direction of displacement of the movable part of the valve, inside an opening 32 provided in the valve body 8.
This movable finger has a tapered front portion 34 and a rear portion 35 effecting the guiding of the finger 30 in the valve body and having an opening 36 inside which is disposed a spring 37 bearing against the valve body 8 in order to maintain the part 34 of the movable finger in contact with the front face 38 of the piston 6. This face 38 is the face of the piston remote from the face 7 which comes into contact with the valve operating fluid when it is returned to its closed position.
The rear portion and the front portion of the movable finger are connected by an intermediate portion 39 having a frusto-conical outer surface.
The front part 34 of the movable finger is provided with a predetermined breaking point 40 ahead of the frustoconical surface 39.
It will be understood that, when the movable part of the valve moves in the axial direction, the finger 30 will accompany this movable part, to which it is connected kinematically and against which it bears directly by its front part 34.
The displacement detection arrangement 31 is of a construction entirely comparable to the detection device 9 shown in FIG. 2, and has a rod 45 held against the frusto-conical surface 39 of the movable finger by a spring 46.
Like the rod 15, the rod 45 is mounted for translatory movement in a direction at right angles to the axial direction of displacement of the valve, inside the valve body.
The displacement monitoring device 31 likewise comprises a displacement transducer 48 of the differential transformer type, for monitoring the displacements of the rod 45 which accompany the displacements of the movable finger 30, i.e., of the movable part of the valve.
In the embodiment of the device shown in FIGS. 3 and 4, the movable member of the detection device, accompanying the displacements of the movable part of the valve, is composed of the assembly comprising the movable finger 35 and the rod 45 moving inside the valve body and kinematically connected to the movable part of the valve.
The displacements and the positions of the movable part of the valve can be monitored by the device 48, as in the embodiment shown in FIG. 2.
The predetermined breaking point 40 makes it possible to interrupt the kinematic connection between the movable part of the valve and the movable detection member in the event of the jamming of the latter.
In this way, the valve can operate even if the detection device suffers damage entailing its mechanical jamming.
It can be seen that the principal advantages of the invention are that it permits the use of an extremely simple and extremely reliable detection device connected directly to the movable member of the valve, thereby eliminating all risk that the movements of the valve will be hindered by the movable member of this detection device.
The invention extends to the use of any contact surface between the detection member and the movable part of the valve, provided that this surface makes it possible to transmit to the detection member displacements representing the displacements of the movable part of the valve.
While, a displacement transducer of the differential transformer type has been described, this transducer may be of a different type, for example of the potentiometer type, of the stress gauge type, of the variable capacitor type, or of the staged contact series type. This transducer may also be in the form of an induction type proximity transducer or of an optical detector.
The predetermined breaking point may be disposed on any part of this movable member, or a plurality of predetermined breaking points may be provided on the different parts of this movable member. For example, in the case of the device shown in FIG. 4, it is possible to have a predetermined breaking point both on the tapered portion 34 of the movable finger and on the displacement monitoring rod 45.
Finally, the device according to the invention is applicable to all safety valves whose correct operation should usefully be verified in an extremely reliable manner. | Device for detecting the operation of a valve, comprising a movable member (15) connected kinematically to a movable part (6) fastened to the closure member of the valve. A detector (24, 25, 26) makes it possible to monitor the displacements or the position of the detection member (15). The detection member (15) has at least one part provided with a predetermined breaking point (20). The kinematic connection between the valve and the detection member (15) can thus be interrupted by the breaking of the member (15) in the event of the jamming of the latter. The invention is in particular applicable to safety valves in nuclear power stations. | 8 |
This is a continuation of application Ser. No. 07/923,061, filed Jul. 31, 1992, U.S. Pat. No. 5,402,477.
TECHNICAL FIELD OF THE INVENTION
This invention relates in general to communication systems and in particular to a method and system for configuring a telephone.
BACKGROUND OF THE INVENTION
Typical business and residential telephone systems are limited in the array of services which are offered to a telephone user. This shortcoming can be based on limitations (1) in the telephone instrument itself or (2) in the switching network to which the telephone instrument is connected. For example, some special services might not be supported by the switching network's software or hardware.
Even if a special service is supported by the switching network's software and hardware, a user normally establishes and accesses the special service (1) by using one or more preprogrammed control function keys of the telephone instrument or (2) by entering a touchtone command sequence through the telephone instrument's numeric keypad. Although a control function key usually is more convenient for the user than a touchtone command sequence, the telephone instrument might offer only a fixed array of such control function keys for establishing special services.
Moreover, previous techniques typically fail to automatically configure a telephone to offer the user only those services which are actually supported by the switching network. Instead, under previous techniques, the telephone is manually configured. Each time a service is modified or added to the system, the configuration is manually repeated.
Thus, a need has arisen for a method and system for configuring a telephone, in which a user establishes and accesses a special service by using one or more control function keys of the telephone. Also, a need has arisen for a method and system for configuring a telephone, in which the telephone offers a variable array of control function keys for establishing special services. Further, a need has arisen for a method and system for configuring a telephone, in which the telephone is automatically configured to offer the user only those services which are actually supported by the switching network.
SUMMARY OF THE INVENTION
In a first aspect of a method and system for configuring a telephone, a connection is formed between the telephone and a telephone environment. A list of services offerable through at least one type of telephone environment is generated. A list of candidate procedures for establishing each listed service through the telephone environment is generated. Ones of the listed procedures are executed to determine whether each listed service is supported by the connection.
In a second aspect of a method and system for configuring a telephone, multiple lines supportable by the telephone are determined. A number of the lines supported by the connection are determined in response to whether the telephone environment is responsive to a respective condition of each line.
In a third aspect of a method and system for configuring a telephone, a connection is formed through a telephone environment between the telephone and a device. Information is communicated from the device to the telephone. At least one function is provided on the telephone in response to the information, such that the telephone communicates additional information to the device in response to the function being selected.
It is a technical advantage of the present invention that a user establishes and accesses a special service by using one or more control function keys of the telephone.
It is another technical advantage of the present invention that the telephone offers a variable array of control function keys for establishing special services.
It is a further technical advantage of the present invention that the telephone is automatically configured to offer the user only those services which are actually supported by the switching network.
BRIEF DESCRIPTION OF THE DRAWINGS
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:
FIGS. 1a-c illustrate an exemplary programmable telephone;
FIG. 2 is a block diagram of a network and switch environment;
FIG. 3 is a flow chart of a first technique for determining capability profile information of a network and switch environment, according to the preferred embodiment; and
FIG. 4 is a flow chart of a second technique for determining capability profile information of a network and switch environment, according to the preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the present invention and its advantages are best understood by referring to FIGS. 1-4 of the drawings, like numerals being used for like and corresponding parts of the various drawings.
FIG. 1a illustrates an exemplary programmable telephone, indicated generally at 10, which is programmable for a variety of applications. Telephone 10 inputs and outputs audio signals through an associated handset 12. Telephone 10 includes a touch screen 14 over an LCD display. Touch screen 14 includes defined regions 16a-m which function as simulated buttons. Region 17 displays a telephone number associated with telephone 10.
Telephone 10 further includes (1) a dual tone multi-frequency ("DTMF") signal generator and (2) speaker-independent speech recognition circuitry. Also, telephone 10 includes memory card circuitry for reading and writing to a removable memory card 18, such as a magnetic or optical storage card. Alternatively, telephone 10 can be connected to a peripheral device including such memory card circuitry.
In response to any of regions 16a-n being physically contacted, telephone 10 performs a specified function associated with the physically contacted region. As shown in FIG. 1a, regions 16a-l display twelve standard buttons of a traditional telephone. Telephone 10 outputs a DTMF signal on a network line 20 either in response to the user touching any of regions 16a-l, or in response to a digit orally specified by the user's voice into handset 12. A region 21 displays telephone number digits as associated DTMF signals are output by telephone 10.
Instead of orally specifying a digit, the user can engage in "spoken speed dialing", where the user specifies a receiving site by orally stating a phrase (e.g. "Call Home") into handset 12. In response to such a phrase, telephone 10 outputs a series of DTMF signals on network line 20. Such DTMF signals correspond to digits of the telephone number associated with the specified receiving site (e.g. "Home").
Accordingly, telephone 10 stores a directory of telephone numbers. Region 16m on screen 14 is defined as a "directory" button. In response to the user touching region 16m, the display of screen 14 changes to that shown in FIG. 1b. As shown in FIG. 1b, screen 14 includes regions 22, 24, 26a-b, 28a-c, 30a-b, 32, 34 and 36.
In fields 38a-g, region 22 displays a directory of names and associated telephone numbers stored by telephone 10, indexed under the highlighted letter "J" in region 32. Region 24 displays information from a highlighted field 38b of region 22. The user can change the highlighted field of region 22 to be any of fields 38a-g by selectively touching regions 26a-b in order to scroll through fields 38a-g. Alternatively, the user can change the highlighted field by directly touching a selected one of fields 38a-g in region 22.
Similarly, the user can change the highlighted letter in region 32 by selectively touching regions 30a-b in order to scroll through letters A-Z displayed in region 32. Alternatively, the user can change the highlighted letter in region 32 by directly touching a selected one of letters A-Z displayed in region 32. As another letter is highlighted, the display of names and associated telephone numbers in region 22 is updated to display the names and associated telephone numbers indexed under the highlighted letter.
By touching region 34 ("Dial"), the user dials the telephone number displayed in the highlighted field of region 22. By touching region 28c ("Erase Name"), the user erases the name and associated telephone number in the highlighted field of region 22. By touching region 28a ("Add Name"), the user can add a new name and associated telephone number to region 22 for storage in telephone 10. Similarly, by touching region 28b ("Change Name"), the user can change the name or associated telephone number in the highlighted field of region 22.
When the user touches either region 28a ("Add Name") or region 28b ("Change Name"), the display of screen 14 changes to that shown in FIG. 1c. As shown in FIG. 1c, screen 14 includes a region, indicated generally at 40, displaying a typewriter-like keyboard.
If the user touches a region 42 ("Name") of screen 14, the user can use region 40 to enter a new name into telephone 10, or to edit the name earlier highlighted in region 22 when the user touched region 28b ("Change Name") of FIG. 1b.
If the user touches a region 44 ("Phone Number"), the user can use region 40 to enter a new telephone number into telephone 10, or to edit the telephone number earlier highlighted in region 22 when the user touched region 28b ("Change Name") of FIG. 1b.
If the user touches a region 46 ("Record Name"), telephone 10 records a phrase orally stated by the user into handset 12. As directed by the user, telephone 10 associates the recorded phrase with a stored telephone number. When the user subsequently engages in "spoken speed dialing", the user can specify the stored telephone number by orally restating the phrase into handset 12.
Telephone 10 is able to read and write stored information to removable memory card 18. The stored information includes directory structure and voice templates. Accordingly, if the user touches a region 48 ("Read Card"), telephone 10 reads and stores information from removable memory card 18. Similarly, if the user touches a region 50 ("Write Card"), telephone 10 writes its stored information to removable memory card 18. Then, memory card 18 can be removed from telephone 10 and reinserted into a different telephone in order to transfer the stored information.
When the user touches a region 52 ("Go Back"), the display of screen 14 returns to that shown in FIG. 1b. Such a "directory" application, as discussed hereinabove in connection with FIGS. 1a-c, is only one example of many functions performable by telephone 10. Users can program various other types of functions to be performed by telephone 10, with each programmed function having an associated user-defined region displayed on screen 14.
FIG. 2 is a block diagram of a network and switch environment ("telephone environment"), indicated generally at 60, including a switch 62 and a network 64. Switch 62 and network 64 are included within a commercial telephone service company system, but alternatively can be included within a Private Branch Exchange ("PBX"). Environment 60 interacts with one or more telephones, such as telephone 10 of FIGS. 1a-c.
As shown in FIG. 2, switch 62 is connected to telephone 10 through network line 20, to a telephone 66 through a network line 68, and to a telephone 70 through a network line 70. Accordingly, telephones 10, 66 and 70 are coupled through switch 62 to network 64. Similar to telephone 10, each of telephones 66 and 70 includes respective memory card circuitry for reading and writing to removable memory cards 18, 74 and 76. Any of memory cards 18, 74 and 76, are insertable into any of telephones 10, 66 and 70. The system of the preferred embodiment includes the interconnected combination of environment 60, and at least one of telephones 10, 66 and 70.
Telephone 10 is representative of telephones 66 and 70. In a significant aspect of the preferred embodiment, telephone 10 is configurable to match the capabilities and limitations of environment 60. Accordingly, telephone 10 advantageously adapts to the capabilities and limitations of environment 60 in order to achieve substantially optimal functionality.
The base capabilities of telephone 10 are supported by information stored in a memory of telephone 10, together with information stored on memory cards 18, 74 and 76. If telephone 10 lacks a priori knowledge of environment 60, then telephone 10 is subject to complete or partial reconfiguration upon (1) insertion or removal of a memory card into telephone 10 or (2) initial connection or reconnection of telephone 10 to switch 62. Telephone 10 detects such situations and self-initiates its reconfiguration. Although telephone 10 is also subject to reconfiguration upon a power-on cycle of telephone 10, telephone 10 preferably memorizes its configuration between power-on cycles.
Moreover, telephone 10 is subject to reconfiguration upon initial programming or reprogramming of switch 62 or of network 64, so that telephone 10 effectively adapts to the service mix of capabilities and limitations of environment 60. Environment 60 (including switch 62 and network 64) initiates the reconfiguration of telephone 10 by notifying telephone 10 in the event of such programming.
Although telephone 10 is comprehensively programmable, environment 60 provides only limited services that can be offered through telephone 10. This limitation is a function of network/switch hardware and of switch software. Moreover, even if environment 60 provides a particular service, environment 60 might not authorize telephone 10 to access the particular service. Services offered through telephone 10 might also be limited by a lack of standardized procedures for accessing the services of environment 60, such as where the procedures vary according to different telephone service vendors.
If standardized procedures are available, such procedures are used in the system of the preferred embodiment for communicating between telephone 10 and environment 60. Using such standardized procedures, telephone 10 electronically exchanges capability profile information with environment 60 (including switch 62 and network 64) for establishing available services. Such an exchange of information can be initiated either by telephone 10 or by environment 60. After exchanging capability profile information, telephone 10 stores the established capability profile. In situations discussed hereinabove where telephone 10 is subject to reconfiguration, telephone 10 again exchanges capability profile information with environment 60 in order to update the stored capability profile.
Moreover, if standardized procedures are available for communicating between telephones 10, 66 and 70, then for example telephone 66 can communicate information to telephone 10 for display on screen 14. In response to such information displayed on screen 14 of telephone 10, the user can touch one or more defined regions of screen 14 in order to communicate information to telephone 66. Such an exchange of information can occur between telephone 10 and any other type of device connected to switch 62. For example, network line 72 can be connected to a computer instead of telephone 70.
If standardized procedures are not available for accessing the services of environment 60 according to different telephone service vendors or switch hardware/software vendors, then the system of the preferred embodiment supports user-interactive procedures in which the user specifies the vendor to telephone 10. After learning of the specified vendor, telephone 10 reads information either from its own memory or from memory card 18, in order to determine vendor-specific procedures and capability profile information for establishing available services. If the vendor changes, then the user specifies the new vendor to telephone 10. If the vendor-specific procedures change, or if the vendor's capability profile information changes, then the user either updates the memory of telephone 10 or inserts an updated version of memory card 18.
Although the system of the preferred embodiment supports user-interactive procedures, such user-interactive procedures slightly inconvenience the user and therefore are not preferred. Significantly, vendor-independent techniques are advantageously used in the system of the preferred embodiment for communicating between telephone 10 and environment 60. According to such vendor-independent techniques of the preferred embodiment, it is unnecessary for the user to specify information to telephone 10 concerning vendors, vendor-specific procedures, or capability profile information.
Using vendor-independent techniques of the preferred embodiment, telephone 10 electronically "explores" environment 60 to determine capability profile information for establishing available services. Telephone 10 performs such a determination in situations discussed hereinabove where telephone 10 self-initiates its reconfiguration. After determining capability profile information, telephone 10 stores the established capability profile. In situations discussed hereinabove where telephone 10 self-initiates its reconfiguration, telephone 10 again electronically "explores" environment 60 in order to update the stored capability profile.
FIG. 3 is a flow chart of a first technique of telephone 10 for determining capability profile information, according to the preferred embodiment. Telephone 10 has a maximum number of lines that are supportable by a connection to environment 60. According to the technique of FIG. 3, telephone 10 determines which of its maximum number of lines are actually supported by the connection to environment 60.
Execution begins at a step 80, where telephone 10 initializes a present line to be line #1. At step 82, telephone 10 sets the present line off-hook. At decision block 84, telephone 10 determines whether a dial tone is detected in response to the present line being off-hook. If a dial tone is detected, then at step 86 telephone 10 stores an indication that the present line is supported by the connection to environment 60. Execution then continues to decision block 88.
If a dial tone is not detected at decision block 84, then at decision block 88 telephone 10 determines whether the present line equals the maximum number of lines supportable by a connection to environment 60. If not, then step 90 increments the present line number, and execution returns to step 82.
If at decision block 88 telephone 10 determines that the present line equals the maximum number of lines, then decision block 92 determines whether any lines are supported by the connection to environment 60 (in response to the indications stored at step 86). If yes, then at step 94 telephone 10 sets up for operation on all the supported lines, such that screen 14 of telephone 10 displays for each supported line an associated region (e.g. a region labelled as "Line #3") for the user to touch in order to select the supported line. If no lines are supported by the connection to environment 60, then at step 96 telephone 10 notifies the user to check the connection to environment 60.
FIG. 4 is a flow chart of a second technique of telephone 10 for determining capability profile information, according to the preferred embodiment. Telephone 10 comprehensively determines capability profile information by using the technique of FIG. 4 together with the technique of FIG. 3. For determining capability profile information, telephone 10 stores (1) a list of services possibly offered through environment 60 and (2) a list of candidate procedures for establishing each listed service.
For example, the list of offerable services includes camp-on, call forwarding, transfer, conference calls, call waiting, and call pickup. In the list of candidate procedures, telephone 10 is programmed to test a variety of control standards appropriate for different PBX manufacturers and different service vendors. For example, one vendor might support the camp-on service in response to receiving the command sequence FLASH#1 from telephone 10. Another vendor might require a different command sequence. Moreover, network responses to such command sequences might vary from one vendor to another. Advantageously, telephone 10 is programmed to support a wide range of expected interface standards.
Using the stored lists (i.e., list of offerable services, and list of candidate procedures), telephone 10 determines capability profile information by sequentially attempting to establish each possibly available service through environment 60, and by then monitoring the response through environment 60 to determine whether the service is supported by the connection to environment 60.
Accordingly in FIG. 4, execution begins at a step 100, where telephone 10 initializes a present service to be the first service in the list of possibly available services. At step 102, telephone 10 initializes a present procedure to be the first procedure in the list of possible procedures for establishing the present service. At step 104, telephone 10 communicates with environment 60 in order to execute the present procedure.
At decision block 106, telephone 10 determines whether the present service is established. For example, telephone 10 is able to monitor network line 20 either (1) for a fast busy response from environment 60 indicating that the service is not available) or (2) for a recorded announcement indicating that the service is available. For a service involving multiple lines (such as camp-on, call forwarding, transfer, conference calls, call waiting, and call pickup), telephone 10 tests the service's functionality at decision block 106 in order to determine whether the service is properly established.
Accordingly, if telephone 10 has a requisite number of lines supported by the connection to environment 60, then telephone 10 autonomously tests the service's functionality at decision block 106. For example, in testing the functionality of camp-on service, telephone 10 sets its own Line #1 off-hook. Then, telephone 10 uses its own Line #2 to automatically call its own Line #1. In response to the busy signal resulting from Line #1 being off-hook, telephone 10 returns Line #2 to on-hook. Telephone 10 then returns Line #1 to on-hook. After returning Line #1 to on-hook, telephone 10 determines whether camp-on service is functional by monitoring whether environment 60 rings Line #2.
Similarly, in testing the functionality of call waiting service, telephone 10 uses its own Line #2 to automatically call its own Line #1. Telephone 10 then uses its own Line #3 to automatically call Line #1. After using Line #3 to call Line #1, telephone 10 determines whether call waiting service is functional by monitoring whether environment 60 provides a call waiting indication to Line #1. Telephone 10 likewise uses three lines to autonomously test the functionality of other services such as call forwarding, transfer, conference calls, and call pickup.
If telephone 10 does not have the requisite number of lines for autonomously testing a particular service's functionality, then telephone 10 communicates with one or more other telephones (such as telephones 66 and 70 of FIG. 2) in order to test the particular service's functionality at decision block 106. For example, if telephone 10 has a line (Line #1), if telephone 66 has a line (Line #2), and if telephone 70 has a line (Line #3), then telephones 10, 66 and 70, together are sufficient to test the functionality of call waiting service within environment 60. In this example, telephone 10 (Line #1) automatically calls telephone 66 (Line #2). In response to a command sequence from telephone 10, telephone 66 starts an internal timer. The command sequence notifies telephone 66 concerning the type of service being tested. After disconnecting from telephone 66, telephone 10 (Line #1) automatically calls telephone 70 (Line #3). In response to a command sequence from telephone 10, telephone 70 starts an internal timer which is set to expire after the internal timer of telephone 66 expires. Telephone 10 then disconnects from telephone 70.
After the internal timer of telephone 66 expires, telephone 66 (Line #2) automatically calls telephone 10 (Line #1). Later, after the internal timer of telephone 70 expires, telephone 70 (Line #3) automatically calls telephone 10 (Line #1). Since telephone 10 knows when the internal timer of telephone 70 is set to expire (and therefore when telephone 70 is set to call telephone 10), telephone 10 (Line #1) determines whether call waiting service is functional by monitoring whether environment 60 provides a call waiting indication after the internal timer of telephone 70 is set to expire. Telephone 10 likewise coordinates with telephones 66 and 70 to test the functionality of other services such as call forwarding, transfer, conference calls, call pickup, and camp-on.
If telephone 10 determines at decision block 106 that the present service is not established, then telephone 10 determines at decision block 108 whether more procedures are included in the list of possible procedures. If more procedures are included, then at step 110 telephone 10 sets the present procedure to be the next procedure in the list of possible procedures. Execution then returns to step 104.
If telephone 10 determines at decision block 106 that the present service is established, then at step 112 telephone 10 sets up for operation of the present service, such that screen 14 of telephone 10 displays for the present service an associated region (e.g. a region labelled as "Camp-On") for the user to touch in order to select the present service. Execution then continues to decision block 114.
If telephone 10 determines at decision block 108 that more procedures are not included in the list of possible procedures, then telephone 10 determines at decision block 114 whether more services are included in the list of possibly available services. If yes, then at step 116 telephone 10 sets the present service to be the next service in the list of possibly available services. Execution then returns to step 102. If telephone 10 determines at decision block 114 that more services are not included in the list of possibly available services, then execution ends.
Accordingly, telephone 10 uses the technique of FIG. 4 to determine availability of specific network features such as CLASS or CENTREX services. Although such a service is supportable in response to a user-specified command sequence (e.g. "*60"), telephone 10 simplifies the user interface by displaying a region (e.g. a region labelled as "Call Block") on screen 14 for the user to touch in order to select the service.
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. | A method and system are provided for configuring a telephone (10). A connection (20) is formed between the telephone (10) and a telephone environment (60). A list of services offerable through at least one type of telephone environment is generated (100). A list of candidate procedures for establishing each listed service through the telephone environment is generated (102). Ones of the listed procedures are executed (104) to determine whether each listed service is supported by the connection (20). | 7 |
BACKGROUND OF THE INVENTION
This invention related to the field of sawing, and more particularly to a device for orienting logs so as to maximize useful yield when the logs are sawn.
In a sawmill, as logs are moved longitudinally relative to a saw blade, either by moving the logs or by moving the saw, a cut substantially parallel to the log axis results. In order to maximize yield, the angularity of the log axis with respect to the direction of log movement may be controlled; the orientation of the log about its axis, with respect to the plane of the saw blade may also be controlled. These orientations become more important the more a particular log deviates from an ideal cylindrical shape.
A common variation from cylindrical shape in logs is "sweep", which term describes a log whose axis is curved, rather than being a straight line. Feeding mechanisms normally are not adapted to follow the sweep of the log, so straight-line sawing must be done in a way that maximizes yield from such a log. Although it is possible for a log axis to follow a corkscrew path, or other compound curve, it is more common for a log axis to follow a simple curve lying substantially in a single plane. For such a log, it can be shown that yields are maximized by cutting the log in planes parallel to the plane containing the log axis. Thus, where a saw blade lies in a vertical plane, the plane in which the log axis lies should also be vertical.
Prior devices have been proposed for controlling the orientation of logs as they are fed to a saw. U.S. Pat. Nos. 4,294,149, 4,365,704, 4,570,687 and 4,458,567 are representative. Optical scanners and the like may be used in association with log turners to properly orient logs for sawing, as in U.S. Pat. No. 4,294,149, above. Otherwise, the logs may be rotated manually, or by manually controlled machines, with the exercise of human judgment.
SUMMARY OF THE INVENTION
The present invention has an object of automatically orienting curved logs about their axis as they are fed to a saw in such a way as to maximize yield. It is desired to do so without employing log turners, and without the need for automatic sensors and the like, and yet to avoid the errors inevitably resulting from the use of judgment.
Accordingly, the invention is summarized as a method of orienting curved logs for sawing by a vertical sawblade, comprising a step of supporting the log near its center of gravity for a period of time, while permitting the log to rotate freely about its axis under the influence of gravity. By this simple method, the logs automatically orient themselves properly--with the curve of the axis in a vertical plane--in a minimum amount of time, without the need for human supervision or artificial intelligence.
The method is carried out by an apparatus comprising a device for supporting a log near its center of gravity, the supporting means including means for permitting the log to rotate freely about its axis.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings,
FIG. 1 is an isometric view showing a typical log having sweep, supported horizontally by a conveyor.
FIG. 2 shows in isometric the same log, properly oriented for sawing by a vertical blade.
FIG. 3 is an end view in partial section, showing the method of the invention being implemented by a apparatus supporting the log.
FIG. 4 is a side elevation of the apparatus illustrated in FIG. 3, with portions partially broken away to show underlying structure.
FIG. 5 is a top plan view showing details of the apparatus.
FIG. 1 shows a curved log L supported by a roller conveyor 10 so that the axis of the log extends generally horizontally. The curve is exaggerated, so as to show clearly that the plane P containing the simply curved axis A is substantially horizontal; thus, the log is not oriented optimally for sawing by a vertical blade. In FIG. 2, the log, supported at its midpoint by a turning device 12, has been permitted to rotate by gravitational force so that the plane P is substantially vertical. The turning device and method are described in detail below.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is embodied in a log turning device 12, associated with the conveyor 10 described above.
As shown in FIGS. 3-5, the device comprises a frame 30 attached to the frame of the conveyor 10 and extending upwardly therefrom. A pair of antifriction bearings 32 connected to the frame support a horizontal shaft 34 upon which a cage 36 is mounted in such a way that the cage may rotate with respect to the shaft. Sprockets 38 on either side of the cage are connected by drive chains 40 to respective sprockets 42 on a driveshaft 44, so that the driveshaft turns the cage.
The cage 36 supports a pair of hollow cams 46, each of which has the shape of the frustum of a cone, each tapering toward the other so that an annular groove or valley is formed between the cams, as seen in FIG. 3. The cams have a common cone axis C, which is parallel to but radially offset from the axis of the cage; thus the cams are eccentrically mounted with respect to the cage, for reasons that will become apparent. Each cam has a base 48 connected to the cage, as by welding, and a peripheral surface 50 which engages logs as described hereafter. The peripheral surfaces may be provided with studs or spikes if desired, to prevent logs from rotating while supported by these surfaces. A segment of each cam is cut out of each cam, defining edge 52.
As shown in FIG. 5, a pair of log drive rolls 60 are supported by the cage, each roll being rotatable about an axis parallel to that of the shaft 34. Four sprockets 62 are mounted on each of the rolls, the sprockets being spaced along the length of each roll. The sprockets are connected by respective chains 64 to correspondingly spaced sprockets 66 mounted on and affixed to the shaft 34. Thus, the rolls 60 rotate in the same direction as the shaft 34.
On the opposite side of the cage, two parallel rods 68, FIG. 4, whose axes lie in planes perpendicular to the axis of shaft 34, are supported by webs welded within the cage. Each of these rods supports four wheels 70 having bearings or bushings that render the wheels freely rotatable at all times. The periphery 72 of each wheel 70 protrudes through an opening in the cam with which it is associated, slightly above the peripheral surface thereof, so that it can engage logs passing over the device, in certain angular positions of the cage.
The cage may be turned, by means of the driveshaft, between a log driving position in which the sprockets 62 are uppermost, and a log turning position in which the wheels 70 are uppermost. In the driving position, a log passing over the device is engaged from below solely by the sprockets 62 and chains 64. In the turning position, the log is supported solely by the wheels 70, and in intermediate positions, the log is supported by the peripheral surfaces of the cams.
In operation, a series of logs are passed down the conveyor 10 to the device 12. The cage is normally maintained stationary in the log driving position ("first position", in the following claims), so that the sprockets 62 contact the log. During the feeding phase, the shaft 34 is rotated by drive means (not shown), so the sprockets rotate as well, and propel the log forward. As the log progresses across the device 12, with drive shaft 34 rotating, a point is reached at which the midpoint of the log is upstream of the device by a distance equal to one-half the circumference of the cage assembly. This point may be determined by an operator or by various devices, such as optical sensors, particularly where the logs are of known length. The operator or the sensor then activates the drive shaft 44 to rotate the cage 36, whose cam surfaces serve as means for elevating the log while continuing to carry it forward so that the wheels 70 contact the log at approximately its midpoint. After about 160° of rotation from the drive position, the log becomes supported solely by the wheels 70, and is then free to rotate about its axis.
At the 180° point ("second position", in the following claims), because the wheels define a flat, and now horizontal supporting surface, the log drops slightly; the jarring action helps initiate any necessary turning. Since the log is centered lengthwise on the device, the great majority of its weight is supported by the wheels, with only incidental contact, perhaps, occurring between one end of the log and the conveyor 10. Regardless, the log is substantially free now to rotate around its own axis, and does so under the influence of gravity, until the center of gravity of the log is at a minimum height. For a simply curved log, at this point, the "horns" at the ends of the curve are downward, and the curve is in a substantially vertical plane, properly oriented for sawing by a vertical blade, designated B in FIGS. 1 and 2.
Upon continued rotation of the device, the cage lowers the log back onto the conveyor, whereafter convention devices may be employed to maintain the log in its proper angular orientation on the conveyor. Once the chains 64 come back into contact with the logs, they propel it down the conveyor, and the positioning device is ready for another log.
The foregoing description, and the accompanying drawings, describe only one embodiment of the invention, which is subject to many variations and changes in detail. For example, the number of sprockets and wheels can be changed and still produce the desired effect, and equivalent components can be substituted for those mentioned. Therefore, the invention should be measured by the claims that follow. | A curved log to be sawn lengthwise by a vertical saw blade is supported for a time, near its center of gravity, by a device which permits the log to rotate about its axis, and thus find an orientation at which the plane of the curve of the log axis is vertical, so as to maximize yield from the log. The device also includes drive sprockets which operate, at certain angular positions of the device, to move the log lengthwise. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a rapid and accurate photometric means for displaying exposure time by digital or analog displays, wherein the exposure time is determined by an associated density measurement of a projected negative and said exposure time includes reciprocity compensation for the photographic paper, and wherein said density measured and displayed by digital means is representative of a particular print reflectivity. Further photometric means relate to measuring and displaying by digital means, the optical densities of compensating filters required to obtain a color balance of a photographic print from a color negative. An additional photometric means relates to exposure-time measurements by a digital exposure meter wherein the exposure time displayed by digital means is inversely proportional to the light intensity of a projected negative. A drawback in the prior art has been that most devices for this purpose utilize ammeters and the like, which are subject to drift and mechanical offset introducing uncertainty in the readings as well as consuming an operator's time locating the position of a deflected needle relative to a dimly illuminated scale. Furthermore, to provide reasonably accurate measurements and sensitivity, a high-cost delicate meter must be used. Selectable reciprocity effect compensation for a photographic paper cannot be utilized in a meter instrument, and no means are provided in prior art to determine exposure time by density measurements of a negative regardless of the light level.
We have circumvented these drawbacks by developing an economical instrument capable of accurately and rapidly measuring and digitally displaying optical densities of color compensating filters for photographic color printing and exposure times by density measurements, utilizing among other things, memory gain means to vary the signal gain, a signal integrator coupled to the memory gain means and to a voltage comparator, a reset voltage pulse generator controlling a plurality of gates, an exponential decaying voltage source coupled to the voltage comparator, a voltage pulse generator generating a reference voltage pulse of predetermined duration, a gatable clock controlled by the voltage comparator and reference voltage pulse, decimal counter, latch and a digital read-out to display optical density or optical density differences, a binary counter controlling the slope of a second integrator voltage, a second voltage comparator coupled to the second integrator and to a fixed or variable voltage source, a gate coupled to the second voltage comparator controlling the integration interval of the signal integrator and gating a second gatable clock, a decimal counter, latch and digital readout to display exposure time.
SUMMARY OF THE INVENTION
A reference area of a color negative illuminated by light from a light source transmitted through a color compensating filter pack is imaged on the aperture of a probe. A light guide directs the light from the probe through selectable primary color filters or a neutral density filter, onto the photosensitive surface of a photodetector producing detector currents proportional to the light intensity incident on the probe. The voltage developed across a resistor by the detector current is amplified by a first variable gain linear amplifier. Memory gains are provided by a second linear amplifier, the gain of which is fixed for selection of the red primary color filter and independently controlled by the variable feedback resistive means associated with the selection of the remaining primary color filters and neutral density filter, and wherein the memory gains are preset by measurements of a standard color negative. The output terminal of the second linear amplifier is coupled through an input gate-controlled switch and selected variable or fixed resistive means to the input terminal of an integrator, the capacitor of which is shunted by a gate-controlled switch. Said switches are controlled by further gating means coupled to a second integrator or to a voltage pulse generator, wherein the input switch is closed and the switch shunting said capacitor is opened coincident with the occurence of a periodically generated reset voltage pulse, and the input switch is opened by gating means coupled to the second integrator or to a voltage pulse generator. A ganged switching means, mechanically coupled to selection means of primary color and neutral density filters, couples the signal integrator to said variable resistive means for primary color filter selection associated with color density measurements and to said fixed resistive means for selection of the neutral density filter associated with exposure time related density measurements. The output voltage of the signal integrator is held when said input switch is opened, wherein said output voltage is proportional to the time of integration, intensity of light incident on the photodetector, the memory gain and resistance of said selected resistive means. A capacitor, which is gated to charge abruptly coincident with the occurence of the reset voltage pulse, is gated to discharge exponentially through a resistive means when the input switch to the signal integrator opens. Said capacitor is coupled to one input terminal and the output terminal of the signal integrator is coupled to the other input terminal of a voltage comparator, the output terminal of which is coupled to one of the input terminals of NAND and NOR gates. A pulse generator, which generates a reference voltage pulse of predetermined and fixed duration and is gated on by the reset voltage pulse, is coupled to the other input terminals of said NAND and NOR gates, the output terminals of which are coupled to the set and reset input terminals of a set-reset flip-flop, respectively. The enabling terminal of a gate-controlled clock is coupled to the set output terminal of said set-reset flip-flop, wherein said clock is enabled for the set state of said flip-flop. Said clock is therefore enabled when either the output voltage of the voltage comparator or reference voltage pulse change from high to low, and said clock is inhibited when both of said voltages are low. The output terminal of the voltage comparator is further coupled to one input terminal of an AND gate and said pulse generator is coupled to the other input terminal through an inverter. The reset input terminal of a second set-reset flip-flop is coupled to the output terminal of said AND gate. Said second flip-flop is reset only if the voltage reference voltage pulse changes from high to low and before the output voltage of said voltage comparator. A decimal counter which is reset by said reset voltage pulse is coupled to the clock wherein the count of said decimal counter is latched and transferred to a density LED digital readout. Set and reset output terminals of the second flip-flop are coupled to a latch, said latch transferring a positive sign for the set state and a negative sign for the reset state of said second flip-flop to a sign LED readout. The sign displayed by the sign LED readout and the count displayed by the density LED digital readout indicate the density of a selected primary color compensating filter to add or subtract from a filter pack to obtain a color balanced print from a measured negative; the density indicated by the density LED digital readout related to exposure time is the density representative of a particular print reflectivity, wherein the density read out is dependent on the integration time of the signal integrator. Gating means coupled to a second integrator and voltage comparator controls said integration time such that said integration time is inversely proportion to the light intensity of an imaged reference area of a negative producing said particular print reflectivity; density-measurement and exposure-time display selection is provided by a two position-exposure selectror switch. In the exposure-time display position of the exposure selector switch, the density measuring circuitry is inhibited. A voltage source is coupled to a gated resistive means, wherein gate-controlled switches are coupled to a binary counter. Said resistive means is coupled to the input terminal of the second integrator, the capacitor of which is shunted by a gate-controlled switch. The output terminal of the second integrator is coupled to one input and a variable exposure voltage source coupled to the other input of the second voltage comparator, the output terminal of which is coupled to the reset input terminal of a third set-reset flip-flop, which is reset by the reset voltage pulse. The set output terminal of the third set-reset flip-flop is coupled to the enabling terminal of the second clock, the switch shunting the capacitor of the second integrator and to the input switch of the signal integrator. The set state of the third flip-flop enables the second clock, closes the input switch to the signal integrator and opens the switch shunting the capacitor of the second integrator; the reset state of the third flip-flop inhibits said clock, opens the switch to the signal integrator and closes the switch shunting the capacitor of the second integrator. A decimial counter is coupled to said clock and is reset by the reset voltage pulse. The clock count of the decimal counter is lateched and transferred to an exposure LED digital readout, wherein the count displayed indicates exposure time including compensation for the reciprocity effect of the photographic paper. The reciprocity compensation is provided for by the decreasing slope of the second integrator output voltage resulting from said gated resistive means. For the density-measurement position of the exposure selector switch, the density measuring circuitry is enabled and the second integrator capacitor is charged through a fixed resistive means. The reset state of said third flip-flop opens the input switch to the signal integrator. Thus, the integration time of the signal integrator is a linear function of the variable exposure voltage whereas the exposure time displayed is a function of the variable exposure voltage that provides compensation for the reciprocity effect. The density displayed by digital means and representative of a print reflectivity which will result for the projected area of the negative and for the exposure time displayed by digital means, is determined by the variable exposure voltage, the exposure memory gain having been preset by measurement of a standard negative.
The second decimal counter may comprise an up-down counter wherein the count is held by the latch associated with said decimal counter may be utilized for automatically timing a photographic printing system when enabled to down-count. Alternatively the count held in the latch may be strobed into an external digital timer which could be used for automatic exposure timing.
A switch is provided to either couple the second linear amplifier input terminal to the output terminal of the first amplifier or to a fixed voltage source. When the input terminal of the second amplifier is coupled to the fixed voltage source, the memory gains of the second amplifier are displayed by the density LED digital readout, providing means for accurately resetting the memory gains.
A potentiometer means coupled to a voltage source and to one of the input terminals of the first amplifier provides means for balancing the off-set voltage of the first amplifier and the dark current of the photodetector to zero.
An alternative digital-analog circuit may be used for making exposure time measurements including the reciprocity effect compensation for the photographic paper by density measurements of a projected image, wherein the density measured is representative of a particular print reflectivity: a dial, calibrated to display exposure time including reciprocity effect compensation for the photographic paper, is coupled to a feedback potentiometer which controls the gain of a linear amplifier coupled between the first and second amplifiers and said switches coupled to the input terminal of the signal integrator and shunting the capacitor of the signal integrator are controlled by a voltage pulse of predetermined and fixed duration produced by a voltage pulse generator. The density displayed by digital means for the projected image is representative of the print reflectivity which will result for the exposure time displayed on the dial, the exposure memory gain having been preset by measurement of a standard negative. The modified circuit also provides the capability for measuring and displaying by digital means the densities of color compensating filters required for a color balance of a color negative.
A combination of components of the analog to digital circuit for measuring filter densities and exposure time by density measurements may be utilized to function as an exposure meter. The exposure time measured and displeyed by digital means is the the exposure time as conventionally measured which is inversely proportional to the light intensity of a projected image, wherein: phtocurrent produced by light from a reference area of a negative imaged on the probe is amplified by a linear amplifier, the output terminal of which is coupled to the input terminal of the signal integrator through a variable resistive means. Said variable resistive means controls the gain of said signal integrator, the output terminal of which is coupled to one input terminal of a voltage comparator and a fixed voltage source is coupled to the other input of the voltage comparator, the output terminal of which is coupled to the reset input terminal of a first set-reset flip-flop which is reset when the voltage at the output terminal of the voltage comparator changes from low to high. A gate-controlled switching shunting the signal integrator capacitor is coupled to the set output terminal of said flip-flop and is opend when said flip-flop is set and closed when said flip-flop is reset. A gate-controlled clock is coupled to the set output terminal of a second set-reset flip and is enabled when said flip-flop is set and inhibited when said flip-flop is reset. The reset pulse generator sets said flip-flops and resets a decimal counter coupled to said clock; said capacitor coupled to the integrator is linarly charged by the voltage at the output of said amplifier and said clock is enabled. When the integrator output voltage is equal to said fixed voltage, the voltage at the output of the voltage comparator changes from low to high, resetting the second flip-flop, which inhibits the clock and resets the first flip-flop, which closes the switch shunting the integrator capacitor. The clock count of the decimal counter is latched and transferred to an LED digital readout, said count displayed corresponding to exposure time wherein the resistance of said variable resistive means is preset by measurement of a standard negative.
OBJECTS OF THE INVENTION
It is therefore an object of the invention to detect by integrating means and to indicate by digital means the optical density differences for primary color components of light between a standard color negative and a color negative to be printed.
A further object of the present invention is to measure optical density differences for the primary color components of light between a standard color negative and a negative to be printed without regard to the absolute densitites.
Another object of the invention is to store reference gains proportional to the primary colors transmitted through a standard filter pack and reference area of a standard color negative, one of which is a predetermined fixed gain.
An additional object of the invention is to prove digital means to measure and analog means to displey exposure times incouding reciprocity effect compensation for the photographic paper.
A further object of the invention is to store a reference gain proportional to light transmitted through a selected area of a standard negative by adjusting the exposure memory gain to reproduce a density display representative of a particular print reflectivity for the exposure time digitally displayed or displayed by analog means.
Another object of the invention is to display by digital means the density representative of a particular print reflectivity for any reference area of a photographic negative to be printed and to display the exposure time required to produce the particular print reflectivity either by digital or analog means.
A further object of the invention is to provide reciprocity effect compensation plug-in modules so that changes in the reciprocity effect compensation for different photographic papers can easily be made.
Another object of the invention is to provide down-count capability of a decimal counter for automatically timing a photographic printing system or interfacing with an existing digital timer.
A further object of the invention is to utilize an integrated circuit means to provide voltage regulation for a switching tansformer to develop the high voltage for a photodetector.
An additional object of the invention is to provied a digital exposure meter means, wherein the exposure time measured and displayed by digital means is inversely proportional to the light intensity of a projected negative.
DRAWINGS
FIG. 1A is a schematic diagram of the circuit to measure and display by digital means the color filter compensation density corrections and the exposure time for photographic color printing, wherein the exposure time is determined by density and density-range measurements of a projected photographic negative. The exposure time displayed includes compensation for the reciprocity effect of the photographic paper.
FIG. 1B is a circuit diagram of a linear amplifier coupled to a dial calibrated to display exposure time by density and density-range measurements of a projected photographic negative or positive image. The dial displaying exposure time is calibrated to compensate for the reciprocity effect of the photographic paper.
FIG. 2 is a timing diagram of one period showing signals utilized for digitally displaying the color compensating filter density corrections for printing a photographic color negative.
FIG. 3A is a timing diagram of one period showing signals utilized to display exposure time digitally including compensation for the reciprocity effect of the photographic paper.
FIG. 3B is a timing diagram of one period showing signals utilized for density measurements representative of print reflectivies that will be produced for a reference area of a projected image of a negative and exposure time that is displayed digitally.
FIG. 4 is a schematic diagram of the digital exposure meter.
DETAILED DESCRIPTION
Referring to FIG. 1A, there is shown a white light source 01 which is used to image a photographic color negative. A plurality of optical elements including: a filter pack 02; a negative holder 03; an adjustable aperture 04; an objective lens 05; a light probe 06; a light guide 07 and cylindrical filter wheel 08 are serially disposed in the path of light between the light source 01 and photodetector 09 mounted within said filter wheel. Cylindrical filter wheel 08 is provided with a plurality of filter windows, which in the preferred embodiment include a red filter R, a green filter GR, a blue filter BL and a neutral density filter ND. These filters may be selectively adjusted in alignment with the light guide 07. For reasons which will become apparent, the adjustment means of the cylinder is mechanically coupled and indexed by a ganged selector switch S2 which selectively aligns filters R, GR, BL and ND.
Light probe 06 and light guide 07 provide a convenient means for monotoring light imaged by a photographic printing system on the aperture of said light probe. Light probe 06 may utilize a suitable light pipe or simply a planar mirror to direct the imaged light into light guide 07.
Switch S2, mechanically coupled to said filter wheel, is a five-pole, five-position switch indexed to select an off position in position 1 and said R, GR and BL filters in positions 2, 3, and 4, and said ND filter in position 5. Imaged light transmitted through a selected filter is collected and directed to the photosensitive surface of the photodetector, which produces a photocurrent through resistor R1. The voltage generated by said photocurrent through resistor R1 is amplified by linear amplifiers 101 and 102. Switch section S2a of switch S2 is coupled to amplifier 102 and associated feedback resistors. In position 2 of switch S2, corresponding to selection of the red primary color filter, the gain of amplifier 102 is constant and determined by the ratio R4/R3. In positions 3, 4 and 5 of Switch S2, the gain of amplifier 102 is adjustable by means of feedback potentiometers R6, R11, and R12, respectively, which in turn are coupled to resistors R5 and R7, R8 and R10 and R11 and R13. The output terminal of amplifier 102 is coupled to variable resistor R14 for positions 2, 3, and 4 of switch S2 and to a fixed resistor R15 for position 5 of switch S2 by coupling means to switch section S2b.
Referring to FIG. 2 there is shown a timing diagram for one period of a reset voltage pulse generated periodically by reset pulse generator 113 and for switch S2 in positions 2, 3 or 4 and switch S1 in position 1. The circuit description directly following corresponds to switches S2 and S1 in these positions. Gate-controlled switches G1-G8 shown in FIG. 1A are FET switches shown in positions corresponding to logical "0" bias. The pole of switch section S2b of switch S2 is coupled to signal integrator 103 through switch G1. Set input terminals of set-reset flip-flops 114 and 126 are coupled to said reset pulse generator and are set by the reset voltage pulse. The set output terminal of flip-flop 114 is coupled to switch G2, wherein switch G2 is opened by the set output voltage of flip-flop 114. The set output terminal of flip-flop 121 is coupled to switches G1 and G3, wherein the set output voltage of flip-flop closes switch G1 and opens switch G3. Capacitor C1, which is coupled to signal integrator 103, is therefore charged linearly by the signal voltage as the output of amplifier 102 coupled to C1 through resistor R14. The reset voltage pulse, which is coupled to the reset input terminals of binary counter 118 and decimal counter 123, reset said counters. Enabling terminal EN1 of the gate-controlled clock 122 is coupled to the output terminal of AND gate 124; the set output terminal of flip-flop 121 and the pole of switch section S2d of switch S2 are coupled to the input terminals of said AND gate. The output voltage of said AND gate is held low since one input of the AND gate is coupled to ground through switch section S2d. Therefore, clock 122 is inhibited. Switches G4-G7, in series with resistors R18-R21 are coupled to the binary output terminals of binary counter 118 and are opened sequentially by the voltages at the binary output terminals by the count of binary counter coupled to said clock. Switches G4-G7 remain closed since said clock is inhibited. Capacitor C3, coupled to integrator 119 and to resistors R18-R22 is therefore linearly charged by current produced by voltage source VR coupled to resistors R18-R21 in parallel combination. The output terminal of integrator 119 is coupled to one input terminal of voltage comparator 120 and the voltage divider R16 is coupled to the other input terminal of said voltage comparator; the output terminal of said voltage comparator is coupled to the input reset terminal of flip-flop 121. When the voltage at the output terminal of said voltage comparator changes from low to high, flip-flop 121 is reset, wherein the voltage change at the set output terminal of said flip-flop opens switch G1 and closes switch G3. The output voltage of signal integrator 103 is held since switches G1 and G2 are open. The input terminals of AND gate 115 are coupled to the set output terminal of flip-flop 114 and reset output terminal of flip-flop 121. The voltage at the output of said AND gate is held low when flip-flops 114 and 121 are set by the reset voltage pulse. Switch G8 is then closed and capacitor C3 of the exponential ramp generator 117 is charged by the voltage source V+ coupled to said capacitor. When flip-flop 121 is reset by said voltage comparator, the voltage at the output of said AND gate changes from low to high. Gate G8 therefore opens and capacitor C3 discharges exponentially through resistor R23. Capacitor C3 is further coupled to one input terminal of voltage comparator 104 and the output terminal of integrator 103 is coupled to the other input terminal of said voltage comparator. Pulse generator 116, which is coupled to reset pulse generator 113 and gated on by the reset voltage pulse, produces a reference voltage pulse of predetermined and fixed duration. The output terminal of pulse generator 116 and that of voltage comparator 104 are coupled to the input terminals of NAND gate 111, the output terminal of which is coupled to the set input terminal of set-reset flip-flop 109. Said reset voltage pulse which is coupled through OR gate 108A to the reset input terminal of flip-flop 109 and decimal counter 112 resets said flip-flop and decimal counter. Gate-controlled clock 110 is inhibited by the voltage coupled to the enable terminal EN2 of said clock at the set output terminal of flip-flop 109. At the instant when either the output voltage of pulse generator 116 changes from high to low or the voltage comparator 104 output voltage changes from high to low, the voltage at the output terminal of NAND gate 111 changes from low to high, setting flip-flop 109 which enables clock 110. Said decimal counter which is coupled to clock 110, counts clock pulses when said clock is enabled. Output terminals of voltage comparator 104 and pulse generator 106 are further coupled to the input terminals of NOR gate 108, the output terminal of which is coupled to reset terminals of flip-flop 109 through OR gate 108A and flip-flop 114. When the output voltages of voltage comparator 104 and pulse generator 116 are both low, the output voltage of NOR gate 108 changes from low to high, which resets said flip-flops and generates a latch enable voltage LE1. Clock 110 is inhibited by the voltage coupled to the enable terminal EN2 of the clock by the set output terminal of flip-flop 109 when said flip-flop is reset and the voltage at the set output terminal of flip-flop 114, which is coupled to one input terminal of AND gate 115 produces a voltage change from high to low at the output terminal of said AND gate which closes switches G2 and G8, charging capacitor C3 coupled to voltage source V+ and discharging capacitor C1. The count of clock pulses counted by decimal counter 112 is held by a latch enabled by the latch enable voltage LE1 and transferred to a density LED digital readout. Pulse generator 116 is further coupled to one input terminal of AND gate 115 through an inverter 106 and the other input terminal of AND gate 105 is coupled to voltage comparator 104. The output terminal of said AND gate is coupled to the reset input terminal of set-reset flip-flop 107, the set input terminal of which is coupled to reset generator 113 and is set by the reset voltage pulse. Only when the output reference voltage of pulse generator 116 changes from high to low before the output voltage of voltage comparator 103 is flip-flop 107 reset. The reset output terminal of flip-flop 107 is coupled to a latch which transfers a negative sign to an LED sign readout; the set output terminal of said flip-flop is coupled to a latch which transfers a positive sign to said LED sign readout. To provide density read out in CP (color compensating) filter units, the duration of the reference voltage pulse is selected to be equal to 100·Log 10 (V+/V2) in units of the period of clock 110 and the time constant of the exponential discharge of capacitor C3 through resistor R23 is selected to be equal to 230 in units of the period of clock 110; the voltage V2 determines the measureable density range.
To calibrate the instrument for density measurements, a standard negative and filter pack which produce a color balanced print are selected. Light transmitted through a selected reference area of the standard negative is imaged on the probe and directed to the photodetector through the selected primary color filters. For position 2 of switch S2 corresponding to selection of the red primary color filter, the signal integrator gain control R14 and/or adjustable aperture adjusted until the output voltage of voltage comparator 104 changes from high to low at the same time that the the out voltage of pulse generator 116 changes from high to low, wherein clock 110 is not enabled and the count displayed by the LED digital readout is zero. For positions 3 and 4 of switch S2, corresponding to green and blue primary color filter selection, respectively, potentionmeters R6 and R11 are adjusted in turn so the count displayed by the density LED digital readout is zero.
To determine the densities of color compensating filters for a color negative to be printed, the light through a selected filter pack and reference area of the negative to be printed similar in color content to the reference area of the standard negative, is imaged on the aperture of the probe. For switch S2 in position 2, corresponding to selection of the red primary color filter, the signal integrator gain control R14 and/or adjustable aperture adjusted until the count displayed by the density LED digital readout is zero. Then, for position 3 of switch S2, the sign displayed by the LED sign readout and the count displayed by the density LED readout indicate the green absorbing compensating filter density to add or subtract from the selected filter pact to obtain a color balanced print; for position 4 of switch S2, the sign displayed by the LED sign readout and the count displayed by the density LED digital readout indicates the blue absorbing compensating filter density to add or subtract from the selected filter pack to obtain a color balanced print of the negative.
Referring to FIG. 3A, there is shown a timing diagram for signals utilized to display exposure time digitally including compensation for the reciprocity effect of the photographic paper, wherein selector switch S2 is set in position 5 and selector switch S3 in position 1. One input of AND gate 115 is coupled to ground through switch section S3b of switch S3, inhibiting the density measuring circuitry. Reset terminals of binary counter 118 and decimal counter 123 and the set input terminal of set-reset flip-flop 121 are coupled to the reset pulse generator 113; said counters are reset and said flip-flop is set by the reset voltage pulse. Input terminals of AND gate 124 are coupled to the set output terminal of flip-flop 121 and to voltage source V+ through switch section S3b of switch S3. The voltage output of said AND gate is therefore set high providing a clock enabling input to terminal EN1 of gate-controlled clock 122. Clock input terminals of binary counter 118 and decimal counter 123 are coupled to the clock output terminal of said clock. Binary counter counts clock pulses of said clock, opening switches G4, G5, G6 and G7 at clock counts 2, 4, 8 and 16, respectively. Switch G3, which is coupled to the set output terminal of flip-flop 121, is opened by the set output voltage of said flip-flop. Capacitor C2, coupled to integrator 119, is therefore charged by voltage source VR through a decreasing number of resistors in parallel corresponding to clock counts 2, 4, 8 and 16. These resistors are selected so that the slope of the output voltage of integrator 119 decreases with time in such a way as to compensate for the reciprocity effect of the photographic paper. One input terminal of the voltage comparator 120 is coupled to the exposure control potentiometer R17 through switch section S2c and the other input terminal of said voltage comparator is coupled to the output terminal of integrator 119. When the output voltage of said integrator is equal to the voltage controlled by potentiometer R17, the output voltage of said voltage comparator changes from low to high, resetting flip-flop 121. The reset state of flip-flop 121 closes switch G3 and inhibits clock 122 by the set output voltage of said flip-flop coupled to the input terminal of AND gate 124. The count of clock pulses by decimal counter 123 is transferred to an exposure LED digital readout by a latch, enabled by the reset output voltage LE2 of set-reset flip-flop 121. The count displayed by the exposure LED digital readout is equal to the exposure time including compensation for the reciprocity effect of the photographic paper.
Referring to FIG. 3B, there is shown a timing diagram of signals utilized in the density measuring circuitry to measure and display by digital means the density of a reference area of a projected image of a negative, wherein said density corresponds to a particular print reflectivity for the exposure timed displayed by the exposure LED digital readout, wherein switch S3 is set in position 2. The density measuring circuitry is enabled by by the coupling of one input of AND gate 115 to the reset output terminal of flip-flop 121 through switch section S2e; clock 122 is inhibited by the input of AND gate 124 coupled to ground through switch section S2d and switch section S3a. Since clock 122 is inhibited, binary counter 118, reset by the reset voltage pulse remains reset, holding switches G4-G7 closed. Switch G3, shunting capacitor C2, is opened by the set output voltage of flip-flop 121 coincident with the occurence of the reset voltage pulse. Capacitor C2 is therefore linearly charged by voltaged source VR coupled to resistors R18-R12 connected in parallel. The timing diagram for the density measurement is essentially that shown in FIG. 2 except that the time interval of integration of signal integrator 103 is equal to the time between the occurence of the reset voltage pulse and the time that the output voltage of integrator 119 is equal to the voltage produced by the exposure potentiometer R17 coupled to voltage comparator 120. The density displayed by the density LED digital readout is representative of the print reflectivity for the exposure time displayed by the exposure LED digital readout, the exposure memory gain having been preset by measurement of a standard negative.
To calibrate the instrument for exposure time measurements, the exposure time is determined for a standard negative having a density range required to produce a print with a desired range of reflectivity. Exposure switch S3 is switched to position 1 and the exposure control voltage produced by potentiometer R16 is adjusted so that the exposure time displayed by the exposure LED digital readout is equal to the exposure time determined for the standard negative. Switch S3 is then switched to position 2. Light from a reference area of the standard negative producing near zero print reflectivity is imaged on the aperture of the probe. The gain or amplifier 102 is adjusted by potentiometer R12 until the density displayed by the density LED digital readout is zero.
To determine the exposure time for a negative to be printed, switch S3 is switched to position 2 and a reference area of the negative is imaged on the probe. The exposure control potentiometer R17 is adjusted so that the density displayed by the density LED digital readout is representative of a desired print reflectivity. Switch S3 is then switched to position 1. The exposure time displayed by the exposure LED digital readout is the exposure time including compensation for the reciprocity effect of the photographic paper required to produce said desired print reflectivity. The count of decimal counter 123, latched and displayed may be strobed into an external digital timer or alternatively the decimal counter 123 may comprise an up-down counter coupled to a suitable clock when the up-down counter is enabled to down count, thus providing automatic digital timing for a photographic printing system.
Resistors R18-R21 may be mounted in a plug-in module to provide means for changing the slope of the output voltage of integrator 119 to conform with that required to compensate for the reciprocity effect of various photographic papers.
R1S and potentiometer R2 coupled to positive and negative voltage sources V+ and V- provide means to compensate for the offset voltage of amplifier 101 and dark current of photodetector 09. Potentiometer R1 and amplifier 101 provides means for adjusting the gain of said amplifier to compensate for sensitivity variations between photodetectors.
Memory gains can be displayed digitally by coupling the input terminal of amplifier 102 to voltage source V+ by switch S1, thereby providing means for accurately resetting memory gains.
The photodetector 09 may comprise a photomultiplier tube, wherein an economical and convenient means for generating a regulated high voltage is to utilize a push-pull switching transformer coupled to transistor means and to integrated circuit voltage regulator means.
An alternative circuit can be derived from the circuit shown in FIG. 1A, wherein the exposure time including compensation for the reciprocity effect of a photographic paper, is displayed by analog means: terminals A1' and B1' of linear amplifier 100 shown in FIG. 1B are coupled to terminals A1 and B1 in the circuit shown in FIG. 1A. Feedback potentiometer R1A controls the gain of amplifier 100; calibration means are provided, wherein a dial coupled to said potentiometer is calibrated to read exposure time including compensation for the reciprocity effect of a photographic paper. A pulse generator, coupled to the reset generator 113 and its output terminal coupled to the set input terminal of set-reset flip-flop 121 replaces the voltage comparator 120 and associated circuitry coupled to said voltage comparator. All other circuit connections for exposure measurements correspond to switch S2 in position 5 and switch S3 in position 2. The pulse generator is gated on by the reset voltage pulse and produces a voltage pulse of predetermined and fixed duration. The exposure time read on the calibrated dial includes the reciprocity compensation and the density measured for a reference area of a negative projected on the probe and displayed by the density LED digital readout is representative of a particular print reflectivity for said exposure time.
A combination of circuit components of FIG. 1A shown in FIG. 4 comprise a digital exposure meter means, wherein the exposure time measured is inversely proportional to the light intensity of a reference area of a negative imaged on the probe. Photodetector current produced by said light imaged on the probe produces a voltage at the output of amplifier 101 which is inversely proportional to the intensity of said imaged light. Position 1 of selector switch S1 is coupled to the output terminal of amplifier 101 and position 2 is coupled to a voltage source VR and the pole of said switch is coupled through a variable resistor R14 to the input of integrator 103 providing memory means. The input terminals of voltage comparator 104 are coupled to the output terminal of said integrator and to a fixed voltage source V+ and the output terminal of said voltage comparator is coupled to the reset input terminal of set-reset flip-flop 109. Reset pulse generator 113 is coupled to the set input terminals of set reset flip-flops 109 and 114 and to the reset terminal of decimal counter 112, setting said flip-flops and resetting said decimal counter. Coincident with the occurence of the reset voltage pulse, gate-controlled switch G2 is opened by the set output voltage of flip-flop 114 coupled to said switch and gate-controlled clock 110 is enabled by the set output voltage of flip-flop 109 coupled to the enable terminal EN2 of said clock. Capacitor C1 is therefore charged linearly by the voltage output of amplifier 101 coupled to the input terminal of said integrator through variable resistor R14. At the instant when the integrator output voltage is equal to the fixed voltage applied to said voltage comparator, flip-flop 109 is reset; the voltage change at the reset output terminal of flip-flop 109 from low to high resets flip-flop 114 closing switch G2 which discharges capacitor C1; the change in voltage at the set output terminal of flip-flop 109 from high to low inhibits said clock. Decimal counter 112, coupled to said clock, counts the clock pulses. A latch, coupled to said decimal counter, is enabled by the latch enable voltage LE2, transferring the count of said decimal counter to an exposure LED digital readout.
To calibrate the meter, a standard negative is selected and the exposure time determined to provide a print with a normal exposure. A selected reference area of the standard negative is imaged on the probe and the gain of said integrator 103 is adjusted by means of the variable resistor R14 so that the count displayed by the exposure LED digital readout is equal to the exposure time determined for the standard negative.
To determine the exposure time for a selected negative, a reference area of the negative having a density similar to that of the standard negative is imaged on the probe. The count displayed by the exposure LED digital readout corresponds to the proper exposure time inversely proportional to the light intensity of said negative image.
Integrator 103 is coupled to the fixed voltage source VM through memory gain control resistor R14 by switch S1. The count displayed by the exposure LED digital readout when said integrator is coupled to the voltage source VR is proportional to the integrator gain and thus provides means for accurately resetting the memory gain. | A photometric device for measuring and displaying by digital means primary color densities of a color negative to be printed to determine densities of color compensating filters. Exposure time, including reciprocity effect compensation for the photographic paper, is displayed digitally and determined by density measurements of the projected image.
A reference area of a color negative illuminated by light through color compensating filters is projected on the aperture of a probe which directs light through a light guide to a photodetector. The resulting photocurrents generate voltages amplified by a first and second variable gain linear amplifier. The second amplifier provides primary color and exposure density reference by means of gains stored by measurement of a standard negative. Digital display means is provided to display memory gains for accurately modifying or resetting reference gains. The output of the second amplifier is coupled to a signal integrator alternately gated by a pulse generator and an exposure-time controlled integrator. A voltage comparator and digital circuitry coupled to the signal integrator serve to display the density of color compensation negative optical density representative of a particular print reflectivity.
The exposure-time integrator is coupled to a voltage comparator which gates digital counters to display exposure time including compensation for reciprocity effects. An alternative exposure-time circuit utilizes analog means to display exposure time. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims priority under 35 U.S.C. § 119(a)-(d) to Japanese Patent Application No. 2005-029816, filed Feb. 4, 2005, the entire contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to straddle type vehicles (e.g., motorcycles) and, in particular, to a straddle type vehicle having a system for discharging exhaust air from a radiator adapted to efficiently discharge such exhaust air to the outside of the vehicle.
2. Description of the Related Art
Motorcycles typically have an engine disposed in a longitudinally central portion of a vehicle body, a radiator positioned in front of the engine, and a front cowl disposed on a front portion of the vehicle so as to cover a front surface of the vehicle body. The front cowl often includes air discharge ports in its side walls, which are adapted to discharge the exhaust air that has passed through the radiator. Such constructions are taught, for instance, by Japanese Utility Model Publication JP-UM-B-5-9995, Japanese Utility Model JP-UM-B-4-50228 and Japanese Patent Publication No. JP-A-62-283082.
Coolant circulates through the radiator and is used to cool various engine components. The radiator receives cool air that flows through the radiator in order to conduct heat away from the radiator and thereby reduce the temperature of the circulating coolant. Outside air (i.e., cool air) is typically delivered to the radiator while the motorcycle is operating via openings positioned in the center portion of a front wall of the front cowl. After such air passes through the radiator, heated exhaust air is sent out of the radiator through air discharge ports. In typical front cowl assemblies, forward movement of the motorcycle forces outside air to travel rearward along the side surfaces of the front cowl. The exhaust air exiting the air discharge ports is drawn out of the radiator by the outside air flowing along the side surfaces of the front cowl. As a result, the discharge of exhaust air from the radiator is dependent on the air flow along the side surfaces of the front cowl and, therefore, is limited.
SUMMARY OF THE INVENTION
To address the aforementioned limitation, an object of the present invention is to provide a straddle type vehicle (e.g., a motorcycle) that can efficiently discharge the exhaust air that has passed through the radiator to the outside of the vehicle by providing vent passages that force outside air to flow rearward along the side surfaces of the front cowl.
One aspect of the present invention involves a straddle type vehicle comprising a frame. The frame is supported by a wheel. The wheel rotates about a generally horizontal axis. An engine is supported by the frame. A radiator is positioned generally forward of the engine. A front cowl encloses at least a portion of the frame. The front cowl extends from a location generally over the front wheel to a location proximate the engine. The front cowl generally defines a chamber in which the radiator is positioned. An air discharge port is defined in a side surface of the front cowl at a location generally rearward of the radiator. The discharge port is capable of receiving air that has passed through the radiator. A vent passage is defined along a longitudinal portion of the side surface of the front cowl. At least a portion of the longitudinal portion is positioned vertically above the air discharge port. The vent passage has a forward facing opening such that air through which the vehicle operates can be directed into the vent passage and at least a portion of the vent passage comprises a generally c-shaped cross-section.
An aspect of the present invention also involves a straddle type vehicle comprising at least one wheel that rotates about a generally horizontal axis and a vehicle body supported at least in part by the at least one wheel. The vehicle body supports an engine and a radiator such that the radiator, in one embodiment, is positioned farther forward than the engine. A front cowl having at least one side wall covers the front portion of the vehicle body and includes at least one vent passage and at least one discharge port. The at least one vent passage receives outside air and directs such air rearward along the at least one side wall of the front cowl, while the at least one discharge port discharges heated exhaust air from the radiator to the outside of the vehicle.
An additional aspect of the present invention involves a straddle type vehicle having at least one wheel and a vehicle body supported by the at least one wheel. The vehicle body includes a front portion having a front end. The vehicle body supports an engine and a radiator such that the radiator, in one embodiment, is positioned farther forward than the engine. A front cowl is provided which comprises an upper cowl, a middle cowl, and a lower cowl. At least one vent passage and at least one discharge port are disposed on the front cowl. The at least one vent passage includes at least one extension that extends the at least one vent passage in a generally longitudinal direction to a position above and substantially near the at least one discharge port.
In accordance with an additional aspect of the present invention, a straddle type vehicle comprises at least one wheel that rotates about a generally horizontal axis, a vehicle body supported at least in part by the at least one wheel, and a radiator supported at least in part by the vehicle body. The vehicle also includes a front cowl that at least partially covers a front portion of the vehicle body. In this embodiment, the front cowl comprises at least one vent passage for receiving air from outside of the vehicle and directing such air rearward and at least one discharge port for discharging exhaust air from the radiator to the outside of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will now be described in connection with a preferred embodiment of the invention shown in the accompanying drawings. The illustrated embodiment, however, is merely an example and is not intended to limit the invention. The drawings include thirteen figures.
FIG. 1 is a left side elevational view of a straddle type vehicle including a system for discharging exhaust air from a radiator of the vehicle, which system is arranged and configured in accordance with a preferred embodiment of the present invention. The straddle type vehicle is shown in a condition where no riders are seated on the vehicle, the front and rear wheels are both on the ground, and the vehicle is not leaning to a side or supported by a main stand.
FIG. 2 is a right side elevational view of the straddle type vehicle of FIG. 1 .
FIG. 3 is an enlarged front view of an upper portion of the straddle type vehicle of FIG. 1 .
FIG. 4 is a perspective view taken from the front of the vehicle showing a right side portion of the straddle type vehicle of FIG. 1 .
FIG. 5 is a perspective view taken from the rear of the vehicle showing a front right side portion of the straddle type vehicle of FIG. 1 . The straddle type vehicle is shown having a rider seated on the vehicle.
FIG. 6 is a front view of a front cowl of the straddle type vehicle of FIG. 1 .
FIG. 7 is a side elevational view of the front cowl shown in FIG. 6 .
FIG. 8 is an enlarged side view of an upper portion of the front cowl shown in FIG. 6 .
FIG. 9 is a cross-sectional view of the upper portion of the front cowl taken along line IX-IX of FIG. 8 .
FIG. 10 is a front view of a lower cowl disposed on the front cowl shown in FIG. 6 .
FIG. 11 is a side elevational view of the lower cowl shown in FIG. 10 .
FIG. 12 is a side elevational view of an upper cowl disposed on the front cowl shown in FIG. 6 .
FIG. 13 is a side elevational view of a middle cowl disposed on the front cowl shown in FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A system for discharging exhaust air from a radiator is illustrated in the drawings and is described below in the context of a straddle type vehicle. However, the system can be used with other types of vehicles. Preferably, the system can be used with vehicles which have a wheel that rotates about a generally horizontal axis, a steering column, a steering mechanism coupled to the top of the steering column, and a straddle type seat located substantially near the steering column. For example, such vehicles in which the system described herein can be employed include, but are not limited to, a motorcycle, a motorized scooter, and a multi-terrain vehicle. Accordingly, the following description and the drawings describe a motorcycle; however, the present system for discharging exhaust air from a radiator can be used on other types of straddle type vehicles as well.
Embodiments of the present invention will now be described with reference to the accompanying drawings. As shown in FIGS. 1 and 2 , a straddle type vehicle (e.g., a motorcycle) is provided that has the following components: a body frame 20 ; a front wheel 1 ; a rear wheel 2 ; an engine 3 ; a radiator 4 ; a front fork 5 ; a handlebar 6 ; a fuel tank 7 ; an air cleaner 8 ; a fuel injection system 9 ; a pivot 10 ; a rear frame 11 ; a swing arm 12 (as shown in FIG. 1 only); a power transmission 13 (as shown in FIG. 1 only); a seat 14 ; a rear suspension 15 ; an exhaust pipe 16 ; a muffler 17 (as shown in FIG. 2 only); and a front cowl 50 .
With reference to FIGS. 1 and 2 , the illustrated body frame 20 (see FIG. 2 ) comprises left and right main frames that extend diagonally downward and rearward from a head pipe 21 . The head pipe 21 is positioned at a front end of the vehicle. Rear frames 11 are connected to the main frames 22 . In the illustrated construction, the rear frames 11 extend rearward of a rearward portion of the main frames 22 . Swing arms 12 are connected to a lower portion of the main frames 22 . The swing arms 12 are connected so that the swing arms 12 can be pivoted vertically about an axis defined by a pivot 10 . A rear wheel 2 is supported by the swing arms 12 . Preferably, the rear wheel 2 rotates about a generally horizontal axis A1. A suitable rear suspension 15 is provided between the swing arms 12 and the rear frames 11 . Other frame and suspension constructions also can be used.
On the head pipe 21 , which is disposed at the front end of the body frame 20 , a handlebar 6 is pivotably supported. Below the handlebar 6 , front forks 5 are connected to the handlebar 6 such that the front forks 5 can be maneuvered by the handlebar 6 . The front wheel 1 is connected to lower portions of the front forks 5 . Preferably, the front wheel 1 rotates about a generally horizontal axis A 2 .
In one embodiment of the straddle type vehicle (e.g., motorcycle), an engine 3 is provided in a substantially longitudinally central portion and suspended from an engine suspension frame 23 provided on the lower side of and made integral with the main frame 22 of the body frame 20 . Other constructions also can be used. In one embodiment, the engine 3 is a parallel 4-cylinder engine that is transversely mounted. In this configuration, the engine 3 has a cylinder 3 A that is positioned generally above a crank case and that is slightly inclined. Because the engine 3 is mounted in this manner, the engine 3 is positioned generally below and between the left and right main frames 22 .
Multiple exhaust pipes 16 are joined to an exhaust port that is positioned on a front side of the cylinder 3 A. From the exhaust ports, the exhaust pipes 16 extend rearward along an underside of the illustrated engine 3 . The exhaust pipes 16 merge and are connected to a muffler 17 .
In one embodiment, a radiator 4 is positioned at substantially the same vertical height as the cylinder 3 A. The radiator 4 also preferably is positioned generally forward of the engine 3 with an air passing surface facing in the forward direction. In other words, the surface through which air is introduced into the radiator 4 extends in a plane that is generally normal to a longitudinal direction of the vehicle.
A fan 4 A can be provided rearward of the radiator 4 . An air cleaner 8 and a fuel injection system 9 can be provided above the engine 3 . A fuel tank 7 can be provided rearward of the engine at a location generally above the main frame 22 . A seat 14 on which a rider can sit is placed on the rear frame 11 at a location generally rearward of the fuel tank 7 . Generally below the seat 14 , electrical equipment, such as a battery 18 A, a relay 18 B, and an ECU (engine control unit) 18 C can be positioned on the rear frame 11 . A power transmission system 13 can be positioned to the left of the rear portion of the vehicle body and the muffler 17 can be positioned to the right of the rear portion of the vehicle body.
With reference now to FIGS. 6 through 13 , a front cowl 50 preferably extends from a location proximate an instrument panel (which is provided forward of the handlebar 6 ) to a location that is proximate the left and right sides of the engine 3 . In one embodiment, the left and right sides of the engine as well as the exhaust pipe 16 are substantially covered by the front cowl 50 . The front cowl 50 can be formed by a combination of an upper portion 51 and a lower portion 52 , both of which, in one embodiment, can be formed from a reinforced plastic material. The front cowl upper portion 51 and the front cowl lower portion 52 can be composed of other suitable materials as well.
With reference to FIG. 7 , the front cowl upper portion 51 preferably is sized and configured to cover components that are positioned ahead of the handlebar 6 . The front cowl lower portion 52 preferably is sized and configured to cover the range from a lower edge portion of the front cowl upper portion 51 to the side portions of the engine 3 . As shown in FIG. 6 , the front cowl 50 advantageously comprises a central port 66 . The central port 66 can be positioned at a central portion of a front wall of the front cowl 50 . In one configuration, the central port 66 is formed in the lower portion 52 of the front cowl. As shown in the illustrated embodiment, the central port 66 can be positioned in proximity to the front wheel 1 . Air traveling toward the radiator 4 is received from the central port 66 and the radiator 4 can be positioned rearward of the central port 66 . Thus, air traveling through the central port 66 can be directed toward the radiator 4 .
In one embodiment of the straddle type vehicle (e.g., motorcycle), left and right headlights 54 are positioned in the front cowl upper portion 51 . Preferably, the headlights 54 are mounted such that the front cowl upper portion 51 is generally streamlined as a whole. With reference to FIG. 6 , an air intake port 55 through which air is drawn into the air cleaner 8 can be positioned generally between the left and right headlights 54 . A windscreen 56 preferably extends diagonally upward and rearward direction from the central upper portion of the front cowl upper portion 51 . The windscreen 56 , in one embodiment, covers the instrument panel from the front side. The windscreen 56 preferably is formed of a transparent resin. Recesses 57 preferably extend from the front side to the rear side of the front cowl upper portion 51 and can be provided along the longitudinal curves of the two side surfaces. The recesses 57 desirably are positioned lower than the headlamps 54 and higher than the radiator 4 .
As shown in FIG. 6 , the front cowl lower portion 52 can include a lower cowl 61 (as described below in connection with FIGS. 10 and 11 ) sized and configured to cover both sides of the radiator 4 and the exhaust pipe 16 . The illustrated front cowl lower portion 52 also comprises a hooked upper cowl 62 (as described below in connection with FIG. 12 ) that is spaced from the lower cowl 61 and that extends along the main frame 22 . The hooked upper cowl 62 preferably is connected at a front end to the front cowl upper portion 51 . In some configurations, the front cowl upper portion 51 and the upper cowl 62 can be integrally formed. Knife-shaped panel type middle cowls 63 (as described below in connection with FIG. 13 ) can be provided between the lower cowl 61 and the upper cowl 62 . Preferably, spaces are defined between the lower cowl 61 and the upper cowl 62 when the middle cowls 63 are removed. The spaces can be sized and configured to expose large portions of the side surfaces of the engine 3 and a portion of each of the side surfaces of the radiator 4 .
The middle cowls 63 preferably are sized to be not large enough to cover the open portion as a whole between the lower cowl 61 and upper cowl 62 . The middle cowls 63 extend generally longitudinally such that they vertically divide the air discharge ports for air being exhausted from the radiator. In one embodiment, between the middle cowls 63 and the lower cowl 61 , a lower air discharge port 71 is defined. The lower discharge port 71 discharges air exhausted from the radiator 4 . In addition, between the middle cowls 63 and the upper cowl 62 , an upper air discharge port 72 is defined. The upper air discharge port 72 discharges air exhausted from the radiator 4 . The upper air discharge port 72 is a discharge port mainly for the exhausted air that has passed through an upper portion 4 U of the radiator 4 while the lower air discharge port 71 is a discharge port mainly for the exhausted air that has passed through a lower portion 4 D of the radiator 4 .
As shown in FIGS. 5 and 12 , the upper cowl 62 preferably is formed in the shape of a hook, as seen from a side elevational view, and is generally mountain-shaped in cross-section. The mountain-shaped cross-section comprises a ridge portion 62 a and an inner inclined surface 62 b . Preferably, the inner inclined surface 62 b extends at an angle relative to the ridge portion 62 a . At least a portion of the inner inclined surface 62 b is positioned opposite to the middle cowls 63 and generally parallel with an upper edge of the middle cowl 63 . In this manner, the upper air discharge port 72 is seen with a larger opening in a side elevation view than the same port when viewed from a location diagonally above the discharge port 72 . Therefore, radiator exhaust air that travels diagonally upward passes through the upper air discharge port 72 .
The ridge portion 62 a preferably is curved with the inner inclined surface 62 b being on the inside of the curve defined by the ridge portion 62 a . Therefore, the bent portion of the inclined surface 62 b , which has an apex at the ridge portion 62 a , defines a valley-shaped terminal wall 62 c . The terminal wall 62 c preferably is positioned along a rearward portion of the upper cowl 62 . More preferably, the terminal wall 62 c is positioned ahead of the foot of a driver sitting on the seat (as shown in FIG. 5 ). Since the inner inclined surface 62 b comprises a hooked configuration, the upper cowl 62 , and the inclined surface 62 b of the illustrated embodiment, defines a recess 62 d recessed inward in the widthwise direction of the vehicle body relative to the balance of the upper cowl 62 .
With reference to FIGS. 4 and 5 , the recess 57 defined in the lateral sides of the front cowl upper portion 51 are substantially connected to the inclined surface 62 b and recess 62 d of the upper cowl 62 . The recess 57 , together with the region defined between the inclined surface 62 b and the middle cowls 63 define a vent passage 73 . More particularly, the region can be defined as the space formed by the inclined surfaces 62 b , the recess 62 d and the middle cowls 63 . The region can be called an extension 73 E. The extension 73 E preferably is positioned above the upper air discharge port 72 . The extension 73 E elongates the vent passage 73 to define a longer air travel path than just the recess 57 alone. Thus, the vent passage 73 is positioned above the upper air discharge port 72 and the vent passage 73 is adapted to receive traveling outside air and pass such air rearward therethrough. At a rear end of the extension 73 E, diverter passages 73 F can be positioned to redirect the outside air flowing rearward in the vent passages 73 to an outward flow.
This diverted passage 73 F can be formed by the downwardly sloping inclined surface 62 b and ridge portion 62 a of the upper cowl 62 . The diverter passage 73 F also can extend in a horizontal section divergently in the rearward direction with the width of the diverter passages increasing in the lateral direction of the vehicle. In other words, the diverter passages 73 F become wider in a direction away from the center of the vehicle. Because the air enters the recesses 57 forcibly, the air flows along the vent passage 73 substantially linearly from the front side to the rear side. Therefore, the traveling air necessarily spreads outward in the transverse direction (i.e., the width) of the vehicle and flows rearward as the air is directed laterally outward by the diverter passage 73 F formed by the inclined surfaces 62 b of the upper cowl 62 . In one preferred configuration, the diverter passages 73 F direct the airflow downward and outward to direct the air away from the legs of a rider.
The upper edges 63 a of the side covers 63 preferably are fixed to upper side of the recesses 57 such that they project laterally outward. In this manner, the cross-section of the corresponding portions of the vent passage 73 is generally C-shaped. Therefore, the air flow can be focused and directed rearward without significant airflow bleed-off (i.e., significant air flow escaping from the passage 73 ). In one embodiment, the middle cowls 63 are fixed to the lower cowl 61 by screws. Any other suitable technique can be used. Because the vent passages 73 can be formed by combining the middle cowls 63 with the upper cowl 62 from the outer side so as to cover the lower portion of the upper cowl 62 (see FIG. 9 ), forming of the vent passage 73 can be done with ease.
As shown in FIGS. 1 , 2 , and 7 , the outside air induction ducts 80 are provided inside of the lower cowl 61 and middle cowls 63 such that a forward facing intake port 67 opens toward the direction in which traveling air is introduced and such an outlet port is opened toward a space surrounded by the main frame 22 , the engine 3 , and the fuel tank 7 . At the rear of this space, air discharge passages for moving the air flow toward the rear are secured. These air discharge passages preferably are secured between the rear frames 11 and the swing arms 12 in a position that is lower than the pivot 10 such that the swing arms 12 can be freely swung in the vertical direction.
The intake ports 67 preferably are formed in side walls of the lower cowl 61 of the front cowl lower portion 52 . The intake ports 67 preferably communicate with the front end of the outside air induction ducts 80 . The intake ports 67 advantageously are positioned lower than the lower end of the radiator 4 . In one preferred configuration, the intake ports 67 are positioned in the side walls of the front cowl lower portion 52 at a location vertically below the lower side air discharge ports 71 .
The operation of the straddle type vehicle (e.g., motorcycle) will now be described. Some of the air passed through the radiator 4 during movement of the vehicle flows out upward or rearward from the upper air discharge ports 72 provided in side walls of the front cowl 50 . As the outside air flows relative to the straddle type vehicle, shown by arrows F in FIGS. 1 through 5 , the traveling air F flows from front to rear at a high speed along in the vent passage 73 , which is positioned above the air discharge port 72 . The air flow F creates a pressure differential with the air flow having a lower pressure than the chamber in which the radiator is positioned. Because of the pressure difference, the heated exhaust air that passed through the radiator will be sucked through the upper air discharge port 72 to the outside of the vehicle. As a result, the heat in the front cowl 50 can be discharged efficiently to the outside of the vehicle.
Moreover, since the vent passage 73 extends in the longitudinal direction of the vehicle up to a position just above the upper air discharge port 72 , heated air that is passed through the radiator 4 can flow smoothly in the rearward direction. Because the diverter passages 73 F for inducing the air flowing rearward in the vent passages 73 outward are positioned at the rearward portions of the extensions 73 E of the vent passages 73 , the heated exhaust air from the radiator 4 can be diverted outward in positions in front of the legs of the driver. Therefore, the heated exhaust air is less likely to contact the legs of the driver, which results in a more comfortable riding experience.
In this straddle type vehicle (e.g., motorcycle), two vertically spaced ports (i.e., the lower air discharge port 71 and the upper air discharge port 72 ) for discharging the radiator-passed exhaust air are provided. As a result, even when a cooling operation is carried out solely by operation of the radiator fan 14 A, the hot air can be discharged smoothly. In addition, because the vent passages 73 mentioned above are formed in regions not occupied by the headlight 54 and the radiator 4 , a typically vacant space in the vehicle between the headlight 54 and the radiator 4 can be effectively utilized.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. For instance, it is possible to form any or all of the cowlings either integrally or to further segment the cowlings in to sub-cowlings that perform in the manners discussed herein. In other words, the upper cowling can be formed in multiple pieces in some embodiments relative to the constructions shown and described above. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims. | A system for discharging exhaust air from a radiator in a straddle type vehicle (e.g., a motorcycle) is provided that can discharge heated air from the radiator to the outside of the vehicle in an efficient manner. The system comprises a radiator that can be positioned farther forward than an engine in the straddle type vehicle. A front cowl at least partially covers the front portion of the vehicle, including the radiator and engine. The front cowl comprises at least one vent passage for receiving outside air and directing such air rearward and at least one discharge port for discharging exhaust air from the radiator. Because of a pressure difference occurring due to high-speed air current flowing along the at least one vent passage, the heated exhaust air can be positively discharged from the radiator through the at least one discharge port. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. provisional patent application Ser. No. 60/328,487 for “Server For Geospatially Organized Flat File Data,” filed Oct. 10, 2001, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to organization and processing of flat file data, and more particularly to systems, methods, and computer program products for delivering content from several flat file databases that can reside locally and/or remotely.
2. Description of the Background Art
Conventionally, stored data on a server is organized according to a plurality of files in a file system. In an application for storing, retrieving, and drawing geospatially organized data (such as an interactive viewer for geospatial data), each node may use a separate file for each drawable, with the various files being organized in a hierarchy of directories. Data representing imagery can be stored in basically the same way, possibly with different directory hierarchy and file naming protocols (for example, the clipgen format). Quadtree packets, which are the data files that are sent to the client that describe the quadtree structure and contents of the database, are computed beforehand and stored as files on the server. If a large amount of data is to be managed, creation and storage of such a database can overload a conventional file system. In order to mitigate the strain on the file system, a special output format may be employed to transfer the files. Even with such an arrangement, large amounts of data can result in corruption of the file system.
SUMMARY OF THE INVENTION
In order to avoid the excessive transfer time and inefficiency of using a conventional file system, the present invention employs a flat file data organization technique, referred to herein as “Keyhole Flatfile,” or KFF, for storing and retrieving geospatially organized data. KFF reduces transfer time by transferring a few large files in lieu of a large number of small files. It also moves the process of locating a given data file away from the file system to a proprietary code base. Finally, KFF makes database management much easier by having the quadtree packets generated on demand. Items can be added to the database by simply inserting the files rather than inserting and regenerating the appropriate quadtree packets. Keyhole Flatfile assumes very low cache coherency, to account for the fact that in an application such as a geospatial data viewer, users might be looking at multiple different places on the globe, so that requests are likely to hit disparate parts of database and not just one location. Given this scenario, it is beneficial to minimize disk seeks. The indexing system of Keyhole Flatfile is a quadtree-based structure, wherein each node points to a location in a binary file that contains the data files.
In practice, the Keyhole Flatfile system has actually benefited significantly from the caching of the file system. Since it was designed for the worst-case scenario, it performs better than expected during normal access to the server. A memory caching system may be employed in conjunction with Keyhole Flatfile, if desired. Performance may be further improved by adding more memory to the server.
Keyhole Flatfiles may be accessed directly over the Internet by applications such as Earthviewer 3D and Earthviewer PocketPC. Earthviewer HTML viewer accesses the data directly on the server and delivers the rendered image to the web browser.
The present invention uses a quadtree index not only to help find data objects within a massive database, but also for fast delivery of the quadtree index itself to a remote application. This is accomplished by a four-level sectioning of the quadtree index, which allows for the quadtree packets to be generated with a minimal amount of reads from disk. The invention further provides the ability to quickly merge quadtree packets on the fly, thus allowing delivery of multiple databases without requiring that they be preprocessed into one database. Such functionality has benefits in the management of the database and for rapid deployment of new data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of KFF data retrieval according to one embodiment of the present invention.
FIG. 1A is a legend for various Figures of the present application.
FIG. 2 is a flow chart of QuadTree packet generation according to one embodiment of the present invention.
FIG. 3 is a flow chart of QuadTree packet merging according to one embodiment of the present invention.
FIG. 4 is a flow chart of obtaining a session key according to one embodiment of the present invention.
FIG. 5 is a flow chart of using a session key with a data packet according to one embodiment of the present invention.
FIG. 6 is a flow chart of general data migration according to one embodiment of the present invention.
FIG. 7 is a flow chart of the basic system flow according to one embodiment of the present invention.
FIG. 8 is a diagram showing a QuadTree packet and data file list according to one embodiment of the present invention.
FIG. 9 is a diagram showing a QuadTree-based approach to spatially organize data according to one embodiment of the present invention.
FIG. 10 is a diagram showing a data section according to one embodiment of the present invention.
FIG. 11 is a diagram showing a basetree structure according to one embodiment of the present invention.
FIG. 12 is a diagram showing a subtree structure according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Definitions
EarthServer DataStream—A server employing the techniques of the present invention.
Earthviewer 3D—A client application for viewing data provided via EarthServer DataStream.
Earthviewer PocketPC—A client application for viewing data provided via EarthServer DataStream.
Earthviewer HTML—An HTML-based viewer for viewing data provided via EarthServer DataStream.
Keyhole Binary File (KBF)—A file containing drawable packets that are concatenated one after another with a header describing where it should go in the database attached to the front of each packet.
Keyhole Flat File (KFF)—A file containing a set of data packets that are spatially indexed. It is the primary data format for EarthServer DataStream.
Raw Flat File (FF)—A file containing imagery or terrain tiles that are concatenated one after another with a header describing where it should go in the database attached to the front of each tile.
dbRoot—A file containing the version and channel information of a given KFFDB. It is used in deployment of a KFFDB to the EarthViewer 3D client.
QuadTree Packet—The QuadTree packet contains a set of nodes organized in recursive order describing the contents of the database at those specific nodes. This is the data packet that is sent to the EarthViewer 3D client to tell it what is contained in the KFFDB database.
Drawable Packet—This packet contains a set of drawables that can include, etSite (labeled points), etStreet (labled lines for drawing streets), and etPolyLines (multi-point line). These packets are associated with a particular node in the QuadTree and are sent to the client in order to draw such things as roads, points of interest, and state borders.
Image Tile—This is a one section of imagery at a particular resolution and position (i.e. a particular point in the QuadTree).
Terrain Tile—This is a one section of the terrain at a particular resolution and position (i.e. a particular point in the QuadTree).
System Architecture
Referring now to FIG. 7 , the basic flow of the EarthServer DataStream product consists of first taking the customer's data 701 and converting it via a data migration tool 702 into a Keyhole Flatfile Database (KFFDB) 703 . This KFFDB is then transferred over to EarthServer DataStream server 704 and its contents are then delivered to the Earthviewer products (such as Earthviewer 3D 705 and/or Earthviewer HTML 706 ) over the Internet.
Data Migration
Referring now to FIG. 6 , there is shown a flowchart of data migration as performed by data migration tool 702 according to one embodiment of the present invention. Tool 702 gets 602 a data item from list 601 of data items, and adds 603 the data item to QuadTree structure 605 . If, in 604 , there are more data items in list 601 , tool 702 returns to step 602 . Otherwise, it proceeds with steps 606 through 610 . Tool 702 gets 606 a node from QuadTree structure 605 and gets 607 data items in the node. It then creates 608 a data packet for the data items and puts 609 the data packet into Keyhole Flatfile database 703 . If, in 610 , there are more nodes in QuadTree structure 605 , tool 702 returns to step 606 . Otherwise the data migration process is complete.
Keyhole Flat File Database
The KFFDB 703 can come in two forms. One is a Keyhole Flatfile (KFF) and the other is a combination of a KFF and a set of Keyhole Binary Files (KBF).
There are three main parts to a KFF file:
Data 1000 BaseTree 1100 SubTree 1200
Referring now to FIG. 8 , there is shown an example of a QuadTree packet 801 and data file list 802 according to one embodiment of the present invention. Referring also to FIGS. 10 , 11 , and 12 , there are shown examples of structures for data section 1000 , BaseTree 1100 , and SubTree 1200 respectively. The data section 1000 contains the data files 1001 that are inserted into the KFF. The BaseTree 1100 contains all the nodes 1101 A at the base of the tree, which are all nodes 1101 A that reside on the first 12 levels. The SubTree contains all the nodes 1101 B below the base of the tree. The nodes 1101 of the QuadTree packet 801 are stored in four-level packets; each packet has an associated list of data file names and locations. Each node 1101 indexes into that list to store the data file names and locations that are associated with that particular node 1101 . The list of data file names and locations is stored in the data section 1000 .
In one embodiment, the data section 1000 holds data files 1001 and QuadTreeFileLists, the BaseTree section 1100 holds QuadTreeIndexSections 1101 A for the first 12 levels of the QuadTreeIndex, and the SubTree section 1200 holds QuadTreeIndexSections 1101 B for the levels below level 12 of the QuadTreeIndex. Each section includes a set of files.
In the KFF, file space of deleted files is left unused. Therefore, over time with deletions and additions into the KFF, the data file can become fragmented. In the case of replaced files, the space is reused if the new file is less than or equal to the size of the old file. By storing QuadTree packet data file lists 802 in the data section, the invention allows base 1100 and SubTree 1200 sections to remain unfragmented, since QuadTree packets are atomic units (i.e., space for all 85 nodes are allocated when a QuadTree packet is created) while data file lists 802 can change in size.
Given the case where the data files 1001 are inserted into the KFF, the KFF can stand alone as a KFFDB 703 for the EarthServer DataStream.
The second form of the KFFDB 703 includes a KBF. In this case, the KFF is used as an index file into the KBF, which acts as the source for all of the data files. In one embodiment, the KBF file is used only with drawable packets (such as streets, polylines, sites, and the like), while the FF file format is used for imagery and terrain tiles. The KBF/KFF form of the KFFDB 703 may be used for maintaining large KFFDBs 703 such as the Earthserver ASP database, since it allows for small incremental updates to the database rather than a completely new KFFDB 703 .
In one embodiment, KFFDB 703 is implemented using the following files. For a KFFDB 703 called “kffdb.sample”, files might include:
kffdb.sample kffdb.sample.1 kffdb.sample.2 kffdb.sample.base kffdb.sample.sub kffdb.sample.sub.1
The data section 1000 is the first three files (kffdb.sample, kffdb.sample.1, and kffdb.sample.2); the BaseTree section 1100 is in the fourth file (kffdb.sample.base), and the SubTree section 1200 is in the last two files (kffdb.sample.sub and kffdb.sample.sub.1). In this embodiment, each section is split up into a series of files of predetermined size (such as one gigabyte, for example). Numbered file names such as kffdb.sample.1 and kffdb.sample.2 represent the split files. In this embodiment, the collection of these six files would be the KFF.
For the KBF/KFF form, in one embodiment the implementation would consist of the following files. For a KFFDB 703 called “kffdb.sample”, files might include:
kffdb.sample kffdb.sample.base kffdb.sample.sub kffdb.sample.sub1 restaurantdata.kbf streetdata.kbf imagerydata.ff
The first four files (kffdb.sample, kffdb.sample.base, kffdb.sample.sub, and kffdb.sample.sub1) are the KFF that acts as the index into the last three files (restaurantdata.kbf, streetdata.kbf, and imagerydata.ff), which contain data such as streets, points, lines, imagery and terrain. The last three files do not require the .kbf/.ff extension.
EarthServer DataStream Server
In one embodiment, the EarthServer DataStream Server includes the following components:
KFFDB 703 dbRoot Apache modules
mod_flatfile mod_earthrender mod_dbrootmerger
KFFDB 703 is the database that is to be delivered by the server. dbRoot maintains the version and content information of the KFFDB 703 . The Apache modules deliver the contents of the KFFDB 703 .
KFFDB 703
The EarthServer DataStream server can merge multiple KFFDBs 703 in addition to multiple remote databases. The local databases are directly attached and the remote databases are accessed via the mod_flatfile HTTP interface. In one embodiment, mod_flatfile allows ten local databases and ten remote databases to be merged, although in other embodiments additional databases may be merged. In one embodiment, EarthServer DataStream allows for one remote database to be merged—specifically, the Earthserver ASP. In alternative embodiments, any number of databases can be merged together. In one embodiment, the mod_earthrender module can only have one remote database and up to ten local databases; in other embodiments, this module can include any number of databases.
dbRoot
The dbRoot file contains the current version of the KFFDB 703 . In one embodiment, dbRoot is the first thing that the Earthviewer 3D client asks for when it starts up so that it knows whether the data files it has in its cache are current or not. The dbRoot also contains information on what data is contained on each channel. It can potentially contain any other registry values that need to be set or changed in the Earthviewer 3D client, such as the domain name of the stream server, clip texture settings, and default values of buttons.
The dbRoot file also contains the encryption key that is used by the EarthServer DataStream Server to encrypt the content that is being delivered. The encryption key is also used by the client to decrypt the incoming data files.
In one embodiment, whenever the KFFDB 703 is changed on the server, the dbRoot version number must be incremented. If any additional channels of data have been added, in one embodiment they are recorded in the dbRoot file in order for the Earthviewer 3D client to be aware of their existence.
In one embodiment, the dbRoot file is created using the dbRoot tool. The channel information for a given KFFDB 703 is set by attaching a text file with the dbRoot. The text file in the ETA format takes the following form:
<etStruct> [export.layers]
{
<etLayer> [Channel A]
{
″recreation″
0.0
128 true
″ ″
}
<etLayer> [Channel B]
{
″building″
0.0
129 true
″ ″
{
<etLayer> [Channel C]
{
″bang″
0.0
130 true
″ ″
}
}
For each entry in the list, the name of the channel is placed in the brackets [ ]. The first value in an entry is the type of icon to use in the “Show Me/Popular Locations” section of the Earthviewer 3D client. In one embodiment, the possible values for this are:
“american-flag” “asian-flag” “auto” “auto-service” “bang” “bars” “building” “dining” “fast-food” “four-dollars” “french-flag” “italian-flag” “mexican-flag” “misc-dining” “one-dollar” “parks” “recreation” “three-dollars” “transportation” “two-dollars”
The second value is whether the channel is turned on (1.0) or off (0.0) by default. The third value is the channel number. The fourth value is whether the channel is to show up in the “Show Me/Popular Locations” list (true/false). The fifth value sets the channel to be triggered by a button on the Earthviewer 3D UI. The possible values are:
“borders” “roads” “terrain” “weather”
Other values can also be set using the ETA file format.
mod_flatfile
This module delivers data files directly from the KFFDB 703 and generates QuadTree packets on demand for the KFFDB 703 . This is the main interface for Earthviewer 3D and Earthviewer PocketPC. Files are accessed by asking for the QuadTree node location described by a branching traversal guide (BTG) and the name of the file. Data packets just use a BTG. The URI formats for requesting these data objects are as follows:
Data Files:
http://stream.earthviewer.com/flatfile?f1-<BTG>-<datafilename> Example: http://stream.earthviewer.com/flatfile?f1-010302-i.1
Data File Name Formats:
image tiles:
i.<version>
terrain tiles:
t.<version>
data files:
d.<channel>.<version>
QuadTree Packets:
8-bit QuadTree Packets:
http://stream.earthviewer.com/flatfile?q1-<BTG>
16-bit QuadTree Packets:
http://stream.earthviewer.com/flatfile?q2-<BTG>
Example: http://stream.earthviewer.com/flatfile?q1-010302
mod_earthrender
This module delivers image files for viewing the KFFDB 703 through an HTML interface. The following are the parameters for defining a desired image:
lat=[float]
Sets the latitude of the center pixel of the image.
long=[float]
Sets the longitude of the center pixel of the image.
level=[int]
Sets the level to access the database.
xsize=[int]
Sets the width of the image.
ysize=[int]
Sets the height of the image.
clist=[string]
Sets what channels to turn on in the image
(i.e. turn on 1, 3, 34 then string is 001003034)
plat=[float]
Sets the latitude of the annotation point.
plong=[float]
Sets the longitude of the annotatin point.
pname=[string]
Sets the label of the annotation point.
ypsearch=[string]
Sets the string to search for in the yp database.
filetype=[string]
Sets what type of file to return.
jpeg = ″jpg″
gif = ″gif″
eta = ″eta″
textnum=[int]
If value is 1 then sends over comma-delineated
list of visible sites/POIs in the image.
mod_dbrootmerger
This module delivers the dbRoot file. It also merges the dbRoot file with the dbRoot file of remote KFFDBs 703 so that when changes are made to remote KFFDBs 703 it is reflected as a change in the delivered database from the EarthServer DataStream Server. The delivered version number is computed by adding all of the version numbers of each dbRoot together, therefore if any of the dbRoots get upreved then the merged dbRoot gets upreved. It also can merge the channel content information from other remote KFFDBs 703 , if desired.
Session Key Verification and Access Control Layer Restrictions
The EarthServer DataStream works in conjunction with an authorization server that passes out session keys to registered users. The session keys are needed for two reasons: to validate the user and to restrict access to the database.
The validation is done both at the authorization server and the stream server. The authorization server only gives out session keys to registered users. These session keys have an expiration time that is checked by the stream servers, so old session keys can not be stolen and reused.
The session keys also contain additional information that tells the stream server which parts of the database a particular user is allowed to access. This is conveyed through the use of package IDs, where each package ID grants database access for a particular region, at a particular resolution, and for a particular channel (i.e. imagery, terrain, roads, restaurants, etc.).
System
In one embodiment, the present invention runs on a conventional computer, having components such as the following:
1×866 MHz Pentium III 512 MB Main Memory 18 GB Hard Disk Space
In another embodiment, the present invention runs on a conventional computer, having components such as the following:
2×1 GHz Pentium III 1 GB Main Memory 36 GB Hard Disk Space
In yet another embodiment, the present invention runs on a conventional computer, having components such as the following:
2×1.26 GHz Pentium III 2 GB Main Memory 72 GB Hard Disk Space
One skilled in the art will recognize that many other types of hardware components may be used in connection with the present invention. Component characteristics may affect the performance of EarthServer DataStream (ESDS) as follows.
CPU: The processor speed mainly affects how fast ESDS can deliver earthrender images. A faster processor will allow for more images to be delivered per second. The main processor-heavy elements of mod_flatfile are encryption, compression, and QuadTree packet generation.
Memory: The amount of main memory helps tremendously in system caching of file blocks. This increases the speed at which data packets can be pulled out of the KFFDB 703 and therefore general performance of ESDS.
Hard Drive: The more disk space that is available, the more of the KFFDB 703 that can be cached on the local disk, and the fewer requests need to be made to the remote server (i.e. Earthserver ASP). In the case of an NFS-mounted NAS device, it could reduce need to access the NAS device by caching previously requested locally. Also for earthrender, the local drive can be used to cache decompressed image tiles, which can tremendously increase performance. The main factor that affects KFFDB 703 read performance is disk seek time, and disk seek time is directly related to rotational speed. Therefore higher rotational speed generally results in improved performance.
Module Directives
The following is a list of directives for each module. The directives with the * next to them are required directives and the others are optional. There is an explanation of each directive below along with an example of how to use them.
mod_flatfile
*KffFlatfileDatabasePath—a list of kff database paths
Example:
KffFlatfileDatabasePath /gaiadb/db1/kffdb.db1/gaiadb/db2/kffdb.db2
KffFlatfileDatabaseURL—a list of kff database URLs
Example:
KffFlatfileDatabaseURL stream.earthviewer.com stream.companyA.com
*KffDatabaseRootPath—the path for the dbRoot file
Example:
KffDatabaseRootPath /var/www/dbroot/dbRoot.ver1
KffFlatfileLogFilePath—the path for flat file log
Example:
KffFlatfileLogFilePath /var/www/logs/kffdblog
KffFlatfileSessionCheckLevel—the session check level (0—only valid cookie, 1—valid cookie or no cookie, 2—no restrictions)
Example:
KffFlatfileSessionCheckLevel 2
KffFlatfileBinaryLog—flag for using binary log
Example:
KffFlatfileBinaryLog On KffFlatfileBinaryLog Off
KffFlatfileCacheFilePath—the path for cache file
Example:
KffFlatfileCacheFilePath /var/www/esds-cache/
KffFlatfileMaximumCacheSize—the maximum number of MB of the cache file
Example:
KffFlatfileMaximumCacheSize 1000
KffFlatfileACLDictionaryPath—the path for the ACL dictionary
Example:
KffFlatfileACLDictionaryPath
/var/www/acl/ACL_dict1
KffFlatfileACLIndexPath—the path for the ACL index
Example:
KffFlatfileACLIndexPath /var/www/acl/ACL_index — 1
KffFlatfileACLDefaultPolicyPath—the path for the ACL default policy
Example:
KffFlatfileACLDefaultPolicyPath
/var/www/acl/ACL_def1
KffFlatfileACLMemoryResident—flag for whether the dictionary is memory resident or not
Example:
KffFlatfileACLMemoryResident On KffFlatfileACLMemoryResident Off
KffFlatfileCopyrightListPath—the path for the copyright list file
Example:
KffFlatfileCopyrightListPath
/var/www/crlist/copyrightlist.crf
mod_earthrender
*KffEarthrenderDatabasePath—a list of kff database paths
Example:
KffEarthrenderDatabasePath /gaiadb/db1/kffdb.db1/gaiadb/db2/kffdb.db2
KffEarthrenderDatabaseURL—a list of kff database URLs
Example:
KffEarthrenderDatabaseURL stream.earthviewer.com
*KffTexturePath—the path for the texture image files
Example:
KffTexturePath /var/www/textures/
KffYPServerUrlPath—the url for the ypserver
Example:
KffYPServerUrlPath http://yp.earthviewer.com/cgi-bin/ypsearch_beta?long=% lf&lat=% lf&dlat=% lf&dlong=% lf&name=% s
KffEarthrenderCheckLevel—the check level for access
(0—full access, 1—SF only, 2—ACL/SessionKey restricted access)
Example:
KffEarthrenderCheckLevel 2
KffEarthrenderACLDictionaryPath—the path for the ACL dictionary
Example:
KffEarthrenderACLDictionaryPath
/var/www/acl/ACL_dict1
KffEarthrenderACLIndexPath—the path for the ACL index
Example:
KffEarthrenderACLIndexPath
/var/www/acl/ACL_index — 1
KffEarthrenderACLDefaultPolicyPath—the path for the ACL default policy
Example:
KffEarthrenderACLDefaultPolicyPath
/var/www/acl/ACL_def1
KffEarthrenderACLMemoryResident—flag for whether the dictionary is memory resident or not
Example:
KffEarthrenderACLMemoryResident On KffEarthrenderACLMemoryResident Off
KffEarthrenderCopyrightListPath—the path for the copyright list file
Example:
KffEarthrenderCopyrightListPath
/var/www/crlist/copyrightlist.crf
mod_dbrootmerger
KffDbRootMergerURL—a list of kff database URLs
Example:
KffDbRootMergerURL stream.earthviewer.com
*KffDbRootMergerDbRootPath—the path for the dbRoot file
Example:
KffDbRootMergerDbRootPath
/var/www/dbroot/dbRoot.ver1
KffDbRootMergerPostambleMerge—flag for whether to merge the postambles
Example:
KffDbRootMergerPostambleMerge On KffDbRootMergerPostambleMerge Off
Tools
smelter—This tool is used to convert customer data into kbf or kff files. It is the main tool used for data migration, as shown in FIG. 6 .
dbroottool—This tool is used to create the dbRoot file. It can read the contents of a dbRoot file, write out a new dbRoot file, or increment the version number of a dbRoot file.
kbftokff—This tool is used to add a kbf file into a kff file. This mainly pertains to drawables such as points and lines.
fftokff—This tool is used to add an ff file into a kff file. This mainly pertains to imagery and terrain.
kffperf—This is a tool to measure the performance of the EarthServer DataStream. It takes a log file form the apache server and sends those requests to a given server.
kffview—This tool is used to view the contents of a kff file, just like traversing through directories on a unix file system.
kffreadlog—This tool is used to read the binary log file generated by the mod_flatfile module.
Libraries
kff—This library is used to create and modify kff files.
kbf—This is a header file that provides classes to create, read, and write kbf files.
qtpgen—This library is used to create/modify drawable packets and QuadTree packets.
jpegbuffer—This library is used to create 2D representations (such as JPEG images) from the KFFDB 703 database.
Methods
Referring now to FIGS. 1 through 6 , there are shown flow charts of various methods according to the present invention. The following components, associated with KFF, are used in the various methods as depicted in FIGS. 1 through 6 . Referring also to FIG. 1A , there is shown a legend indicating symbols for the various components described below.
Data Packet
Summary: This is a collection of bytes that contain data about a geospecific area of the earth. This data can be of any type: imagery, terrain, vectors, points, etc.
QuadTreeIndexNode
Summary: This is one node of the QuadTreeIndex. The node contains two numbers, offset and length, which refers to a particular section of the QuadTreeFileList of the QuadTreeIndexSection associated with the node. This section contains the list of data packets that are associated with the node, where each item in the list tells the name of the data packet, the location of the data packet, and the size of the data packet.
QuadTreeFilePosition
Summary: This data item contains two numbers, data file index and data file offset, which are used to store the location of a particular data packet. The data file index tells which file it is contained in, and the data file offset tells where in that file the data packet is located.
QuadTreePosition
Summary: This data item contains a particular position of a node in the QuadTree by specifying the level of the node and a list of what child was traversed at each level.
QuadTreeFileEntry
Summary: This data item contains three things: name string, QuadTreePosition, and data packet size. These describe the name of the data packet, the location of the data packet, and the size of the data packet.
QuadTreeFileList
Summary: This data item is a set of QuadTreeFileEntries. It is associated with a QuadTreeIndexSection and it is the list of all the data packets that are contained within that particular QuadTreeIndexSection.
QuadTreeIndexSection
Summary: This data item is a four-level section of the QuadTreeIndex consisting of QuadTreeIndexNodes and an associated QuadTreeFileList. It also contains QuadTreePositions for all the children of the fourth-level nodes.
QuadTreeIndex
Summary: Referring now to FIG. 9 , there is shown the QuadTreeIndex indexing system to the KFF file that tells what is in the database and where in the database it resides. It uses a QuadTree-based approach to spatially organize the data. This means each node of the QuadTree has four children 902 A–C, where each child 902 covers one quarter of its parent's 901 defined area.
QuadTreeQuantum
Summary: This data item contains information about a particular node in the QuadTree that is delivered to the Earthviewer 3D client. This QuadTree is different from the QuadTreeIndex; the information in the node is specific to the Earthviewer 3D client. The node contains version numbers for imagery, terrain, cache node, and channels. It also contains children existence information.
QuadTreePacket
Summary: This data item includes a recursively ordered list of QuadTreeQuantums, which describes a section of the Earthviewer 3D client QuadTree.
KFF Data Retrieval
FIG. 1 is a flow chart of KFF data retrieval according to one embodiment of the present invention. The system gets 101 root QuadTreeIndexSection from KFF 703 and determines 103 whether QuadTreeIndexSection contains the node described by QuadTreePosition 102 . If not, the system gets 104 the next QuadTreeIndexSection from KFF 703 . If QuadTreeIndexSection does contain the node, the system gets 105 the QuadTreeIndexNode identified by the QuadTreePosition from the QuadTreeIndexSection, and gets 106 the QuadTreeFileList associated with the QuadTreeIndexSection from KFF 703 . Then, the system gets 107 the QuadTreeFileEntries from the QuadTreeFileList pointed to by the QuadTreeIndexNode and determines 109 whether Data Name 108 exists in the QuadTreeFileEntries.
If Data Name 108 does not exist in the QuadTreeFileEntries, the system returns 112 a returns 113 a “Data Packet Not Found.” If Data Name 108 does exist in the QuadTreeFileEntries, the system gets 110 QuadTreeFilePosition and size of Data Name 108 Data Packet from QuadTreeFileEntry. The system then gets 111 Data Packet at QuadTreePosition, and returns 113 a “Data Packet Found.”
QuadTree Packet Generation
FIG. 2 is a flow chart of QuadTree packet generation according to one embodiment of the present invention. The system gets 202 the QuadTreeIndexSection that includes the QuadTreeIndexNode at the QuadTreePosition 201 from KFF 703 . The system then gets 203 the QuadTreeIndexNode identified by the QuadTreePosition 201 from the QuadTreeIndexSection, and gets 204 the QuadTreeFileList associated with the QuadTreeIndexSection from KFF 703 . The system then gets 205 the QuadTreeFileEntries from the QuadTreeFileList pointed to by the QuadTreeIndexNode, and creates 206 a QuadTreeQuantum from the QuadTreeFileEntries.
The system then adds 209 the QuadTreeQuantum to the QuadTreeQuantum list 210 . Also, it determines 207 whether the children at the QuadTreePosition 201 extend beyond the QuadTreePacketDepth 208 . If not, the system determines 213 whether there is a first child at the QuadTreePosition 201 ; if so, it creates 214 a QuadTreePosition for the first child. The system determines 215 whether there is a second child at the QuadTreePosition 201 ; if so, it creates 216 a QuadTreePosition for the second child. The system determines 217 whether there is a third child at the QuadTreePosition 201 ; if so, it creates 218 a QuadTreePosition for the third child. The system determines 219 whether there is a fourth child at the QuadTreePosition 201 ; if so, it creates 220 a QuadTreePosition for the fourth child.
The system then determines 211 whether this is the last QuadTreeIndexNode to be processed. If so, it creates 212 the QuadTreePacket 801 from the QuadTreeQuantum list 210 .
QuadTree Packet Merging
FIG. 3 is a flow chart of QuadTree packet merging according to one embodiment of the present invention. The system merges QuadTreePacket 1 801 A and QuadTreePacket 2 801 B as follows. It creates 301 A QuadTreeQuantumList 1 210 A from QuadTreePacket 1 801 A, and creates 301 B QuadTreeQuantumList 2 210 B from QuadTreePacket 2 801 B. The system then determines 302 whether there is another QuadTreeQuantum in List 1 210 A. If not, the system determines 303 whether there is another QuadTreeQuantum in List 2 210 B. If not, the system adds 304 QuadTreeQuantum 2 to the merged QuadTreeQuantumList 210 C and creates 311 a merged QuadTreePacket 801 C.
If, in 303 , the system determines that there is another QuadTreeQuantum in List 2 210 B, it proceeds directly to step 311 to create a merged QuadTreePacket 801 C.
If, in 302 , the system determines that there is another QuadTreeQuanturn in List 1 210 A, it gets 305 the first or next QuadTreeQuantum from List 1 210 A, computes 306 the QuadTreePosition of the next QuadTreeQuantum in List 1 210 A, and determines 307 whether there is another QuadTreeQuantum in List 2 210 B. If not, the system adds 308 QuadTreeQuantum 1 to the merged QuadTreeQuantumList 210 C and creates 311 a merged QuadTreePacket 801 C.
If, in 307 , the system determines that there is another QuadTreeQuantum in List 2 210 B, it gets 309 the first or next QuadTreeQuantum from List 2 210 B and computes 310 the QuadTreePosition of the next QuadTreeQuantum in List 2 210 B. Then, it determines 311 whether the level of QuadTreePosition 1 is less than, greater than, or equal to the level of QuadTreePosition 2 . If the level of QuadTreePosition 1 is less than the level of QuadTreePosition 2 , the system puts back 317 QuadTreeQuantum 2 into QuadTreeQuantumList 2 210 B, adds 318 QuadTreeQuantum 1 to the merged QuadTreeQuantumList 210 C and creates 311 a merged QuadTreePacket 801 C.
If, in 311 , the system determines that the level of QuadTreePosition 1 is greater than the level of QuadTreePosition 2 , it puts back 315 QuadTreeQuantum 1 into QuadTreeQuantumList 1 210 A, adds 316 QuadTreeQuantum 2 to the merged QuadTreeQuantumList 210 C and creates 311 a merged QuadTreePacket 801 C. It also returns to step 302 .
If, in 311 , the system determines that the level of QuadTreePosition 1 is equal to the level of QuadTreePosition 2 , it determines 312 whether the child number of QuadTreePosition 1 is less than, greater than, or equal to the child number of QuadTreePosition 2 . If the child number of QuadTreePosition 1 is less than the child number of QuadTreePosition 2 , the system puts back 315 QuadTreeQuantum 1 into QuadTreeQuantumList 1 210 A, adds 316 QuadTreeQuantum 2 to the merged QuadTreeQuantumList 210 C and creates 311 a merged QuadTreePacket 801 C. It also returns to step 302 . If, in 312 , the child number of QuadTreePosition 1 is greater than the child number of QuadTreePosition 2 , the system puts back 317 QuadTreeQuantum 2 into QuadTreeQuantumList 2 210 B, adds 318 QuadTreeQuantum 1 to the merged QuadTreeQuantumList 210 C and creates 311 a merged QuadTreePacket 801 C. If, in 312 , the child number of QuadTreePosition 1 is equal to the child number of QuadTreePosition 2 , the system merges 303 the QuadTreeQuantums together, puts 314 the merged QuadTreeQuantum into the merged QuadTreeQuantumList 210 C, and creates 311 a merged QuadTreePacket 801 C. It also returns to step 302 .
Obtaining a Session Key
FIG. 4 is a flow chart of obtaining a session key according to one embodiment of the present invention. The system determines 401 whether the user has registered the client application. If not, it gets 402 the first name, last name, and registration ID from the user. Next, the system gets 403 the encryption key from the server. Next, it encrypts 404 the first name, last name, and registration ID, and sends 405 the encrypted message to the server for verification. If the server indicates 406 that the registration ID is not valid, the system exits 407 .
If, in 406 , the server indicates that the registration ID is valid, or if, in 401 , the system determines that the user has registered the client application, the system sends 408 the encrypted registration ID and requests a session key.
The system then determines 409 whether the registration ID is valid. If so, it sends 411 a session key back to the client. If not, the system exits 410 .
Using a Session Key
FIG. 5 is a flow chart of using a session key with a data packet according to one embodiment of the present invention. The system sends 501 the session key with a data packet request to the server. Next, it decrypts 502 the session key on the server side, and gets expiration time 502 , package IDs 503 , and current time 505 . The system then determines 506 whether the current time is past the expiration time. If so, it denies 507 access.
If the current time is not past the expiration time, the system determines 508 whether the data packet requested is accessible to the user given the list of package IDs. If not, it denies 509 access. If the data packet is accessible, the system sends 510 the requested data packet.
In the above description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to avoid obscuring the invention.
Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Some portions of the detailed description are presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self-consistent sequence of steps leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system's memories or registers or other such information storage, transmission or display devices.
The present invention also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, and magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, or any type of media suitable for storing electronic instructions, and each coupled to a computer system bus.
The algorithms and displays presented herein are not inherently related to any particular computer, network of computers, or other apparatus. Various general-purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct a more specialized apparatus to perform the required method steps. The required structure for a variety of these systems appears from the description. In addition, the present invention is not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the invention as described herein.
As will be understood by those familiar with the art, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, the particular architectures depicted above are merely exemplary of one implementation of the present invention. The functional elements and method steps described above are provided as illustrative examples of one technique for implementing the invention; one skilled in the art will recognize that many other implementations are possible without departing from the present invention as recited in the claims. Likewise, the particular capitalization or naming of the modules, protocols, features, attributes, or any other aspect is not mandatory or significant, and the mechanisms that implement the invention or its features may have different names or formats. In addition, the present invention may be implemented as a method, process, user interface, computer program product, system, apparatus, or any combination thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims. | A flat file data organization technique is used for storing and retrieving geospatially organized data. The invention reduces transfer time by transferring a few large files in lieu of a large number of small files. It also moves the process of locating a given data file away from the file system to a proprietary code base. Additionally, the invention simplifies database management by having quadtree packets generated on demand. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation application claiming priority under 35 U.S.C. §120 of U.S. patent application Ser. No. 11/258,742, filed Oct. 26, 2005, now U.S. Pat. No. 7,628,528, the disclosure of which is hereby incorporated by reference.
FIELD OF INVENTION
The invention pertains to apparatus for mixing solutions. More particularly, the invention relates to pneumatically operated mixers for use in closed, sterile environments.
BACKGROUND OF THE INVENTION
Bioreactors have been used for cultivation of microbial organisms for production of various biological or chemical products in the pharmaceutical, beverage and biotechnological industry. A production bioreactor contains culture medium in a sterile environment that provides various nutrients required to support growth of the biological agents of interest. Conventional bioreactors use mechanically driven impellers to mix the liquid medium during cultivation. The bioreactors can be reused for the next batch of biological agents after cleaning and sterilization of the vessel. The procedure of cleaning and sterilization requires a significant amount of time and resources, especially, to monitor and to validate each cleaning step prior to reuse for production of biopharmaceutical products. Due to the high cost of construction, maintenance and operation of the conventional bioreactors, single use bioreactor systems made of disposable plastic material have become an attractive alternative.
While several mixing methods of liquid in disposable bioreactors have been proposed in recent years, none of them provides efficient mixing for large scale (greater than 1000 liters) without expensive operating machinery. For this reason, a number of non-invasive and/or disposable mixing systems that do not require an external mechanical operation have been developed. Many of these systems work well within certain size ranges, however, problems sometimes arise as larger mixing systems are attempted. Some relevant examples of prior art pneumatic mixing systems include the following.
U.S. Pat. No. 6,032,931, issued to Plunkett, discloses an aeration device for use in a pond. Compressed gas is supplied to a conduit to form bubbles as the gas/air exits from a series of apertures. As the bubbles rise, they drive turbines to rotate and thereby create additional mixing turbulence.
U.S. Pat. No. 6,322,056, issued to Drie describes a submarine type liquid mixer with aeration. The buoyancy shells provide a downwardly facing upwardly concave surface for capturing gas bubbles so as to provide a buoyancy force to the struts. The bubbles may be naturally involved within the liquid due to chemical processes or they may be released from a gas inflow into the tank. As the gases are captured by a series of shells, each in turn is displaced upwardly whereupon the gas is released at the top of tank. At this point, one of the shells loses its buoyancy while the lower shell has received gas bubbles, enabling it to be displaced and thus the motion of the shells is reversed. This up and down cyclic motion of the shells mixes the liquid in the tanks.
U.S. Pat. No. 6,406,624, issued to De Vos discloses a flocculation apparatus and apparatus for floating upwardly in a liquid and for moving downwardly in the liquid under the influence of gravity. The flocculation apparatus includes a paddle apparatus and a flotation and compressed gas discharge apparatus. A pressurized or compressed air line with a branch line extending upwardly into the flotation and compressed gas discharge apparatus is also provided. When gas is introduced through the lines into the gas discharge apparatus, the apparatus becomes increasingly buoyant and floats upwardly in the liquid within the basin and thereby moves the paddle apparatus and frame apparatus upwardly in the liquid as well. When the apparatus reaches the top, the compressed air is released and the frame apparatus along with the paddle apparatus are pulled downwardly in the liquid by gravity. During the upward and downward movement of the paddle members, the paddle members agitate or stir the liquid contained within the basin.
U.S. Pat. No. 6,390,455, issued to Lee et al. describes a bubble generating device having a float connected thereto. The object of the invention is to provide a bubble generating device that can be operated in a desired depth of water which ultimately is used to agitate the water and provide a supply of oxygen to the water. The device includes a porous portion which is connected to a source of air through a pipe to generate bubbles while the float maintains the apparatus at a desired level in a water container.
U.S. Pat. No. 5,645,346, issued to Thuna is directed to a food preparation blender with a rotating and vertically oscillating mixing blade. The blender includes a pressure plate which causes a first shaft to be raised, thus raising the mixing blades while mixing takes place.
U.S. Pat. No. 6,649,117, issued to Familletti discloses an improved reactor/fermentor apparatus useful for carrying out cell culture and fermentation. The apparatus utilizes novel design features to provide optimum agitation of the cells while minimizing mechanical shear force. The reactor is composed of two chambers; an upper, wider chamber and a lower, small diameter chamber which are connected by inwardly sloping side walls. Agitation is accomplished by utilizing a gently flowing centrally disposed gas stream.
U.S. Pat. No. 3,963,581, issued to Giacobbe et al. describes an air lift fermentor comprising in combination a hollow cylindrical body, vertically located and subdivided into three zones by a pair of diaphragms parallel to the axis of said cylindrical body, the central zone of which is destined to fermentation of the liquor, and the two lateral zones serve for recirculating the liquor itself, after its passage through a heat exchanger and an air distributor, both located near the bottom of said cylindrical body.
It is an objective of the present invention to provide a pneumatic bioreactor that is capable of efficiently and thoroughly mixing solutions without contamination. It is a further objective to such a reactor that can be scaled to relatively large sizes using the same technology. It is a still further objective of the invention to a bioreactor that can be produced in a disposable form. It is yet a further objective of the invention to provide a bioreactor that can be accurately controlled by internal pneumatic force, as to speed and mixing force applied to the solution without creating a foaming problem. Finally, it is an objective to provide a bioreactor that is simple and inexpensive to produce and to operate while fulfilling all of the described performance criteria.
While some of the objectives of the present invention are disclosed in the prior art, none of the inventions found include all of the requirements identified.
SUMMARY OF THE INVENTION
The present invention addresses all of the deficiencies of prior art pneumatic bioreactor inventions and satisfies all of the objectives described above.
A pneumatic bioreactor providing all of the desired features can be constructed from the following components. A containment vessel is provided. The vessel has a top, a closed bottom, a surrounding wall and is of sufficient size to contain a fluid to be mixed and a mixing apparatus. The mixing apparatus includes at least one gas supply line. The supply line terminates at an orifice adjacent the bottom of the vessel. At least one buoyancy-driven mixing device is provided. The mixing device moves in the fluid as gas from the supply line is introduced into and vented from the mixing device. When gas is introduced into the gas supply line the gas will enter the mixing device and cause the device to mix the fluid.
In a variant of the invention, the buoyancy-driven mixing device further includes at least one floating mixer. The mixer has a central, gas-holding chamber and a plurality of mixing elements located about the central chamber. The mixing elements are shaped to cause the mixer to agitate the fluid as the mixer rises in the fluid in the containment vessel. The central chamber has a gas-venting valve. The valve permits escape of gas as the central chamber reaches a surface of the fluid. A constraining member is provided. The constraining member limits horizontal movement of the floating mixer as it rises or sinks in the fluid. When gas is introduced into the gas supply line, the gas will enter the gas holding chamber and cause the floating mixer to rise by buoyancy in the fluid while agitating the fluid. When the gas venting valve of the central chamber reaches the surface of the fluid, the gas will be released and the floating mixer will sink toward the bottom of the containment vessel where the central chamber will again be filled with gas, causing the floating mixer to rise.
In another variant, means are provided for controlling a rate of assent of the floating mixer.
In still another variant, the means for controlling the rate of assent of the floating mixer includes a ferromagnetic substance attached to either of the floating mixer or the constraining member and a controllable electromagnet located adjacent the bottom of the containment vessel. The gas flow is interrupted by an on/off switch which is controlled by interactions of two magnetic substances. Therefore, the volume of gas supplied into the gas-holding chamber is determined by the strength of the electromagnetic power since the gas flow stops as the floating device starts to rise when the buoyancy becomes greater than the magnetic holding force.
In yet another variant, the central, gas-holding chamber further includes an opening. The opening is located at an upper end of the chamber. A vent cap is provided. The vent cap is sized and shaped to seal the opening when moved upwardly against it by buoyancy from gas from the supply line. A support bracket is provided. The support bracket is located within the chamber to support the vent cap when it is lowered after release of gas from the chamber. When the chamber rises to the surface of the fluid the vent cap will descend from its weight and the opening will permit the gas to escape, the chamber will then sink in the fluid and the vent cap will again rise due to buoyancy from a small amount of gas permanently enclosed in the vent cap, thereby sealing the opening.
In a further variant, a second floating mixer is provided. A second constraining member is provided, limiting horizontal movement of the second mixer as it rises in the fluid. At least one additional gas supply line is provided. The additional supply line terminates at an orifice adjacent the bottom of the vessel. At least one pulley is provided. The pulley is attached to the bottom of the containment vessel. A flexible member is provided. The flexible member attaches the chamber of the floating mixer to a chamber of the second floating mixer. The flexible member is of a length permitting the gas venting valve of the chamber of the floating mixer to reach the surface of the fluid while the chamber of the second floating mixer is spaced from the bottom of the containment vessel. When the floating mixer is propelled upwardly by buoyancy from the gas from the supply line the second floating mixer is pulled downwardly by the flexible member until the gas is released from the chamber of the floating mixer as its gas venting valve reaches the surface of the fluid. The chamber will then sink in the fluid as the second floating mixer rises by buoyancy from gas introduced from the second supply line.
In yet a further variant, the containment vessel is formed of resilient material, the material is sterilizable by gamma irradiation methods.
In still a further variant, the buoyancy-driven mixing device further includes at least one floating plunger. The plunger has a central, gas-holding chamber and at least one disk located about the central chamber. The disk is shaped to cause the plunger to agitate the fluid as the plunger rises in the fluid in the containment vessel. The central chamber has a gas-venting valve. The valve permits escape of gas as the central chamber reaches a surface of the fluid. A mixing partition is provided. The partition is located in the containment vessel adjacent the floating plunger and has at least one aperture to augment a mixing action of the floating plunger. A constraining member is provided. The constraining member limits horizontal movement of the plunger as it rises or sinks in the fluid. When gas is introduced into the gas supply line the gas will enter the gas holding chamber and cause the floating plunger to rise by buoyancy in the fluid while agitating the fluid. When the gas venting valve of the central chamber reaches the surface of the fluid, the gas will be released and the floating plunger will sink toward the bottom of the containment vessel where the central chamber will again be filled with gas, causing the floating plunger to rise.
In another variant of the invention, a second floating plunger is provided. A second constraining member is provided, limiting horizontal movement of the second plunger as it rises in the fluid. At least one additional gas supply line is provided. The additional supply line terminates at an orifice adjacent the bottom of the vessel. At least one pulley is provided. The pulley is attached to the bottom of the containment vessel. A flexible member is provided. The flexible member attaches the chamber of the floating plunger to a chamber of the second floating plunger. The flexible member is of a length permitting the gas venting valve of the chamber of the floating plunger to reach the surface of the fluid while the chamber of the second floating plunger is spaced from the bottom of the containment vessel. The mixing partition is located between the floating plunger and the second floating plunger. When the floating plunger is propelled upwardly by buoyancy from the gas from the supply line the second floating plunger is pulled downwardly by the flexible member until the gas is released from the chamber of the floating plunger as its gas venting valve reaches the surface of the fluid. The chamber will then sink in the fluid as the second floating plunger rises by buoyancy from gas introduced from the second supply line.
In still another variant, the pneumatic bioreactor further includes a cylindrical chamber. The chamber has an inner surface, an outer surface, a first end, a second end and a central axis. At least one mixing plate is provided. The mixing plate is attached to the inner surface of the chamber. First and second flanges are provided. The flanges are mounted to the cylindrical chamber at the first and second ends, respectively. First and second pivot points are provided. The pivot points are attached to the first and second flanges, respectively and to the containment vessel, thereby permitting the cylindrical chamber to rotate about the central axis. A plurality of gas holding members are provided. The members extend from the first flange to the second flange along the outer surface of the cylindrical chamber and are sized and shaped to entrap gas bubbles from the at least one gas supply line. The gas supply line terminates adjacent the cylindrical chamber on a first side of the chamber below the gas holding members. When gas is introduced into the containment vessel through the supply line it will rise in the fluid and gas bubbles will be entrapped by the gas holding members. This will cause the cylindrical chamber to rotate on the pivot points in a first direction and the at least one mixing plate to agitate the fluid.
In yet another variant, a rate of rotation of the cylindrical chamber is controlled by varying a rate of introduction of gas into the gas supply line.
In a further variant, a second gas supply line is provided. The second supply line terminates adjacent the cylindrical chamber on a second, opposite side of the chamber below the gas holding members. Gas from the second supply line causes the cylindrical chamber to rotate on the pivot points in a second, opposite direction.
In still a further variant, the at least one mixing plate has at least one aperture to augment mixing of the fluid in the containment vessel.
In yet a further variant, the containment vessel further includes a closable top. The top has a vent, permitting the escape of gas from the gas supply line through a sterile filter.
In another variant of the invention, a temperature control jacket is provided. The jacket surrounds the containment vessel.
In yet another variant, a pneumatic bioreactor includes a containment vessel. The vessel has a top, a closed bottom, a surrounding wall and is of sufficient size to contain a fluid to be mixed and a mixing apparatus. The mixing apparatus includes at least one gas supply line. The supply line terminates at an orifice at the bottom of the vessel. At least one floating impeller is provided. The impeller has a central, gas-containing chamber and a plurality of impeller blades arcurately located about the central chamber. The impeller blades are shaped to cause the impeller to revolve about a vertical axis as the impeller rises in fluid in the containment vessel.
The central chamber has a gas-venting valve. The valve permits escape of gas as the central chamber reaches a surface of the fluid. An outside housing is provided. The housing is ring-shaped and surrounds the floating impeller and constrains its lateral movement. At least one supporting pole is provided. The pole extends from the bottom upwardly toward the top. The outside housing is slidably attached to the supporting pole. The floating impeller is rotatably attached to the outside housing. When gas is introduced into the gas supply line the gas will enter the gas containing chamber and cause the floating impeller to rise in the fluid while rotating and mixing the fluid. When the gas venting valve of the central chamber reaches the surface of the fluid, the gas will be released and the floating impeller will sink toward the bottom of the containment vessel where the central chamber will again be filled with gas, causing the floating impeller to rise.
In still another variant, the impeller blades are rotatably mounted to the central chamber and the central chamber is fixedly attached to the outside housing.
In a further variant, the impeller blades are fixedly mounted to the central chamber and rotatably mounted to the outside housing.
In still a further variant, the outside housing further includes a horizontal interior groove located on an inner surface of the housing. The impeller blades include a projection, sized and shaped to fit slidably within the groove.
In yet a further variant, means are provided for controlling a rate of assent of the floating impeller.
In another variant of the invention, the means for controlling a rate of assent of the floating impeller includes a ferromagnetic substance attached to either the floating impeller or the outside housing and a controllable electromagnet located adjacent the bottom of the containment vessel.
In still another variant, the central, gas-containing chamber further includes an opening located at an upper end of the chamber. A vent cap is provided. The vent cap is sized and shaped to seal the opening when moved upwardly against it by pressure from gas from the supply line. A support bracket is provided. The support bracket is located within the chamber to support the vent cap when it is lowered after release of gas from the chamber. When the chamber rises to the surface of the fluid the vent cap will descend from its weight and the opening will permit the gas to escape. The chamber will then sink in the fluid and the vent cap will again rise due to pressure from gas introduced into the chamber from the gas line, thereby sealing the opening.
In yet another variant, the vent cap further includes an enclosed gas cell. The cell causes the cap to float in the fluid and thereby to reseal the opening after the gas has been released when the chamber reached the surface of the fluid.
In a further variant, the pneumatic bioreactor further includes a second floating impeller. A second outside housing surrounding the second floating impeller is provided. At least one additional supporting pole is provided. At least one additional gas supply line is provided. The additional supply line terminates at an orifice at the bottom of the vessel. The second outside housing is slidably attached to the additional supporting pole. The second floating impeller is rotatably attached to the second outside housing. At least one pulley is provided. The pulley is attached to the bottom of the containment vessel.
A flexible member is provided. The flexible member attaches the chamber of the floating impeller to a chamber of the second floating impeller. The flexible member is of a length to permit the gas venting valve of the chamber of the floating impeller to reach the surface of the fluid while the chamber of the second floating impeller is spaced from the bottom of the containment vessel. When the floating impeller is propelled upwardly by pressure from the gas from the supply line the second floating impeller will be pulled downwardly by the flexible member until the gas is released from the chamber of the floating impeller as its gas venting valve reaches the surface of the fluid, the chamber will then sink in the fluid as the second floating impeller rises under pressure from gas introduced from the second supply line.
An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and the detailed description of a preferred embodiment.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the invention illustrating floating impellers and their control mechanisms;
FIG. 2 is a top view of the FIG. 1 embodiment illustrating the floating chamber affixed to the constraining member with the impeller blades rotating upon the chamber;
FIG. 2A is a top view of the FIG. 1 embodiment illustrating the floating chamber rotating within the constraining member with the impeller blades fixed to the chamber;
FIG. 3 is a side elevational view of the FIG. 1 embodiment;
FIG. 4 is a side elevational view of the FIG. 2A embodiment of the floating impeller;
FIG. 4A is a side elevational view of the FIG. 2 embodiment of the floating impeller;
FIG. 5 is a perspective view of a second embodiment of the invention illustrating floating plungers and their control mechanisms;
FIG. 6 is a top view of the FIG. 5 embodiment illustrating the floating plungers;
FIG. 7 is a perspective view of the gas supply line and magnetic assent control mechanism;
FIG. 8 is a cross-sectional side elevation of the floating chamber illustrating the vent cap in a closed position;
FIG. 9 is a cross-sectional side elevation of the floating chamber illustrating the vent cap in an open position;
FIG. 10 is a perspective view of a third embodiment of the invention illustrating a rotating drum mixer with gas supply line;
FIG. 11 is an end view of the FIG. 10 embodiment illustrating a single gas supply line;
FIG. 12 is an end view of the FIG. 10 embodiment illustrating a pair of gas supply lines;
FIG. 13 is a side elevational view of the FIG. 10 embodiment illustrating a containment vessel;
FIG. 14 is a perspective view of the FIG. 5 embodiment illustrating a closable top and sterile filters; and
FIG. 15 is a perspective view of the FIG. 5 embodiment illustrating a temperature control jacket surrounding the vessel.
DETAILED DESCRIPTION
A pneumatic bioreactor 10 , as illustrated in FIGS. 1-3 , providing all of the desired features can be constructed from the following components. A containment vessel 15 is provided. The vessel 15 has a top 20 , a closed bottom 25 , a surrounding wall 30 and is of sufficient size to contain a fluid 35 to be mixed and a mixing apparatus 40 . The mixing apparatus 40 includes at least one gas supply line 45 . The supply line 45 terminates at an orifice 50 adjacent the bottom 25 of the vessel 15 . At least one buoyancy-driven mixing device 55 is provided. The mixing device 55 moves in the fluid 35 as gas 60 from the supply line 45 is introduced into and vented from the mixing device 55 . When gas 60 is introduced into the gas supply line 45 the gas 60 will enter the mixing device 55 and cause the device to mix the fluid 35 .
In a variant of the invention, the buoyancy-driven mixing device 55 further includes at least one floating mixer 65 . The mixer 65 has a central, gas-holding chamber 70 and a plurality of mixing elements 75 located about the central chamber 70 . The mixing elements 75 are shaped to cause the mixer 65 to agitate the fluid 35 as the mixer 65 rises in the fluid 35 in the containment vessel 15 . The central chamber 70 , as illustrated in FIGS. 8 and 9 , has a gas-venting valve 80 . The valve 80 permits escape of gas 60 as the central chamber 70 reaches a surface 85 of the fluid 35 . A constraining member 90 is provided. The constraining member 90 limits horizontal movement of the floating mixer 65 as it rises or sinks in the fluid 35 . When gas 60 is introduced into the gas supply line 45 , the gas 60 will enter the gas holding chamber 70 and cause the floating mixer 65 to rise by buoyancy in the fluid 35 while agitating the fluid 35 . When the gas venting valve 80 of the central chamber 70 reaches the surface 85 of the fluid 35 , the gas 60 will be released and the floating mixer 65 will sink toward the bottom 25 of the containment vessel 15 where the central chamber 70 will again be filled with gas 60 , causing the floating mixer 65 to rise.
In another variant, means 95 , as illustrated in FIG. 7 , are provided for controlling a rate of assent of the floating mixer 65 .
In still another variant, the means 95 for controlling the rate of assent of the floating mixer 65 includes a ferromagnetic substance 100 attached to either of the floating mixer 65 or the constraining member 90 and a controllable electromagnet 105 located adjacent the bottom 25 of the containment vessel 15 .
In yet another variant, as illustrated in FIGS. 8 and 9 , the central, gas-holding chamber 70 further includes an opening 110 . The opening 110 is located at an upper end 115 of the chamber 70 . A vent cap 117 is provided. The vent cap 117 is sized and shaped to seal the opening 110 when moved upwardly against it by buoyancy from gas 60 from the supply line 45 . A support bracket 120 is provided. The support bracket 120 is located within the chamber 70 to support the vent cap 115 when it is lowered after release of gas 60 from the chamber 70 . When the chamber 70 rises to the surface 85 of the fluid 35 the vent cap 115 will descend from its weight and the opening 110 will permit the gas 60 to escape, the chamber 70 will then sink in the fluid 35 and the vent cap 115 will again rise due to buoyancy from a small amount of gas 60 permanently enclosed in the vent cap 115 , thereby sealing the opening 110 .
In a further variant, as illustrated in FIGS. 1-3 , a second floating mixer 125 is provided. A second constraining member 130 is provided, limiting horizontal movement of the second mixer 125 as it rises in the fluid 35 . At least one additional gas supply line 135 is provided. The additional supply line 135 terminates at an orifice 143 adjacent the bottom 25 of the vessel 15 . At least one pulley 140 is provided. The pulley 140 is attached to the bottom 25 of the containment vessel 15 . A flexible member 145 is provided. The flexible member 145 attaches the chamber 70 of the floating mixer 65 to a chamber 150 of the second floating mixer 125 . The flexible member 145 is of a length permitting the gas venting valve 80 of the chamber 70 of the floating mixer 65 to reach the surface 85 of the fluid 35 while the chamber 70 of the second floating mixer 125 is spaced from the bottom 25 of the containment vessel 15 . When the floating mixer 65 is propelled upwardly by buoyancy from the gas 60 from the supply line 45 the second floating mixer 125 is pulled downwardly by the flexible member 145 until the gas 60 is released from the chamber 70 of the floating mixer 65 as its gas venting valve 80 reaches the surface 85 of the fluid 35 . The chamber 70 will then sink in the fluid 35 as the second floating mixer 125 rises by buoyancy from gas 60 introduced from the second supply line 135 .
In yet a further variant, the containment vessel 15 is formed of resilient material 155 , the material is sterilizable by gamma irradiation methods.
In still a further variant, as illustrated in FIGS. 5 and 6 , the buoyancy-driven mixing device 10 further includes at least one floating plunger 160 . The plunger 160 has a central, gas-holding chamber 70 and at least one disk 165 located about the central chamber 70 . The disk 165 is shaped to cause the plunger 160 to agitate the fluid 35 as the plunger 160 rises in the fluid 35 in the containment vessel 15 . The central chamber 70 has a gas-venting valve 80 . The valve 80 permits escape of gas 60 as the central chamber 70 reaches a surface 85 of the fluid 35 . A mixing partition 170 is provided. The partition 170 is located in the containment vessel 15 adjacent the floating plunger 160 and has at least one aperture 175 to augment a mixing action of the floating plunger 160 . A constraining member 180 is provided. The constraining member 180 limits horizontal movement of the plunger 160 as it rises or sinks in the fluid 35 . When gas 60 is introduced into the gas supply line 45 the gas 60 will enter the gas holding chamber 70 and cause the floating plunger 160 to rise by buoyancy in the fluid 35 while agitating the fluid 35 . When the gas venting valve 80 of the central chamber 70 reaches the surface 85 of the fluid 35 , the gas 60 will be released and the floating plunger 160 will sink toward the bottom 25 of the containment vessel 15 where the central chamber 70 will again be filled with gas 60 , causing the floating plunger 160 to rise.
In another variant of the invention, a second floating plunger 185 is provided. A second constraining member 190 is provided, limiting horizontal movement of the second plunger 185 as it rises in the fluid 35 . At least one additional gas supply line 135 is provided. The additional supply line 135 terminates at an orifice 143 adjacent the bottom 25 of the vessel 15 . At least one pulley 140 is provided. The pulley 140 is attached to the bottom 25 of the containment vessel 15 . A flexible member 145 is provided. The flexible member 145 attaches the chamber 70 of the floating plunger 160 to a chamber of the second floating plunger 185 . The flexible member 145 is of a length permitting the gas venting valve 80 of the chamber 70 of the floating plunger 160 to reach the surface 85 of the fluid 35 while the chamber 70 of the second floating plunger 185 is spaced from the bottom 25 of the containment vessel 15 . The mixing partition 170 is located between the floating plunger 160 and the second floating plunger 185 . When the floating plunger 160 is propelled upwardly by buoyancy from the gas 60 from the supply line 45 the second floating plunger 185 is pulled downwardly by the flexible member 145 until the gas 60 is released from the chamber 70 of the floating plunger 160 as its gas venting valve 80 reaches the surface 85 of the fluid 30 . The floating plunger 160 will then sink in the fluid 35 as the second floating plunger 185 rises by buoyancy from gas 60 introduced from the second supply line 135 .
In still another variant, as illustrated in FIGS. 10-13 , the pneumatic bioreactor 10 further includes a cylindrical chamber 195 . The chamber 195 has an inner surface 200 , an outer surface 205 , a first end 210 , a second end 215 and a central axis 220 . At least one mixing plate 225 is provided. The mixing plate 225 is attached to the inner surface 200 of the chamber 195 . First 230 and second 235 flanges are provided. The flanges 230 , 235 are mounted to the cylindrical chamber 195 at the first 210 and second ends 215 , respectively. First 240 and second 245 pivot points are provided. The pivot points 240 , 245 are attached to the first 230 and second 235 flanges, respectively and to the containment vessel 15 , thereby permitting the cylindrical chamber 195 to rotate about the central axis 220 . A plurality of gas holding members 250 are provided. The members 250 extend from the first flange 230 to the second flange 235 along the outer surface 205 of the cylindrical chamber 195 and are sized and shaped to entrap gas bubbles 255 from the at least one gas supply line 45 . The gas supply line 45 terminates adjacent the cylindrical chamber 195 on a first side 260 of the chamber 195 below the gas holding members 250 . When gas 60 is introduced into the containment vessel 15 through the supply line 45 it will rise in the fluid 35 and gas bubbles 255 will be entrapped by the gas holding members 250 . This will cause the cylindrical chamber 195 to rotate on the pivot points 240 , 245 in a first direction 262 and the at least one mixing plate 225 to agitate the fluid 35 .
In yet another variant, a rate of rotation of the cylindrical chamber 195 is controlled by varying a rate of introduction of gas 60 into the gas supply line 45 .
In a further variant, as illustrated in FIG. 12 , a second gas supply line 135 is provided. The second supply line 135 terminates adjacent the cylindrical chamber 195 on a second, opposite side 265 of the chamber 195 below the gas holding members 250 . Gas 60 from the second supply line 135 causes the cylindrical chamber 195 to rotate on the pivot points 240 , 245 in a second, opposite direction 270 .
In still a further variant, as illustrated in FIGS. 10 and 13 , the at least one mixing plate 225 has at least one aperture 275 to augment mixing of the fluid 35 in the containment vessel 15 .
In yet a further variant, as illustrated in FIG. 14 , the containment vessel 15 further includes a closable top 280 . The top has a vent 285 , permitting the escape of gas 60 from the gas supply line 45 through a sterile filter 290 .
In another variant of the invention, as illustrated in FIG. 15 , a temperature control jacket 295 is provided. The jacket 295 surrounds the containment vessel 15 .
In yet another variant, as illustrated in FIGS. 1-3 , a pneumatic bioreactor 10 includes a containment vessel 15 . The vessel 15 has a top 20 , a closed bottom 25 , a surrounding wall 30 and is of sufficient size to contain a fluid 35 to be mixed and a mixing apparatus 40 . The mixing apparatus 40 includes at least one gas supply line 45 . The supply line 45 terminates at an orifice 50 at the bottom 25 of the vessel 15 . At least one floating impeller 300 is provided. The impeller 300 has a central, gas-containing chamber 70 and a plurality of impeller blades 305 arcurately located about the central chamber 70 . The impeller blades 305 are shaped to cause the impeller 300 to revolve about a vertical axis 310 as the impeller 300 rises in fluid 35 in the containment vessel 15 .
The central chamber 70 has a gas-venting valve 80 . The valve 80 permits escape of gas 60 as the central chamber 70 reaches a surface 85 of the fluid 35 . An outside housing 315 is provided. The housing 315 is ring-shaped and surrounds the floating impeller 300 and constrains its lateral movement. At least one supporting pole 320 is provided. The pole 320 extends from the bottom 25 upwardly toward the top 20 . The outside housing 315 is slidably attached to the supporting pole 320 . The floating impeller 300 is rotatably attached to the outside housing 315 . When gas 60 is introduced into the gas supply line 45 the gas 60 will enter the gas containing chamber 70 and cause the floating impeller 300 to rise in the fluid 35 while rotating and mixing the fluid 35 . When the gas venting valve 80 of the central chamber 70 reaches the surface 85 of the fluid 35 , the gas 60 will be released and the floating impeller 300 will sink toward the bottom 25 of the containment vessel 15 where the central chamber 70 will again be filled with gas 60 , causing the floating impeller 300 to rise.
In still another variant, as illustrated in FIGS. 2 and 4A , the impeller blades 305 are rotatably mounted to the central chamber 70 and the central chamber 70 is fixedly attached to the outside housing 315 .
In a further variant, as illustrated in FIGS. 2A and 4 , the impeller blades 305 are fixedly mounted to the central chamber 70 and rotatably mounted to the outside housing 315 .
In still a further variant, the outside housing 315 further includes a horizontal interior groove 322 located on an inner surface 325 of the housing 315 . The impeller blades 305 include a projection 330 , sized and shaped to fit slidably within the groove 322 .
In yet a further variant, as illustrated in FIG. 7 , means 95 are provided for controlling a rate of assent of the floating impeller 300 .
In another variant of the invention, the means 95 for controlling a rate of assent of the floating impeller 300 includes a ferromagnetic substance 100 attached to either the floating impeller 300 or the outside housing 315 and a controllable electromagnet 105 located adjacent the bottom 25 of the containment vessel 15 .
In still another variant, as illustrated in FIGS. 8 and 9 , the central, gas-containing chamber 70 further includes an opening 110 located at an upper end 115 of the chamber 70 . A vent cap 115 is provided. The vent cap 115 is sized and shaped to seal the opening 110 when moved upwardly against it by pressure from gas 60 from the supply line 45 . A support bracket 120 is provided. The support bracket 120 is located within the chamber 70 to support the vent cap 115 when it is lowered after release of gas 60 from the chamber 70 . When the chamber 70 rises to the surface of the fluid 35 the vent cap 115 will descend from its weight and the opening 110 will permit the gas 60 to escape. The floating impeller 300 will then sink in the fluid 35 and the vent cap 115 will again rise due to pressure from gas 60 introduced into the chamber 70 from the gas line 45 , thereby sealing the opening 110 .
In yet another variant, the vent cap 115 further includes an enclosed gas cell 310 . The cell 310 causes the cap 115 to float in the fluid 35 and thereby to reseal the opening 110 after the gas 60 has been released when the chamber 70 reached the surface 85 of the fluid 35 .
In a further variant, as illustrated in FIGS. 1 and 3 , the pneumatic bioreactor 10 further includes a second floating impeller 317 . A second outside housing 324 surrounding the second floating impeller 317 is provided. At least one additional supporting pole 326 is provided. At least one additional gas supply line 135 is provided. The additional supply line 135 terminates at an orifice 143 at the bottom 25 of the vessel 15 . The second outside housing 324 is slidably attached to the additional supporting pole 325 . The second floating impeller 317 is rotatably attached to the second outside housing 324 . At least one pulley 140 is provided. The pulley 140 is attached to the bottom 25 of the containment vessel 15 .
A flexible member 145 is provided. The flexible member 145 attaches the chamber 70 of the floating impeller 300 to a chamber 70 of the second floating impeller 317 . The flexible member 145 is of a length to permit the gas venting valve 80 of the chamber 70 of the floating impeller 300 to reach the surface 85 of the fluid 35 while the chamber 70 of the second floating impeller 317 is spaced from the bottom 25 of the containment vessel 15 . When the floating impeller 300 is propelled upwardly by pressure from the gas 60 from the supply line 45 the second floating impeller 315 will be pulled downwardly by the flexible member 145 until the gas 60 is released from the chamber 70 of the floating impeller 300 as its gas venting valve 80 reaches the surface 85 of the fluid 35 , the floating impeller 300 will then sink in the fluid 35 as the second floating impeller 315 rises under pressure from gas 60 introduced from the second supply line 135 .
An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and the detailed description of a preferred embodiment. | A pneumatic bioreactor includes a vessel containing a fluid to be mixed and at least one mixing device driven by gas pressure. A first embodiment includes a floating impeller that rises and falls in the fluid as gas bubbles carry it upward to the surface where the gas is then vented, permitting the impeller to sink in the fluid. The floating impeller may be tethered to a second impeller with a flexible member and pulley. The mixing speed is controlled with electromagnets in the vessel acting upon magnetic material in the impeller or its guides. In another embodiment, floating pistons mix the fluid, pushing it through a mixing plate with one or more apertures. In a third embodiment, the mixing device is a rotating drum with bubble-catching blades and rotating mixing plates with apertures. The top of the vessel for these mixers may include a closed top and sterile filters. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an electroded ceramic metal halide lamp (CMH) assembly, and more particularly, to the lumen maintenance of a CMH.
[0002] CMH lamps can have severe degradation in 100 hr lumens. Such degradation has been known to occur quickly, for example, reduction of 100 hr lumens by 25% in the first 1000 hours of lamp operation. Degradation is believed to arise from wall blackening of the arc-tube.
[0003] Lumen degradation is primarily due to the transport of tungsten to the walls of the discharge tube, by sputtering during starting, and by chemical transport as halides of tungsten in steady state operation. While halides are necessary components of the arc discharge fill, the transport of tungsten during steady state operation is greatly enhanced by the formation of excess halides, such as iodine. Excess iodine found in most high-intensity discharge (HID) lamps is bound by mercury, which forms a mercury iodide.
[0004] In order to optimize lumen maintenance, a design choice is sometimes made that shifts the lamp into a design space that sub-optimizes other key critical-to-quality (CTQ) factors such as color rendering index (CRI), correlated color temperature (CCT), color control, etc. However, it would be desirable to reduce the impact of lumen degradation without sacrificing other CTQ factors.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In accord with a first embodiment of the present invention, an electroded ceramic metal halide lamp is provided including metallic halide getters to allow optimization of lumen maintenance without sacrificing a region of the arc-tube design space that allows optimization of other key CTQ factors. The metallic halides formed from the getters have a Gibbs free energy lower than mercury iodide, but higher than dysprosium iodide, holmium iodide, thulium iodide, sodium iodide and thallium iodide.
[0006] Preferably, metallic halides formed from the getters of the present invention have a vapor pressure lower than mercury iodide.
[0007] In addition, the metallic halides formed from getters create a metallic oxide getter that is less stable than aluminum oxide. The use of metallic halide getters reduce lumen degradation. In another aspect of the present invention, an electroded ceramic metal halide lamp assembly is provided which comprises a light transmissive arc-tube surrounding at least one electrode, a fill disposed in the arc-tube that includes at least one metal halide component; and at least one metallic halide getter wherein the metallic halide getter has a Gibbs free energy value of between about higher than mercury iodide and lower than thallium iodide.
[0008] In another aspect, an electroded ceramic metal halide lamp assembly is provided which comprises a light transmissive arc-tube surrounding at least one electrode. A fill disposed in the arc-tube includes at least one metal halide component and at least one metallic halide getter, wherein the metallic halide getter has a vapor pressure less than the vapor pressure of mercury iodide.
[0009] In yet another aspect of the present invention, an electroded ceramic metal halide lamp assembly is provided which comprises a light transmissive arc-tube surrounding at least one electrode, a fill disposed in the arc-tube that includes at least one metal halide component; and at least one metallic halide getter, wherein the metallic halide getter has a free energy of oxide formation less than the free energy of formation of aluminum oxide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention may take form in various components and arrangement of components, and in various steps and arrangement of steps. The drawings are only for purposes of illustrating a specific embodiment are not to be construed as limiting the invention.
[0011] FIG. 1 is a schematic diagram of a ceramic metal halide lamp assembly according to the present invention.
[0012] FIG. 2 graphically compares the Gibbs free energies of various potential getter iodides, including iodides dosed in ceramic metal halide lamps, at a temperature of 1000K;
[0013] FIG. 3 graphically compares the vapor pressure of various potential getter iodides, including iodides dosed in ceramic metal halide lamps, at a temperature of 1000K; and
[0014] FIG. 4 graphically compares the free energy of the formation of oxides for potential getters.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Lumen degradation is primarily due to the transport of tungsten to the walls of the arc discharge tube, by sputtering during starting, and by chemical transport as halides of tungsten during steady state operation. Halides contemplated by the present invention include bromide, chloride, iodide and other such halides. The transport of tungsten during steady state operation is greatly enhanced by the formation of excess iodine. For example, excess iodine is found in high intensity discharge (HID) lamps bound by mercury, forming mercury iodide, as opposed to the iodine bound to rare earth and sodium. By the addition of metallic halide components, or getters, to the arc discharge tube, the excess iodine is largely removed from the system, minimizing the formation of mercury iodide, and thereby minimizing tungsten transport in steady state operation.
[0016] FIG. 1 shows an electroded ceramic metal halide lamp assembly 100 according to the present invention. The walls of the arc discharge tube 102 can consist of a silica glass, as is known in the art. Preferentially, the discharge vessel walls are comprised of a ceramic, transparent or translucent material which can withstand high thermal conditions. For example, the discharge walls of the arc-tube can consist substantially of a monocrystalline metal oxide, such as sapphire, a polycrystalline sintered metal oxide, such as a polycrystalline sintered metal oxide (PCA), yttrium aluminum garnet or yttrium oxide, or of a polycrystalline non-oxidative material, such as aluminum nitride. Such materials allow for wall temperatures of 1500-1600K and resist chemical attacks by halides and sodium. The arc-tube is preferably tubularly shaped having annularly shaped end surfaces and cylindrically shaped outer and inner surfaces. The wall thickness can be of any suitable size.
[0017] The end caps 104 are formed from a suitable polycrystalline ceramic material, preferably polycrystalline alumina, which is in an unsintered or “green state”. The end caps 104 must preferably include about 0.02 to about 0.2 percent by weight magnesium oxide with polycrystalline alumina powder. Each end cap 104 has a disc-shaped main wall 110 , a cylindrically shaped skirt or flange, and a tubularly shaped extension or flange 106 . The main wall 110 has a planar inner surface facing the end surface of the arc-tube and a planar outer surface facing away from the end surface of the arc-tube.
[0018] The “green” end caps 104 are initially heated to a prefiring or presintering temperature to remove organic or binder material and to develop green strength. The prefiring temperature is relatively low compared to the sintering temperature. Preferably, the prefiring temperature is in the range of about 900° C. to about 1100° C. The prefiring is preferably preformed in air but alternatively can be any other suitable oxidizing atmosphere for burning-off the organic material.
[0019] Once cooled, the presintered end caps 104 are placed over the ends of the arc-tube 102 with the end surfaces of the arc-tube engaging the inner surfaces of the end cap main walls and the outer surface of the arc-tube engaging the inner surfaces of the end cap flanges. The end caps, therefore, close the open ends of the arc-tube.
[0020] The end caps 104 are preferably formed by cold die pressing a mixture of fine ceramic powder into a desired shape. The end caps 104 , however, can alternatively be formed by compressing ceramic powder into a body or block and machining the desired shape from the block, by injection molding, or by any other suitable process.
[0021] The flange 106 extends axially inward toward the arc-tube from the outer periphery of the main wall 110 . The flange 106 has a cylindrically shaped inner surface which has a diameter sized to form a sufficient monolithic seal with the outer surface of the arc-tube 102 . The length of the flange inner surface is sized to provide a sufficient sealing area between the end cap 104 and the arc-tube 102 .
[0022] The flanges 106 extend axially outward from the outer surface of the main wall 110 and is located generally at the center of the main wall 110 . The flange 106 and the main wall 110 cooperate to form an axially extending aperture or hole which passes entirely though the end cap 104 . The aperture is sized and shaped to form a sufficient hermetic seal between the electrode assembly 108 and the end cap 104 . Preferably, the aperture is cylindrically shaped. The length of the extension is sized to provide sufficient support for the electrode assembly 108 and to provide a sufficient sealing area between the end cap 104 and electrode assembly 108 .
[0023] The electrode assembly 108 is of standard construction having a generally straight support and a coil secured to the inner end of the support. The support and the coil are each formed from a high temperature and electrically conductive metal such as molybdenum or tungsten.
[0024] The arc-tube 102 contains a metal halide fill which provides suitable efficacy and color rendition. As an example, a fill in the present invention comprises a combination of a sodium halide and a cerium halide along with xenon gas. Useful sodium and cerium halides can be selected from the group consisting of bromides, chlorides and iodides, including mixtures thereof such as sodium iodide and cerium chloride. The weight proportion of cerium halide is maintained no greater than the weight proportion of sodium halide in the fill, with a reservoir of these fill materials in the arc-tube being desirable to compensate for any loss of the individual constituents during lamp operation. A typical fill may also include an inert ignition gas, for example argon, and mercury, as well as other metal halide additives.
[0025] In choosing a metallic halide getter in accord with the present invention, an important aspect is to choose a getter that has a free energy of formation less than the free energy of formation of the mercury halide. Lumen maintenance is optimized by reducing the amount of mercury iodide located within the arc-tube. Thus, the role of the getter is to remove the halide, most typically iodine, from the arc-tube before the free energy of formation of mercury iodide is reached. As can be seen in FIG. 2 , iodides of zinc, manganese, indium, cadmium, lead and silver satisfy the criteria of metallic halide getters of the present invention having a free energy of formation less than mercury iodide.
[0026] The getter material can be incorporated into the lamp in the same manner as traditional getter materials are. These include, for example, as a strip of metal on a mounting tab associated with the electrode mechanism or attached to a frame secured to the ends of the arc tube. U.S. Pat. Nos. 7,057,350 and 6,586,878 provide teachings of this and are herein incorporated by reference.
[0027] Another important aspect in choosing a metallic halide getter in accordance with the present invention is the vapor pressure of the metallic getter with respect to the vapor pressure of mercury iodide. Getter materials that satisfy this criterion will remove excess iodine formed in the arc-tube from the discharge environment. Metallic iodide getters that meet this requirement are shown in FIG. 3 , and include sodium, tin, lead, indium, copper, manganese, cadmium, zinc and silver.
[0028] A final desirable attribute for the metallic getter is the stability of the oxides of the metallic getters relative to aluminum oxide. Preferably, the free energies of formation of the metallic getter oxides be lower than that of aluminum oxide, otherwise the metallic iodide getter material could cause degradation of the main discharge body of the CMH lamp. As can be seen by the graph in FIG. 4 , copper, thallium, lead, cadmium, tin, indium, zinc and manganese.
[0029] The use of metallic halide getters within the fill of the arc-tube in electroded high watt ceramic metal halide lamps according to the preceding will reduce the formation of mercury iodide, and therefore tungsten transport should be inhibited. This will achieve better lumen maintenance.
[0030] Zinc, manganese, indium, cadmium and lead, which satisfy each criteria may be particularly good selections as a getter material. Furthermore, it is noted that the present invention may be particularly beneficial in conjunction with high wattage CMH lamps. For example, lamps operating at above about 150 watts.
[0031] While the invention has been described with respect to specific embodiments by way of illustration, many modifications and changes will occur to those skilled in the art. It is therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention. | An electroded high watt ceramic metal halide lamp assembly is provided which comprises a light transmissive arc-tube surrounding at least one electrode, a fill disposed in the arc-tube that includes at least one metal halide component and at least one metallic halide getter. The metallic halide getter has a Gibbs Free Energy greater than mercury halide and less than thallium halide, vapor pressure less than mercury halide, free energy of formation of oxide less than Aluminum oxide. | 7 |
GOVERNMENT LICENSE RIGHTS
The U.S. Government may have certain rights in the present invention as provided for by the terms of Contract No. N00174-01-D-0016 awarded by the Dept. of Navy.
TECHNICAL FIELD
The present invention relates generally to the field of contact-less identification such as Radio Frequency Identification (RFID) and, in particular, to hand held RFID readers.
BACKGROUND
Identification and tracking of tangible objects are essential in a multiplicity of industries. Automatic identification systems are replacing manual identification as automatic systems are more accurate, more efficient and more cost-effective. A key feature of automatic identification systems is remote or contact-less identification. Remote identification improves the accuracy of inventory identification, dramatically reduces the effort required, and allows potentially instant verification of inventory. Typical remote identification systems include Radio Frequency Identification (RFID) technology. Incorporating RFID technology reduces the time, cost and effort for performing identification and tracking when compared to manual methods while significantly improving the accuracy. RFID technology also provides a safer means for identification and tracking both in hazardous environments and identification and tracking of hazardous materials.
In general, a typical RFID systems consists of a transmitter (tag) and a receiver (reader). The tag can be either a passive identification device or an active identification device. A passive tag typically is powered by an external means. One embodiment powers the tag from the reader via a magnetic field generated by the reader. A typical active RFID tag contains its own battery for power. A tag is affixed to an object to be identified. The transmitter sends a radio frequency interrogation signal that activates the tag and the tag emits a signal that identifies the object to which it is attached. The reader could be able to distinguish the identification signals from a single tag or a group of RFID tags. RFID tag readers can be found in two manifestations: hand held readers and fixed readers. The selection of a fixed or handheld reader depends on the application in which it is used.
When designing a handheld reader, there are a multiplicity of factors that need to be taken into account. One of the paramount considerations is that the size, weight, and shape of the reader is manageable by a typical user without excessively compromising the functionality of the reader. A key area for size reduction is the antenna used by a handheld reader. The antenna is used to excite the tag in order to elicit a response that identifies the item to which the tag is attached. Unfortunately, reductions in antenna size also result in reductions in antenna efficiency. Antenna efficiency is a measure of the amount of signal power that an antenna radiates to its environment relative to the amount of power supplied to the antenna. It is desirable to keep antenna efficiency as high as possible as low antenna efficiency requires higher power transmitters and this directly reduces battery life in a handheld reader. Frequently, the antenna size is so small and antenna efficiency is so low that the performance of the handheld reader as measured by its usable range is inadequate for many applications.
For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for a hand held RFID reader that provides better performance over existing RFID readers in a variety of environments.
SUMMARY
Embodiments of the present invention provide a hand held RFID reader with better performance over existing readers. In one embodiment, a hand held RFID reader is provided. The reader includes a housing having a perimeter around an inner edge. The reader also includes a full-sized dipole antenna including two antenna elements coupled by a balun transformer. The antenna has nearly a unity gain over a range of angles. The reader also includes a transceiver, coupled to the dipole antenna by a suitable cable, the transceiver adapted to send and receive signals. The reader further includes a processor for processing signals received at the antenna. The first and the second antenna segments of the dipole antenna are wrapped along the perimeter around the inner edge of the housing.
DRAWINGS
FIG. 1 is an illustration of one embodiment of an antenna gain pattern of a compact antenna.
FIG. 2 is an illustration of one embodiment of antenna gain pattern full sized dipole antenna.
FIG. 3 is a block diagram of one embodiment of a RFID reader system.
FIG. 4 is an illustration of one embodiment of a dipole antenna.
FIG. 5 is a perspective view of one embodiment of the back of a hand held RFID reader with the back cover removed and showing one embodiment of a full sized dipole antenna installed in the RFID reader.
FIG. 6 is a perspective view of one embodiment of the front of a hand held RFID reader.
FIG. 7 is an illustration of one embodiment of an environment where RFID readers are used.
DETAILED DESCRIPTION
In the following detailed description of the preferred embodiments, reference is made to accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense.
FIG. 1 is an illustration of the antenna gain pattern of a compact antenna that enables receiving signals by a hand held RFID reader, indicated generally at 100 . As illustrated, the gain is sub-optimal in that the antenna gain never approaches unity. This indicates that the antenna does not efficiently receive or transmit signals. Low antenna efficiency can degrade battery life in portable devices such as an handheld RFID reader by requiring a higher power transmitter to achieve a radiated signal power equivalent to that produced by a lower power transmitter and a more efficient antenna. Also, low antenna gain impacts the apparent usable range of the receiver as some of the signal that reaches the antenna is lost and causes the receiver to be unable to detect weak signals. The overall result of this is lower performance in the handheld reader and the performance may become sufficiently impaired as to affect the usability of the handheld reader.
FIG. 2 is an illustration of the antenna gain pattern of a full-sized dipole antenna, indicated generally at 200 that enables receiving signals in a hand held RFID reader. Antenna gain pattern 200 indicates the antenna gain is nearly unity at a range of angles. This indicates that the antenna has a preferred orientation for optimum gain and is very efficient at receiving signal from those directions. In a typical RFID reader, the antenna is oriented so that the antenna “points” in the direction from which RFID tag signals are most likely to originate. This results in efficient radiation of transmitted signals and also results in best sensitivity of the reader when receiving signals from tags. Generally speaking, a full-sized antenna has higher gain than a compact antenna and results in improved performance of the RFID reader vis-à-vis a compact antenna.
FIG. 3 is a block diagram of one embodiment of a hand held RFID reader, indicated generally at 300 . As illustrated, the hand held RFID reader in 300 comprises a housing 305 , power source 307 , antenna 310 , a transceiver 312 , an interface module 314 , a processor 315 , a bus 316 , a memory 317 , a display 318 and an input/output device 320 . Power source 307 provides power required for the operation of the hand held RFID reader 300 . In one embodiment, antenna 310 is coupled to transceiver 312 using a coaxial feed-line 311 . Transceiver 312 both receives and generates the radio frequency signals from antenna 310 . The interface module 314 facilitates the communication of signals between the transceiver 312 and other modules in the reader.
In one embodiment, display 318 and input/output device 320 are coupled to processor 315 and memory 317 through bus 316 . Display 318 is used to display RFID tag identification information and sundry other information received from interface module 314 . Input/Output device 320 could be used to select which programs stored in memory 317 to run in order to perform desired operations and could also allow the reader to be connected to outside devices via input/output device 320 for purposes such as loading new programs, offloading data from tags that have been read, and other tasks as desired. The programs accessed in memory 317 are processed in processor 315 . Data may be entered at the input/output device 320 using a keypad, touch screen, or other type of data entry device.
In operation, dipole antenna 310 of the RFID reader 300 receives signals transmitted by RFID tags. The tag signals contain tag identification and other information. The tag signals received at dipole antenna 310 are received by transceiver 312 . Transceiver 312 passes the data contained within the terminated RFID tag signal to interface module 314 . Interface module 314 receives the data from the tags and presents this data to internal databus 316 where it is manipulated by processor 315 . Processor 315 may translate the data to a format recognizable by display 318 , prepare the data for input/output device 320 , store the data in memory 317 , or any admixture of the aforementioned processes. In one embodiment, display 318 displays a list of all the RFID tag information carried by the signals from the tag and received at the RFID reader. In another embodiment, RFID reader 300 creates a list of RFID tags that is has received after interrogating the RFID tags and then compares the received list of RFID tag identification to a pre-selected list of RFID tag information stored in memory 317 to check for the presence or absence of specific RFID tags.
FIG. 4 is an illustration of one embodiment of a dipole antenna assembly, indicated generally at 400 . As illustrated, dipole antenna assembly 400 comprises a coaxial feed-line 311 , a balun 412 and antenna wires 410 and 414 . Antenna wires 410 and 414 receive signals from RFID tags and couples the signal to coaxial feedline 311 . Coaxial feed-line 311 carries the signal to a transceiver located within the RFID reader. Balun 412 is a balanced-unbalanced transformer. Balun 412 enables coupling balanced antenna wires 410 and 414 to unbalanced coaxial cable 311 . In one embodiment, antenna wires 410 and 414 are made of equal lengths. In a full-sized antenna, each of antenna wires 410 and 414 are very nearly equal in length and the length is governed by the frequency at which the antenna is designed to operate.
FIG. 5 is a perspective view of one embodiment of the dipole antenna installed inside a hand held RFID reader 500 with the back cover 504 removed. As illustrated, hand held RFID reader 500 includes a non-conductive hand held RFID reader housing 510 , a separation 511 between antenna wire 410 and the inner edge 513 of the housing. An identical separation exists between antenna wire 514 and the inner edge 513 of the housing. The size of the separation 511 is not important. The coaxial cable 311 passes through an orifice 512 into an inner cavity 514 . In one embodiment, the orifice is replaced with a connector that effectively connects the coaxial cable 311 to the inner cavity. In this illustration, the dipole antenna assembly 400 includes antenna wires 410 and 414 , a balun 412 , and a coaxial feed-line 311 .
In one embodiment, antenna wires 410 and 414 are wrapped along a perimeter 511 of the inner edge 513 inside housing 510 of hand held RFID reader 500 to provide a compact design for hand held RFID reader 500 . Placing of full sized dipole antenna assembly 400 in this manner inside hand held RFID reader 500 takes advantage of the antenna gain inherent in a full-sized antenna and enables better performance of hand held RFID reader 500 . Antenna wires 410 and 414 are coupled to a balun 412 which in turn is coupled to a coaxial feed-line 311 . Hand held RFID reader housing 510 includes an inner cavity 514 that contains the necessary components required for the operation of the RFID reader 500 . In one embodiment, coaxial feed-line 311 enters into inner cavity 514 through an orifice 512 to connect with a transceiver located within inner cavity 514 , balun 412 is mounted on housing 510 . Other embodiments are possible. Back cover 504 attaches to the back of housing 510 and protects antenna assembly 400 .
FIG. 6 is a perspective view of one embodiment of the front of a hand held RFID reader, indicated generally at 600 . In this embodiment, the front view of hand held RFID reader 600 includes housing 510 , display 602 , key pad 604 and keys 606 . Display 602 lists the RFID tag information captured by the hand RFID reader 600 . Key pad 604 includes a number of individual keys 606 that may be used to operate the RFID reader and may also be used to enter data that is to be programmed into the RFID tag. Other embodiments are possible where the usage of the keypad and display vary from this illustrative example.
FIG. 7 is an illustration of one embodiment of an environment where handheld RFID readers are used, indicated generally at 700 . In this illustrated, environment 700 includes building 720 , a reflecting wall 730 forming an enclosure 740 , a person 750 carrying a hand held RFID reader 760 , RFID tags 722 - 1 through 722 -N that are attached to objects. Transmitted RFID tag signals are received by hand held RFID reader 760 carried by person 750 . The RFID tags transmit unique identification numbers and possibly additional information related to or derived from the object to which they are attached.
In operation, person 750 moves within enclosure 740 of building 720 to capture the transmitted RFID tag information using hand held RFID reader 760 . In one embodiment, building 720 is an ammunition magazine with an igloo shaped structure. RFID tags 722 - 1 through 722 -N are attached to ammunition containers which may or may not have metal casings. The RFID tags transmit signal and some of the transmitted signals are received directly at hand held RFID reader 760 whereas others are reflected by either the wall 730 or other objects which could be the items to which RFID tags 722 - 1 through 722 -N within enclosure 740 of building 720 are attached.
Because of possible multiple reflections (multipath) of transmitted RF signals from both the tags 722 - 1 through 722 -N and the handheld reader 760 , the strength of the signal received by the handheld reader may be very weak. If a compact antenna were used in the handheld reader, the attendant reduction in antenna gain could cause these signals to be sufficiently weak as to prevent accurate reception and correct decoding. Because of the higher antenna gain of a full-sized dipole antenna, the handheld reader is capable of reading RF signals that are much weaker than could be read by a handheld reader with a compact antenna. Thus, the useful range of the handheld reader is increased and this increases the utility of the handheld reader. | A hand held Radio Frequency Identification (RFID) reader is provided. The reader includes a housing having a perimeter around an inner edge. The reader also includes a full-sized dipole antenna including two antenna elements coupled by a balun transformer. The antenna has nearly a unity gain over a range of angles. The reader also includes a transceiver, coupled to the dipole antenna by a suitable cable, the transceiver adapted to send and receive signals. The reader further includes a processor for processing signals received at the antenna. The first and the second antenna segments of the dipole antenna are wrapped along the perimeter around the inner edge of the housing. | 6 |
FIELD OF THE INVENTION
The invention relates generally to the field of calendars and, more particularly, to perpetual calendars.
BACKGROUND OF THE INVENTION
Perpetual calendars are calendars that can be manipulated to display various different periods of time, such as weeks or months. Perpetual calendars are based upon the known yearly cycle of time as quantified by the months and days.
Many perpetual calendars function by aligning a day of the week, e.g., Monday, Tuesday, with the day on which January 1 st of a given year falls. Once the day of the week on which January 1 st falls in a given year is known, the dates and corresponding days of the weeks within that year are known based on the known number of days within a week and the dates in each month.
Year to year changes on the day of the week on which January 1 st falls are taken into account based on the fixed number of days in a week and the known number of days in a year. While all weeks have seven days, the number of days in a year varies.
All years have 365 days, unless the year is a leap year, which has 366 days. A leap year is any year divisible by 4, except where the year is a century, e.g. 2000, 2100, which is only a leap year if also divisible by 400. Thus, the century 2000 was a leap year but the century 2100 will not be. The known number of days in a year combined with a fixed week of seven days mandates that January 1 st of a year following a 365 day year begin on the next day of the week from which that year began. For example, if January 1 st of a 365-day year was on a Monday, the January 1 st of the following year will be on a Tuesday. In the special case where a year follows a leap year, the January 1 st of the following year is not one day later but two, to account for the extra day in the 366-day year. For example, if January 1 st of a 366-day year was on a Monday, January 1 st of the following year will be on a Wednesday. The day of which January 1 st falls in preceding years may be similarly obtained.
Over the years there have been many structures for perpetual calendars. Many of the calendars, however, do not simultaneously display the days, dates, months and year. Most display only a month with the days and dates therein. In addition, changing the relationship in the calendar to reflect for example months in a different year, particularly a leap year, is complex. Generally, most perpetual calendars make the assumption that a viewer of the calendar is only interested in the current month.
Based on the above, it is an object of the present invention to create a perpetual calendar that is more readily adaptable to changing the relationships depicted thereon.
It is another object of the present invention to create a perpetual calendar that more easily accommodates leap years.
It is still yet another object of the present invention to create a perpetual calendar that displays the entire relationship between the dates, days, months and years.
SUMMARY OF THE INVENTION
The present invention in one aspect is a perpetual calendar having a body with an outer surface. The outer surface is divided into seven segments, the number of segments corresponding to the number of days in a week. Date indicia for the longest month in a year, 31 indicia in all, are successively positioned on the outer surface in the seven segments. At least five-year indicia, representing a repeating pattern based on four years, are also positioned on the outer surface in each segment. The year indicia positioned in any one segment are based on the date indicia therein.
A cap is positioned relative the body and has an outer surface. Positioned on the outer surface of the cap are day indicia and month indicia. The day indicia and month indicia are positioned in a fixed relationship and define seven sections. The seven sections are consistent with the seven segments on the body such that a section aligns with a segment. The cap is positionable about the body permitting the seven sections to align with the seven segments to display a one month calendar for each aligned month and year. Preferably, the cap does not interfere with the viewing of the indicia of at least one month and corresponding year on the body, thus permitting the day, date, month and year to be simultaneously viewed.
The indicia within any segment or section can be arranged as desired therein. In addition, additional month ending indicia, indicia to indicate the last day of month, can be added to the segment having the day indicia that indicates the last day of a month. For example, “Apr” can be added in the segment having day indicia 30 to indicate that April has 30 days.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded side perspective view of one embodiment of a perpetual calendar according to the present invention.
FIG. 2 is a table illustrating the placement of date indicia, year indicia and month ending indicia within the segments of the cylindrical body of the perpetual calendar depicted in FIG. 1
FIG. 3 is a table illustrating the placement of day indicia and month indicia within the sections of the rotating cap of the perpetual calendar depicted in FIG. 1 .
FIG. 4 is an assembly view of the perpetual calendar of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a perpetual calendar, generally denoted by the reference number 10 , includes a cylindrical body 12 and a rotating cap 14 . Referring to FIGS. 1 and 2, the cylindrical body 12 has an outer surface 16 which is divided into seven segments 18 . Each segment 18 is divided into a first portion 20 and a second portion 22 , the demarcation of which is denoted by a dotted line.
On the cylindrical body 12 within each segment 18 in the first portion 20 , date indicia 24 , in this case numbers, are sequentially positioned. As used herein sequentially positioned means positioning an indicia within a segment with the next sequential indicia positioned in an adjacent segment and so forth.
Within each segment 18 in the second portion 22 is at least one year indicia 26 that corresponds to the date indicia 24 already positioned within the segment 18 . As this is a perpetual calendar, there is a fixed relationship between the date indicia 24 and the year indicia 26 . This fixed relationship is based upon the known number of days in the year, 365 or 366, and the fixed pattern of days, weeks and months that define a year. Similarly. the perpetual calendar 10 includes a fixed relationship between the day indicia 36 and month indicia 38 that corresponds with the fixed relationship between the date indicia 24 and year indicia 26 . FIG. 2 provides a layout of date indicia 24 and year indicia 26 . FIG. 3 provides a layout of day indicia 36 and month indicia 38 . While FIG. 2 is complete as to the layout of the date indicia 24 , it only contains a partial layout of the year indicia 26 . A method for laying out additional year indicia 26 is discussed below.
In addition, within appropriate segments 18 in the first portion 20 are month ending indicia 28 . Month ending indicia 28 identify on the calendar 10 the end of a given month. Each month ending indicia 28 is placed to coincide with the date indicia 24 indicating the last day of a month. For example, the month ending indicia 28 for April, “Apr,” is positioned in the segment 18 wherein the date indicia 24 represents the 30 th day.
The rotating cap 14 fits over the outer surface 16 of the first portion 20 of the cylindrical body 12 . The rotating cap 14 defines at least one opening 32 . The openings 32 permit the date indicia 24 and the month ending indicia 28 positioned on the outer surface 16 of the cylindrical body 12 to be framed and viewed. As shown in FIG. 1, a preferred embodiment of the present invention includes a rotating cap 14 that defines seven openings 32 , one corresponding to each of the segments 18 . The rotating cap 14 could also be designed such that no openings 32 are required, or that any number of openings 32 are provided.
The rotating cap 14 is radially divided into seven sections 34 that are consistent in arc segment with the seven segments 18 . Consistent arc segments for the sections 34 and segments 18 assures that when the rotating cap 14 is repositioned on the cylindrical body 12 , the sections 34 and segments 18 are alignable. Each section 34 includes day indicia 36 and month indicia 38 in a fixed relationship that is appropriately alignable with the fixed relationship between the date indicia 24 and year indicia 26 in each segment 18 of the cylindrical body 12 . FIG. 3 illustrates a complete layout for each section 34 .
As indicated above, the layout for the cylindrical body 12 is only a partial layout as it depicts only some number of years. Predominately, the number of years can be increased by following a standard pattern. The standard pattern representing four years has five elements, i.e. x, x+1, x+2, x+3, x+4, x+4. The last two elements are for a single leap year.
An example of the pattern as applied to years is as follows—2001, 2002, 2003, 2004, 2004. The next repeat would be 2005, 2006, 2007, 2008, 2008. In the previous patterns, years 2004 and 2008 are leap years. As it is important for operation of the perpetual calendar 10 , which is explained below, to distinguish between the two year indicia 26 for a single leap year the second leap year indicia 26 is highlighted, such as with the letter “L.”
This pattern, however, is modified in one unique case. As those who understand calendars appreciate, all centuries are not leap years. A leap year is generally defined as any year divisible by 4. While all centuries are divisible by 4, a century is a leap year only if it is also divisible by 400. Thus the century 2000 is a leap year while the centuries 1900, 2100, 2200 and 2300 are not. In this unique case the pattern is altered by deleting the second duplicate entry.
To use the perpetual calendar 10 , the segments 18 of the cylindrical body 12 and the sections of the rotating cap 14 must be properly aligned. In one procedure for using the perpetual calendar, the first step is to determine if the year desired is a leap year or not. As explained above, for each leap year there are two year indicia 2 , e.g. 2004 and 2004L, in adjacent segments. If the year is not a leap year, there is only one year indicia 26 . In the non-leap year case, aligned the desired month indicia 38 with the desired year indicia 26 . For the aligned month and year, a one month calendar will be displayed. In the case of a leap year, if the desired month is January or February align the appropriate month indicia 38 with the first year indicia 26 , e.g., 2004. For all other months in the leap year, align the desired month indicia 38 with the second year indicia 26 , e.g., 2004L.
Referring to FIG. 4 . the perpetual calendar 10 can be used to determine the day of the week for a selected date and year. For example, to determine on what day of the week Aug. 17, 2005 will fall, a user positions the rotating cap 14 to align the month indicia 38 portion containing “August” of section 34 with the year indicia 26 containing the year “2005” in segment 18 . The user then views the date indicia 24 through the cap opening 32 to locate the number “17” corresponding to the selected date. The corresponding day indicia 36 indicates “Wednesday”, which allows the user to thereby determine that Aug. 17, 2005 falls on a Wednesday.
Although the present invention has been described in considerable detail with reference to a certain preferred versions thereof, other versions are possible, particularly versions wherein the indicia within a segment or section are positioned differently, wherein the openings may not be required or additional openings could be used, or the body and cap are not cylindrical. Therefore, the spirit and scope of the invention should not be limited to the description of the preferred versions contained herein. | A perpetual calendar for displaying a monthly calendar by aligning the desired monthly indicia with an appropriate yearly indicia. The calendar is based on a repeating five element pattern representing a four year repeating pattern, which, however, is modified for non-leap year centuries. | 6 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to semiconductor devices and particularly to an improved junction field effect transistor (JFET).
[0002] A conventional JFET is a three-terminal semiconductor device in which a current flows substantially parallel to the top surface of the semiconductor chip and the flow is controlled by a vertical electric field, as shown in FIGS. 1 a , 1 b , and 1 c . It can be used as a current switch or a signal amplifier.
[0003] JFETs are known as unipolar transistors because the current is transported by carriers of one polarity, namely, the majority carriers. This is in contrast with bipolar junction transistor, in which both majority-and-minority-carrier currents are important.
[0004] A typical n-channel JFET fabricated by the standard planar process is shown in FIG. 1 . FIG. 1 a depicts an n-channel JFET of which the channel is a part of an epitaxial semiconductor layer. FIG. 1 b depicts another n-channel JFET of which the channel is formed with a double-diffusion technique in a semiconductor substrate. FIG. 1 c is a schematic representation of the JFETs.
[0005] The body of the JFET comprises a lightly doped n-type channel sandwiched between two heavily doped p + -gate regions. In FIG. 1 a , the lower p + region is the substrate, and the upper p + region is a portion of the silicon epitaxial layer into which boron atoms are diffused. The two p + regions may be connected either internally or externally to form the gate terminal. Ohmic contacts are attached to the two ends of the channel to form the drain and source terminals through which the channel current flows. Alternatively, as illustrated in FIG. 1 b , a JFET may be fabricated by a double-diffusion technique where the channel is formed by diffusing n-type dopant into the substrate. In both cases, the channel and the gate regions run substantially parallel the top surface of the substrate, so does the current flow in the channel.
[0006] When a JFET operates as a switch, without a gate bias voltage, the charge carriers flow in the channel region between the source and the drain terminals. This is the ON state. To reach the OFF state, a reverse-biasing gate voltage is applied to deplete the charge carriers and to “pinch off” the channel. The reverse bias voltage applied across the gate-channel junctions depletes free carriers from the channel and produces space-charge regions extending into the channel.
[0007] With a gate voltage set between ON and OFF levels, the cross-sectional area of the channel and the channel resistance can be varied. Thus the current flow between the source and the drain is modulated by the gate voltage.
[0008] An important figure of merit of a JFET is its cutoff frequency (f co ), which can be represented mathematically as follows:
f co ≦qa 2 μ n N d /(4π kε o L 2 ),
where q is the electric charge of the charge carriers, a is the channel width, μ n is the mobility of the charge carriers, N d is the doping concentration in the channel, k and ε o are the dielectric constant of the semiconductor material and the electrical permittivity of the free space respectively, and L is the channel length.
[0010] Another important figure of merit of a JFET is the noise figure. At lower frequencies the dominant noise source in a transistor is due to the interaction of the current flow and the surface region that gives rise to the 1/f noise spectrum.
[0011] This invention provides a JFET device that has superior f co and 1/f performance over conventional JFETs and a process of making the device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 a is a partial sectional depiction of a semiconductor substrate with a JFET device built in it.
[0013] FIG. 1 b is a partial sectional depiction of a semiconductor substrate with another JFET device built in it.
[0014] FIG. 1 c is a schematical representation of a JFET.
[0015] FIG. 2 is a partial sectional depiction of a semiconductor substrate with a JFET embodying the invention built in it.
[0016] FIG. 3 is a cross-sectional depiction of a partially completed JFET 10 embodying this invention.
[0017] FIG. 4 is a cross-sectional depiction of a further partially completed JFET 10 embodying this invention.
[0018] FIG. 5 is a cross-sectional depiction of a further partially completed JFET 10 embodying this invention.
[0019] FIG. 6 is a cross-sectional depiction of a further partially completed JFET 10 embodying this invention.
[0020] FIG. 7 is a cross-sectional depiction of a further partially completed JFET 10 embodying this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] In FIG. 2 , an n-channel JFET 10 is shown as a three-terminal device, fabricated near the top surface of a semiconductor substrate. The semiconductor material in the preferred embodiment is silicon. A JFET embodying this invention can also be fabricated in other semiconductor materials such as germanium, germanium-silicon, gallium arsenide, or other compound material. FIG. 2 depicts a JFET built in a bulk silicon substrate. A JFET embodying this invention can also be fabricated in a substrate of semiconductor-on-insulator such as SIMOX, silicon-on-sapphire, or in bonded wafer. FIG. 2 depicts an n-channel JFET. A JFET embodying this invention can also be implemented as a p-channel JFET. A JFET may also be one device in an integrated circuit that includes CMOS and Bipolar circuit elements, and passive circuit components.
[0022] The substrate 100 may be either n-type or p-type. In a typical integrated circuit fabricated by a BiCMOS process, the substrate 100 would be a lightly doped, p-type crystalline silicon material. Over a portion of the substrate 100 is an n-type layer 115 of low resistivity that constitutes the drain portion of the JFET. In a BiCMOS structure, a region commonly referred to as “a buried layer” fits this requirement.
[0023] Over a portion of the buried layer 115 is a layer 200 . Layer 200 includes several regions of different materials. Among them, region 220 includes primarily dielectric material. In this embodiment, this material is silicon dioxide, fabricated with a STI technique. Region 220 may also be built with a LOCOS technique or other techniques well known in the art. Element 210 of layer 200 is substantially n-type mono-crystalline silicon. It may be formed by an epitaxial technique.
[0024] Elements 320 are gate regions of the JFET, located above layer 200 . In this embodiment, the gate regions are polycrystalline silicon, heavily doped with p-type dopant. The doping process includes two steps. One step involves a relative light boron implant followed by a diffusion to create a p-region 370 in the body region that includes regions 310 and 210 . Another doping step is the heavier boron implant followed by diffusion, which forms a p-region 360 . The light implant may correspond to a base implant in a BiCMOS flow and the heavy implant may correspond to the p-source/drain implant.
[0025] The double implant and diffusion forms a p-type region that defines within the body region an n-type channel region 350 that is confined laterally by the p-type region and the dielectric region 220 and longitudinally by the buried layer 115 and a source region 510 . The formation of the channel region 350 is depicted more clearly in drawing FIGS. 3-6 and explained in more detail in later paragraphs.
[0026] The source region 510 in this embodiment includes poly-crystalline. It makes contact to the channel region 350 through an opening 415 etched out from an insulating element 410 that comprises silicon dioxide and silicon nitride. In the preferred embodiment, there is an absence of native oxide between the source region 510 and the channel region 350 so the source region contacts the channel region and the silicon immediately above the channel region may retain the mono-crystalline structure within a short range. In another embodiment, minute oxide may exist in the vicinity of the opening 415 as result of chemical processes such as a wet chemical cleanup process. The source region 510 is heavily doped with phosphorus, arsenic, or other n-type dopants and it partially overhangs the gate regions 320 and is insulated from the gate region 320 by the dielectric elements 410 , oxide elements 560 and nitride elements 570 .
[0027] The edges of the source region 510 and the gate region 320 are bordered by what is known in the art as “side-wall” elements, which electrically insulate the source region from the gate region. The sidewall elements in this embodiment include silicon dioxide 560 and silicon nitride 570 .
[0028] FIGS. 3 to 6 depict the formation of the channel portion of a JFET embodying this invention through a fabrication process. The complete fabrication of a functional JFET, in the context of an integrated circuit, involves many well-known processing steps in addition to those illustrated in the drawings. These well-known processing steps include creating a drain contact to the buried layer, a source contact to the source region, and a gate contact to the gate region, and wiring the contacts with metallic elements to connect the JFET to the other circuit elements of the integrated circuit.
[0029] FIG. 3 depicts a cross-sectional view of a partially completed JFET 10 embodying this invention. Element 100 is a semiconductor substrate. In this embodiment, the semiconductor material is silicon. Other semiconductor materials suitable to implement this invention include germanium, silicon-germanium, silicon carbide, and gallium arsenide. In this embodiment, the silicon substrate is a bulk substrate. Other types of substrates suitable to implement this invention include silicon on insulator (SOI).
[0030] Substrate 100 may be doped with a p-type or an n-type dopant. The dopant concentration may vary from light to heavy as understood by a person with reasonable skill in the art of semiconductor processing.
[0031] Element 115 is a heavily doped semiconductor layer partially covering the substrate 100 . In this embodiment, layer 115 is formed by an arsenic or phosphorus implant step followed by a anneal step. In the art of semiconductor processing, this heavily doped region is referred to as “a buried layer”.
[0032] Layer 200 sits on top of the buried layer. In this embodiment, layer 200 includes a region of epitaxial, lightly doped, n-type, mono-crystalline silicon. The thickness of this epi-region may be between 2000 Å and 7000 Å, preferably about 5000 Å. This region may be doped in-situ or it may be doped with an arsenic or phosphorous implant with a dose between 5×10 9 to 5×10 11 ions/cm 2 , to a dopant concentration of about 1×10 15 ions/cm 3 .
[0033] Layer 200 also includes regions of dielectric material. The dielectric regions 220 are places in the layer 200 so the JFET is formed in a mono-crystalline silicon island 210 isolated from other elements in the silicon substrate. In this embodiment, the dielectric material is silicon dioxide and the technique with which the silicon dioxide regions are formed is referred to in the art as the shallow trench isolation (STI) technique.
[0034] FIG. 4 depicts a cross-sectional view of a further partially completed JFET 10 . Features depicted in FIG. 4 include a layer element 300 . In this embodiment, layer 300 is a lightly doped, n-type, silicon layer. The thickness of layer 300 may be between 1000 Å and 3000 Å, preferably 2000 Å. Layer 300 may be doped in-situ or it maybe doped with a boron implant with dose between 5×10 9 and 5×10 11 ions/cm 2 , preferably to a dopant concentration of about 1×10 15 ions/cm 3 . The portion of layer 300 that is in contact with element 210 is mono-crystalline while the portions that contacts elements 220 are poly-crystalline.
[0035] Also depicted in FIG. 4 is a photoresist pattern 330 . This pattern covers at least a portion of the region 310 and uncovers the regions 320 , which are doped and converted from lightly n-type to p-type. In a BiCMOS process flow, this doping step may correspond to the base implant step. The implant step is followed by a high temperature anneal step, which drives the fast diffusing p-type dopant, boron in this embodiment, from the polysilicon regions 320 into a portion 370 of the mono-crystalline silicon regions 310 and 210 .
[0036] FIG. 5 depicts a cross-sectional view of yet a further partially completed JFET 10 embodying this invention. Features depicted in FIG. 5 include a layer 400 that includes a photoresist pattern 420 and a dielectric layer 410 . In this embodiment, the layer includes a silicon-nitride layer and a silicon-dioxide layer. Portion of layer 410 uncovered by the resist pattern is removed. With an etching technique well known in the art of semiconductor processing. The JFET may also be fabricated with a single oxide layer, or a single nitride layer, or an oxynitride layer in the place of the nitride-oxide layer combination 410 as depicted in FIG. 5 .
[0037] FIG. 6 depicts a cross-sectional view of yet a further partially completed JFET 10 embodying this invention. Features depicted in FIG. 6 include a layer 510 . In this embodiment layer 510 comprises polysilicon with a thickness between 1 kÅand 3 kÅ, preferably 2 kÅ. At the vicinity of opening 415 , where layer 510 contacts channel, the crystal may follow the crystalline structure of the channel region and remains mono-crystalline. FIG. 6 also depicts a photoresist pattern 520 that defines the source electrode area, as will be further illustrated in FIG. 7 .
[0038] FIG. 7 depicts a cross-sectional view of yet a further partially completed JFET 10 embodying this invention. Features depicted in FIG. 7 include a source element 510 , gate elements 320 , and p-type regions 360 and 370 , and a channel region 350 .
[0039] In this embodiment, the source element 510 and the gate elements 320 are formed with an etching process well known in the art of semiconductor processing. The etching removes the portion of layer 510 that is uncovered by the photoresist pattern 520 , and the portion of layer 300 that is not under the dielectric element 410 . With a change of etching chemistry following the polysilicon-etch, one further removes the portion of the dielectric element 410 that is uncovered by the source region 510 . The removal of the dielectric element may be omitted if the thickness of the element 410 is sufficiently thin that allows sufficient dopant ions in an ion-implant process that follows to penetrate it.
[0040] The gate implant processes is depicted in FIG. 7 with arrows that point to the direction of the implanting. In this embodiment, the ion species is boron, the dose is 3×10 15 ions/cm 2 , and the implant energy is 20 keV. Here, element 520 is depicted as a second application of the photoresist pattern that defines the source region. The second application of the pattern 520 is necessary because during the plasma etch process, the original photoresist erodes. And in order to prevent the boron ions from being implanted into the source region, one must protect the source region with an implant mask with sufficient stop power. If a suitable photoresist becomes available to serve both the patterning of the gate region and the blocking of the implant dopant, the second application of the pattern 520 would be unnecessary.
[0041] Because boron atoms diffuse relatively rapidly in polysilicon at elevated temperature, some of the boron atom will be driven from region 320 into the mono-crystalline regions 310 and 210 to form a pocket region 360 . The double-boundary in FIG. 7 is for illustration purpose only as the dopant from the two implants would redistribute and may blur the physical boundary between them.
[0042] Not shown in FIG. 7 is the doping of the source region 510 , which may be accomplished with a photoresist pattern that only uncovers the gate region 510 . In this embodiment the implanted species is arsenic, the dose is 1.5×10 15 ions/cm 2 , and the implant energy is 50 keV. Other implant species, dosages and energies maybe used to effect the source and gate implants.
[0043] Contrary to conventional JFETs depicted in FIGS. 1 a , 1 b , and 1 c , in which the channel substantially runs parallel and proximate to the top surface of the semiconductor substrate, the JFET embodying this invention has a “vertical” channel that runs substantially perpendicular to the substrate surface. It is well known in the art of semiconductor physics that the top surface of the semiconductor substrate is heavily populated with imperfections such as charge traps and surface states. The interaction between the charge carrier in the channel and the surface imperfections is partially responsible for the performance limitation of conventional semiconductor devices in which the current flows parallel to and near the surface.
[0044] In contrast, the flow of the charge carriers in the “vertical” channel in the present invention is in a direction substantially perpendicular to the “surface” of the semiconductor surface. Thus the interaction between the charge carrier and the surface imperfection is substantially reduced, which enables the JFETs embodying this invention to have superior cutoff frequency (f co ) and 1/f noise figure. | We disclose the structure of a JFET device, the method of making the device and the operation of the device. The device is built near the top of a substrate. It has a buried layer that is electrically communicable to a drain terminal. It has a body region above the buried layer. A portion of the body region contacts a gate region connected to a gate terminal. The device has a channel region, of which the length spans the distance between the buried layer and a source region, which projects upward from the channel region and is connected to a source terminal. The device current flows in the channel substantially perpendicularly to the top surface of the substrate. | 7 |
FIELD OF THE INVENTION
The present invention relates in general to an automatic power transmission system and more particularly to a control system which shifts the transmission down to the next lower vehicle speed gear ratio when the accelerator pedal is depressed to its full extent. More specifically, the present invention is concerned with such control system by which the downshaft condition is continued for a certain period of time even when the accelerator pedal is released from its fully depressed position.
BACKGROUND OF THE INVENTION
It is known that some of the conventional power transmissions are arranged in a manner that downshift during a relatively high vehicle speed is achieved only when the accelerator pedal is continuously depressed to its full extent. However, in this case, the following drawbacks will inevitably arise: since the downshift is established by the continuous full depression of the accelerator pedal, it will induce wasteful fuel consumption of the engine. Furthermore, if the accelerator pedal is abruptly released from its fully depressed position, upshift takes place suddenly. This is very undesirable in case rapid acceleration of the vehicle is required.
SUMMARY OF THE INVENTION
Therefore, the present invention is proposed to eliminate such drawbacks encountered in the abovementioned conventional automatic transmission of a vehicle.
It is an object of the present invention to provide a control system for an automatic power transmission which maintains the transmission in the downshift condition until the accelerator pedal is permitted to return to or beyond a partially depressed position corresponding to about 1/2 open position of the throttle valve.
It is another object of the present invention to provide a control system for an automatic power transmission of a vehicle driven by an engine the output of which is controlled by the opening degree of a throttle valve operatively connected to the accelerator pedal, the transmission having a downshift circuit for providing a shift down operation when energized and providing a shift up operation when deenergized, the control system comprising: a snap-action switch having first and second states thereof which alternately take place in a snap-action manner, the first state being a state in which the switch closes to energize the downshift circuit and the second state being a state in which the switch opens to deenergize the downshift circuit; and actuating means for permitting the snap-action switch to take the first state when the accelerator pedal is depressed beyond a relatively long predetermined distance corresponding to a first predetermined position of the throttle valve and to take the second state when the accelerator pedal is permited to return to a partially depressed position corresponding to a second predetermined position of the throttle valve, the opening degree of the throttle valve at the first predetermined position being greater than that of the second predetermined position.
Other objects and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanied drawings.
SUMMARY OF THE DRAWINGS
FIG. 1 is a schematic circuit diagram of a control system connected to an automatic power transmission of a vehicle according to the present invention;
FIG. 2 is a schematic view of position holding means used in the control system of the present invention;
FIG. 3 is an enlarged sectional detailed view of a main part of the position holding means shown in FIG. 2;
FIGS. 3A to 3C are views of the main part of the position holding means, but show various conditions of the main part, respectively;
FIG. 4 is an illustration showing downshift and upshift characteristics of the automatic power transmission in case the position holding operation is not given by the position holding means, the illustration being plotted of the vehicle speed against the throttle opening;
FIG. 5 is an illustration showing downshift and upshift characteristics of the automatic power transmission in case that the position holding operation is given by the position holding means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, a control system 10 for an automatic power transmission is shown as communicating with an internal combustion engine 12 and an automatic power transmission 14 of known construction. The engine 12 has therein conventional means producing a throttle pressure the magnitude of which is substantially proportional to the output of the engine 12. Usually, the means communicates with a throttle valve 16 of the engine 12 so as to produce the throttle pressure the magnitude of which is substantially proportional to the opening degree of the throttle valve 16. Thus, the throttle pressure is maximum when the throttle valve 16 is fully open and minimum when the valve 16 is only slightly open. The automatic power transmission 14 includes therein a conventional downshift circuit (not shown) into which a hydraulic fluid from a source of fluid under pressure is introducible to move shifting points, at which the transmission shifts to another vehicle speed gear ratio, toward the higher vehicle speed.
The control system 10 generally comprises a D.C. source 18 and a position holding means 20 actuated by an accelerator pedal 22, and a downshift circuit actuator 24. The downshift circuit actuator 24 functions to open the fluid communication between the before-mentioned source of fluid and the before-mentioned downshift circuit, thus establishing the above-mentioned shift points moving, when electrically energized.
FIG. 2 shows clearly the positional relation between the position holding means 20 and the accelerator pedal 22. The position holding means 20 generally comprises a snap-action switch 26 electrically connected to the downshift circuit actuator 24, a rod 28 for operating the snap-action switch 26 by the axial movements thereof, and an arm 30 for transferring the movements of the accelerator pedal 22 to the rod 28 in a proportional manner. A support member 32 is for the pivotal movements of the arm 30, so that the depression of the accelerator pedal 22 urges the arm 30 against the operating rod 28. Designated by the numeral 34 is a wire which connects the arm 30 with the throttle valve 16 so that the depression of the accelerator pedal 22 induces opening operation of the throttle valve 16.
FIG. 3 shows the detailed construction of the snap-action switch 26 and the rod 28 which are combined. The snap-action switch 26 comprises a housing 36 which is fixed to a stationary body portion of the vehicle. A lever member 38 is rotatably supported at its middle portion by a support member 40 fixed to an upper portion of the housing 36. The lever member 38 and the support member 40 are made of some electrically conductive material. A movable contact 42 is fixed to one end portion of the lever member 38 and a stationary contact 44 is fixed to a part of the housing 36 at a position contactable with the movable contact upon clockwise rotation of the lever member 38. The support member 40 and the stationary contact 44 are respectively connected to the D.C. source 18 and the downshift circuit actuator 24 through lead lines 46. In order to facilitate the following explanation on the construction of the snap-action switch 26, a state in which the lever member 38 is tilted in a direction to engage the movable contact 42 with the stationary contact 44 will be called a first state, and another state in which the lever member 38 is tilted in an opposite direction to disengage the movable contact 42 from the stationary contact 44 will be called a second state. Thus, the lever member 38 now shown in the drawing takes the second state.
Located below the lever member 38 is a generally triangular plate 48 which is swingably rotated about a pin 50 as shown. The plate 48 has outwardly extending first and second projections 52 and 54 at both ends of the base side thereof and has an elongate slot 56 extending from the generally central portion thereof to the apex opposite the base side. The positional relation between the lever member 38 and the triangular plate 48 is such that when the plate 48 is in the neutral position thereof, the apex opposite to the base side is positioned in an imaginary line passing through the supported portions or pivot axes of the lever member 38 and the plate 48.
Slidably disposed into the elongate slot 56 is a dog member 58 which is urged outwardly by a compression spring 60 disposed between the bottom of the elongate slot 56 and the rear end of the dog member 58, as shown. With this, it will be appreciated that the before-mentioned first and second states of the lever member 38 alternatively take place in a snap-action manner in response to the swinging movement of the triangular plate 48. More specifically, when the triangular plate 48 is tilted leftward or counterclockwise in the drawing, the first state of the lever member 38 takes place, on the contrary, when the plate 48 is tilted rightward or clockwise, the second state of the lever member 38 takes place.
The rod 28 is slidably disposed in through holes 62 formed at lower portions of the housing 36 so that a part thereof positioned in the housing 36 is located under the triangular plate 48. As shown, the actuating rod 28 is provided at the part thereof with a radially outwardly projecting portion or boss portion 64 which is selectively engageable with the first and second projections 52 and 54 of the triangular plate 48. Now, it should be noted that the setting of the rod 28 to the housing 36 is so made that when the triangular plate 48 is tilted rightward causing the before-mentioned second state of the lever member 38, the boss portion 64 is positioned in the leftmost position as shown in the drawing.
A helical spring 66 is disposed about the rod 28 between a spring seat 68 fixed to the head portion of the rod 28 and the housing 36 so as to urge the rod 28 to move leftward in this drawing. Accordingly, the rod 28 remains in the leftmost position thereof in the drawing as long as the accelerator pedal 22 is not depressed, and the rod 28 is gradually moved rightward in accordance with the depression degree of the accelerator pedal 22. Thus, it will be noted that when the rod 28 is moved rightward beyond a certain distance, the triangular plate 48 snaps to the other position by the urging action of the boss portion 64 against the second projection 54 of the plate 48. Thus, the first state of the lever member 38 takes place. Now, is should be noted that once the triangular plate 48 is tilted counterclockwise, the plate 48 remains in this position until the boss portion 64 abuts or strikes the first projection 52 of the plate 48 to urge the plate 48 clockwise in accordance with the leftward movement of the rod 28. Accordingly, the space 53 formed between the first and second projections 52 and 54 of the triangular plate 48 permits the boss 64 to travel a predetermined distance before urgingly abutting the first and second projections to initiate a switching operation and therefore provides a so-called "lost motion" characteristics to the switch 26.
According to the present invention, the following relationship is established between the throttle valve 16 and the snap-action switch 26, that is, the first state of the lever member 38 causing the energization of the downshift circuit actuator 24 is initiated as the accelerator pedal 22 is depressed beyond a relatively long predetermined distance corresponding to 7/8 open position of the throttle valve 16, and the second state of the lever member 38 causing the deenergization of the actuator 24 takes place when the accelerator pedal 22 is permitted to return to a partially depressed position corresponding to 1/2 open position of the throttle valve 16. Of course, the mutual relationship between the throttle valve 16 and the snap-action switch 26 is more freely selected besides the above-mentioned one.
With the above, the operation of the control system 10 is as follows:
In order to facilitate the explanation of the operation, the following description will be made by the aid of FIGS. 3A to 3C. When the vehicle driver wishes downshift of the transmission 14 during a relatively high speed vehicle driving, he strongly depresses the accelerator pedal 22 to its full extent so as to exceed the position corresponding to 7/8 open position of the throttle valve. With this operation, the rod 28 is shifted from a position shown in FIG. 3A into the rightmost position shown in FIG. 3B causing the triangular plate 48 to tilt counterclockwise with a result that the lever member 38 takes the first state thereof as shown in FIG. 3B. Thus, in this state, the electrical connection between the D.C. source 18 and the downshift circuit actuator 24 is established to achieve downshift of the transmission. Now, it should be noted that the electrical connection between the D.C. source 18 and the downshift circuit actuator 24 is not broken even if some slight movement of the accelerator pedal 22 from its fully depressed position occurs. More specifically, the electrical connection is not broken unless the accelerator pedal 22 is permitted to return to or beyond the partially depressed position corresponding to 1/2 open position of the throttle valve 16 for the reason previously explained. This will be well understood from reference to FIG. 3C.
When the rod 28 returns beyond the position corresponding to 1/2 open position of the throttle valve 16 in response to return movement of the accelerator pedal 22 toward the idle position, the lever member 38 takes the second state shown in FIG. 3A so that the electric connection is again blocked, thus causing the upshift of the transmission. In addition to this, when the vehicle driver wishes to accelerate the vehicle without kickdown operation, he gently depresses the accelerator pedal 22. Under this movement, the lever member 38 does not shift to the first state even when the rod 28 is moved into the rightmost position. This is because of the absence of considerable inertia force applied to the second projection 54 of the plate 48 by the rod.
FIG. 4 shows upshift and downshift characteristics of the transmission 14 equipped with the control system 10 of the invention in a case that the accelerator pedal 22 is moved from its dormant or idling position in a direction to open the throttle valve 16. First, second and third gear ratios of the transmission 14 are respectively represented by the letters I, II and III. The solid lines represent respective shifting points in case of upshifts, while the broken lines represent the shifting points in case of downshifts. The zone represented by KD-OFF (kickdown off) is a zone in which the lever member 38 takes the second state representing an "off" condition of the snap-action switch 26, and the zone positioned above a line represented by KD-ON (Kickdown on) is a zone in which the lever member 38 takes the first state representing an "on" condition of the snap-action switch 26 due to nearly full depression of the accelerator pedal 22. In this zone, the shifting points of the transmission 14 are positioned at the higher vehicle speed side, as shown.
FIG. 5 shows upshift and downshift characteristics of the transmission 14 with the control system 10 of the invention in a case where the lever member 38 takes the first state by the kickdown operation of the accelerator pedal 22. The zone represented by the point KD-ON is a zone in which the lever member 38 remains in the first state by the "lost motion" operation of the snap-action switch 26. Accordingly, in this zone, the shifting points are still set at the higher vehicle speed side, as shown.
With the above-stated construction of the control system of the present invention, the following several advantages and effects will be achieved.
(1) Since downshifting can be continued even when the accelerator pedal is somewhat returned from its nearly fully depressed position, the vehicle driver can accelerate the vehicle more sportily or easily by adjusting the depression of the accelerator pedal.
(2) Since downshifting can be continuously achieved even when continuous depression of the acclerator pedal is not provided, the acceleration of the vehicle in the lower vehicle speed gear ratio can be made with a small fuel consumption.
(3) Even if slight movements of the accelerator pedal from its nearly fully depressed position occur, the first state of the lever member causing the energization of the downshift circuit actuator is held. Thus, the unwanted sudden upshifting of the transmission is not induced.
(4) Since the control system of the subject invention can be made only by adding an improved switch to the conventional automatic power transmission, it can be constructed economically.
It should be noted that the foregoing description shows only an exemplary embodiment. Various modifications are apparent to those skilled in the art without departing from the scope of the present invention which is only limited by the appended claims. | A snap-action switch operated by movements of the accelerator pedal is interposed between a D.C. source and a downshift circuit actuator of the automatic power transmission in a manner that once the switch closes by nearly full depression of the accelerator pedal, the switch remains closed unitl the accelerator pedal is permitted to return to or beyond a partially depressed position corresponding to about 1/2 open position of the throttle valve. The saving of fuel is accomplished by the "lost motion" existant between the boss portion of the rod and the respective projection surfaces engaged by the boss portion in the acceleration and deceleration phases of operation. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-in-part of U.S. patent application Ser. No. 10/200,364 filed Jul. 22, 2002 which is a Continuation-in-part of U.S. patent application Ser. No. 10/067,010, filed Feb. 4, 2002 which is a Continuation-in-part of U.S. patent application Ser. No. 09/958,050 filed Oct. 2, 2001, which is 35 USC 371 filing of International Patent Application No. PCT/GB01/03495 filed Aug. 3, 2001, which claims priority to United Kingdom Patent Application No. GB 0019112.6 filed Aug. 5, 2000.
FIELD OF THE INVENTION
The present invention relates to a novel composition containing an anti-inflammatory and anti-allergic compound of the androstane series and to processes for its preparation. The present invention also relates to pharmaceutical formulations containing the composition and to therapeutic uses thereof, particularly for the treatment of inflammatory and allergic conditions.
BACKGROUND OF THE INVENTION
Glucocorticoids which have anti-inflammatory properties are known and are widely used for the treatment of inflammatory disorders or diseases such as asthma and rhinitis. For example, U.S. Pat. No. 4,335,121 discloses 6α,9α-Difluoro-17α-(1-oxopropoxy)-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester (known by the generic name of fluticasone propionate) and derivatives thereof. The use of glucocorticoids generally, and especially in children, has been limited in some quarters by concerns over potential side effects. The side effects that are feared with glucocorticoids include suppression of the Hypothalamic-Pituitary-Adrenal (HPA) axis, effects on bone growth in children and on bone density in the elderly, ocular complications (cataract formation and glaucoma) and skin atrophy. Certain glucocorticoid compounds also have complex paths of metabolism wherein the production of active metabolites may make the pharmacodynamics and pharmacokinetics of such compounds difficult to understand. Whilst the modern steroids are very much safer than those originally introduced, it remains an object of research to produce new molecules which have excellent anti-inflammatory properties, with predictable pharmacokinetic and pharmacodynamic properties, with an attractive side effect profile, and with a convenient treatment regime.
SUMMARY OF THE INVENTION
We have now identified a novel glucocorticoid compound and a crystalline composition thereof which substantially meets these objectives.
Thus, according to one aspect of the invention, there is provided a crystalline chemical composition comprising a compound of formula (I)
in which the crystal lattice is stabilised by the presence of a guest molecule, characterised in the crystalline composition is of space group P2 1 2 1 2 1 having unit cell dimensions of about 7.7±0.6 Å, 13.7±0.7 Å, and 37±3 Å when determined at 120K (hereinafter “a composition of the invention”).
In the composition of the invention the crystalline lattice is stabilised by a hydrogen bonding interaction between the hydrogen atom of the C11 hydroxy on the compound of formula (I) with the oxygen of the C3 carbonyl on a second molecule of the compound of formula (I).
The nature of the crystal lattice can be seen by reference to FIG. 1 which shows the spacial arrangement of 4 molecules of steroid and 8 guests within a single unit cell for an example composition. Detail of the hydrogen bond interaction between the steroid molecules is shown in FIG. 3 . FIG. 2 shows the conformation of the steroid molecule with 2 guest molecules present.
We have determined the XRPD profiles for a number of compositions according to the invention. These XRPD profiles are also apparently characteristic of the crystalline composition according to the invention. In particular they exhibit one or more of the following 3 features when determined at ambient temperature (eg around 295K):
(a) A peak in the range of around 4.3-5.0.
(b) A peak in the range of around 6.6-6.9.
(c) A peak in the range of around 11.5-11.8.
Typically they exhibit 2 or more of the above 3 features, especially 3 of the above features.
The XRPD profiles of compositions of the invention when crystallographically pure also preferably exhibit one or more of the following 6 features when determined at ambient temperature (eg around 295K):
(a) Absence of a peak at around 7.3 (eg around 7.1-7.5) which is associated with the profile of unsolvated Form 1, 2 and 3 polymorphs;
(b) Absence of a peak at around 7.5 (eg around 7.2-7.7) which is associated with the profile of another class of compositions of compound of formula (I);
(c) Absence of a peak at around 12.5 (eg around 12.3-12.7) which is associated with the profile of unsolvated Form 1, 2 and 3 polymorphs;
(d) Absence of a peak at around 8.8-9.6 which is associated with the profile of another class of compositions of compound of formula (I);
(e) Absence of a peak at around 10.5-11.1 which is associated with the profile of another class of compositions of compound of formula (I);
(f) Absence of a peak at around 12.2-12.6 which is associated with the profile of another class of compositions of compound of formula (I).
Preferably one or more preferably both of features (a) and (b) at least are exhibited. Preferably 3 or more preferably 4, especially 5, most especially all 6 of the above 6 features are exhibited.
The chemical name of the compound of formula (I) is 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester.
The compound of formula (I) and compositions thereof have potentially beneficial anti-inflammatory or anti-allergic effects, particularly upon topical administration, demonstrated by, for example, its ability to bind to the glucocorticoid receptor and to illicit a response via that receptor, with long acting effect. Hence, the compound of formula (I) and compositions thereof is useful in the treatment of inflammatory and/or allergic disorders, especially in once-per-day therapy.
Space group P2 1 2 1 2 1 is characterised by angles of 90° being present in each of the 3 axes.
We have discovered that the compound of formula (I) can form a crystalline composition of characteristic space group, unit cell dimensions and crystalline structure as evidenced by X-ray diffraction with a number of guest molecules.
The guest molecule preferably has a relative molecular weight in the range 16 to 150, more preferably 60 to 130, especially 70 to 120. Preferably the guest molecule is a liquid at ambient temperature and pressure (eg 295K, 1.013×10 5 Pa). However guest molecules which are a liquid under pressure may also be capable of acting as a guest molecule (especially under pressurised conditions). Substances which are solids at ambient temperature and pressure are also included.
Examples of suitable guest molecules include solvents e.g.:
Aromatic compounds eg benzene and substituted derivatives, especially benzene substituted with one or more (eg 1 or 2) halogen or C 1-4 alkyl groups, for example toluene, o-xylene, m-xylene, fluorobenzene, chlorobenzene, ethylbenzene.
Preferred guest molecules are pharmaceutically acceptable substances and, as described below, compositions of the invention containing them may be used in therapy. However even if the guest molecule is not pharmaceutically acceptable then such compositions may be useful in the preparation of other compositions containing compound of formula (I), for example, other compositions of the invention containing guest molecules that are pharmaceutically acceptable or compound of formula (I) in unsolvated form.
The stoichiometry of the composition will usually be such that the ratio of compound to formula (I) to guest molecule, in molar terms, is 1:5-0.25, preferably 1:3.0-0.3, more preferably 1:2.2-0.6, especially 1: 2.2-0.8.
Unusually a composition of the invention has a crystal structure which is quite distinct from that of compound of formula (I) in the absence of a guest molecule, eg. the compound of formula (I) as unsolvated polymorph Form 1 which has a space group of P2 1 (i.e. two of the axis angles are 90°) and cell dimensions of 7.6, 14.1, 11.8 Å when determined at 150K. Thus if the guest molecule is removed below a threshold level (which will differ from guest to guest) for example by heating (optionally at reduced pressure eg under vacuum) then the crystal structure of the composition starts to break down and converts to that of the structure of an unsolvated compound of formula (I), typically unsolvated polymorph Form 2 or 3.
Preferably the unit cell dimentions are about 7.7±0.4 Å, 13.8±0.3 Å, and 36.8±3 Å when determined at 120K. Usually the unit cell dimensions are about 7.7±0.2 Å, 13.8±0.2 Å, and 36.8±2.7 Å when determined at 120K.
Table 1 shows the unit cell dimensions and peak positions for a number of example compositions:
TABLE 1
Guest molecule
Unit cell dimensions
Peak positions
Toluene
7.8
13.7
34.2
4.9
6.8
11.8
m-xylene
7.8
13.8
35.9
4.8
6.8
11.5
o-xylene
ND
ND
ND
5.0
6.9
11.7
fluorobenzene
7.7
13.9
38.7
ND
ND
ND
ethylbenzene
7.7
13.8
37.8
ND
ND
ND
chlorobenzene
7.8
13.7
39.3
4.3
6.6
—
ND = not determined
Compound (I) undergoes highly efficient hepatic metabolism to yield the 17-β carboxylic acid (X) as the sole major metabolite in rat and human in vitro systems. This metabolite has been synthesised and demonstrated to be >1000 fold less active than the parent compound in in vitro functional glucocorticoid assays.
This efficient hepatic metabolism is reflected by in vivo data in the rat, which have demonstrated plasma clearance at a rate approaching hepatic blood flow and an oral bioavailability of <1%, consistent with extensive first-pass metabolism.
In vitro metabolism studies in human hepatocytes have demonstrated that compound (I) is metabolised in an identical manner to fluticasone propionate but that conversion of (I) to the inactive acid metabolite occurs approximately 5-fold more rapidly than with fluticasone propionate. This very efficient hepatic inactivation would be expected to minimise systemic exposure in man leading to an improved safety profile.
Inhaled steroids are also absorbed through the lung and this route of absorption makes a significant contribution to systemic exposure. Reduced lung absorption could therefore provide an improved safety profile. Studies with compound (I) have shown significantly lower exposure to compound (I) than with fluticasone propionate after dry powder delivery to the lungs of anaesthetised pigs.
An improved safety profile is believed to allow the compound of formula (I) to demonstrate the desired anti-inflammatory effects when administered once-per day. Once-per-day dosing is considered to be significantly more convenient to patients than the twice-per day dosing regime that is normally employed for fluticasone propionate.
Examples of disease states in which the compound of formula (I) and compositions thereof have utility include skin diseases such as eczema, psoriasis, allergic dermatitis, neurodermatitis, pruritis and hypersensitivity reactions; inflammatory conditions of the nose, throat or lungs such as asthma (including allergen-induced asthmatic reactions), rhinitis (including hayfever), nasal polyps, chronic obstructive pulmonary disease, interstitial lung disease, and fibrosis; inflammatory bowel conditions such as ulcerative colitis and Crohn's disease; and auto-immune diseases such as rheumatoid arthritis.
The compound of formula (I) may also have use in the treatment of conjunctiva and conjunctivitis.
The composition of the invention is expected to be most useful in the treatment of inflammatory disorders of the respiratory tract e.g. asthma, COPD and rhinitis particularly asthma and rhinitis.
It will be appreciated by those skilled in the art that reference herein to treatment extends to prophylaxis as well as the treatment of established conditions.
As mentioned above, the composition of the invention is useful in human or veterinary medicine, in particular as an anti-inflammatory and anti-allergic agent.
There is thus provided as a further aspect of the invention the composition of the invention for use in human or veterinary medicine, particularly in the treatment of patients with inflammatory and/or allergic conditions, especially for treatment once-per-day.
According to another aspect of the invention, there is provided the use of the composition of the invention for the manufacture of a medicament for the treatment of patients with inflammatory and/or allergic conditions, especially for treatment once-per-day.
In a further or alternative aspect, there is provided a method for the treatment of a human or animal subject with an inflammatory and/or allergic condition, which method comprises administering to said human or animal subject an effective amount of the composition of the invention, especially for administration once-per-day.
The composition of the invention may be formulated for administration in any convenient way, and the invention therefore also includes within its scope pharmaceutical compositions comprising the composition of the invention together, if desirable, in admixture with one or more physiologically acceptable diluents or carriers. Pharmaceutical compositions suitable for once-per-day administration are of particular interest.
Further, there is provided a process for the preparation of such pharmaceutical compositions which comprises mixing the ingredients.
The composition of the invention may, for example, be formulated for oral, buccal, sublingual, parenteral, local or rectal administration, especially local administration.
Local administration as used herein, includes administration by insufflation and inhalation. Examples of various types of preparation for local administration include ointments, lotions, creams, gels, foams, preparations for delivery by transdermal patches, powders, sprays, aerosols, capsules or cartridges for use in an inhaler or insufflator or drops (e.g. eye or nose drops), solutions/suspensions for nebulisation, suppositories, pessaries, retention enemas and chewable or suckable tablets or pellets (e.g. for the treatment of aphthous ulcers) or liposome or microencapsulation preparations.
Advantageously compositions for topical administration to the lung include dry powder compositions and spray compositions.
Dry powder compositions for topical delivery to the lung by inhalation may, for example, be presented in capsules and cartridges for use in an inhaler or insufflator of, for example, gelatine. Formulations generally contain a powder mix for inhalation of the compound of the invention and a suitable powder base (carrier substance) such as lactose or starch. Use of lactose is preferred. Each capsule or cartridge may generally contain between 20 μg-10 mg of the compound of formula (I) in a composition of the invention optionally in combination with another therapeutically active ingredient. Alternatively, the composition of the invention may be presented without excipients. Packaging of the formulation may be suitable for unit dose or multi-dose delivery. In the case of multi-dose delivery, the formulation can be pre-metered (e.g. as in Diskus, see GB 2242134 or Diskhaler, see GB 2178965, 2129691 and 2169265) or metered in use (e.g. as in Turbuhaler, see EP 69715). An example of a unit-dose device is Rotahaler (see GB 2064336). The Diskus inhalation device comprises an elongate strip formed from a base sheet having a plurality of recesses spaced along its length and a lid sheet hermetically but peelably sealed thereto to define a plurality of containers, each container having therein an inhalable formulation containing a composition of the invention preferably combined with lactose. Preferably, the strip is sufficiently flexible to be wound into a roll. The lid sheet and base sheet will preferably have leading end portions which are not sealed to one another and at least one of the said leading end portions is constructed to be attached to a winding means. Also, preferably the hermetic seal between the base and lid sheets extends over their whole width. The lid sheet may preferably be peeled from the base sheet in a longitudinal direction from a first end of the said base sheet.
Pharmaceutical formulations which are non-pressurised and adapted to be administered as a dry powder topically to the lung via the buccal cavity (especially those which are free of excipient or are formulated with a diluent or carrier such as lactose or starch, most especially lactose) are of particular interest.
Spray compositions for topical delivery to the lung by inhalation may for example be formulated as aqueous solutions or suspensions or as aerosols delivered from pressurised packs, such as a metered dose inhaler, with the use of a suitable liquefied propellant. Aerosol compositions suitable for inhalation can be either a suspension or a solution and generally contain the composition of the invention optionally in combination with another therapeutically active ingredient and a suitable propellant such as a fluorocarbon or hydrogen-containing chlorofluorocarbon or mixtures thereof, particularly hydrofluoroalkanes, especially 1,1,1,2-tetrafluoroethane, 1,1,1,2,3,3,3-heptafluoro-n-propane or a mixture thereof. The aerosol composition may optionally contain additional formulation excipients well known in the art such as surfactants e.g. oleic acid or lecithin and cosolvents e.g. ethanol. One example formulation is excipient free and consists essentially of (e.g. consists of) composition of the invention (optionally together with a further active ingredient) and a propellant selected from 1,1,1,2-tetrafluoroethane, 1,1,1,2,3,3,3-heptafluoro-n-propane and mixture thereof. Another example formulation comprises particulate composition of the invention, a propellant selected from 1,1,1,2-tetrafluoroethane, 1,1,1,2,3,3,3-heptafluoro-n-propane and mixture thereof and a suspending agent which is soluble in the propellant e.g. an oligolactic acid or derivative thereof as described in WO94/21229. The preferred propellant is 1,1,1,2-tetrafluoroethane. Pressurised formulations will generally be retained in a canister (e.g. an aluminium canister) closed with a valve (e.g. a metering valve) and fitted into an actuator provided with a mouthpiece.
Medicaments for administration by inhalation desirably have a controlled particle size. The optimum particle size for inhalation into the bronchial system is usually 1-10 μm, preferably 2-5 μm. Particles having a size above 20 μm are generally too large when inhaled to reach the small airways. To achieve these particle sizes the particles of the composition of the invention as produced may be size reduced by conventional means e.g. by micronisation. The desired fraction may be separated out by air classification or sieving. Preferably, the particles will be crystalline, prepared for example by a process which comprises mixing in a continuous flow cell in the presence of ultrasonic radiation a flowing solution of compound of formula (I) as medicament in a liquid solvent with a flowing liquid antisolvent for said medicament (e.g. as described in International Patent Application PCT/GB99/04368) or else by a process which comprises admitting a stream of solution of the substance in a liquid solvent and a stream of liquid antisolvent for said substance tangentially into a cylindrical mixing chamber having an axial outlet port such that said streams are thereby intimately mixed through formation of a vortex and precipitation of crystalline particles of the substance is thereby caused (e.g. as described in International Patent Application PCT/GB00/04327).
When an excipient such as lactose is employed, generally, the particle size of the excipient will be much greater than the inhaled medicament within the present invention. When the excipient is lactose it will typically be present as milled lactose, wherein not more than 85% of lactose particles will have a MMD of 60-90 μm and not less than 15% will have a MMD of less than 15 μm.
Formulations for administration topically to the nose (e.g. for the treatment of rhinitis) include pressurised aerosol formulations and aqueous formulations administered to the nose by pressurised pump. Formulations which are non-pressurised and adapted to be administered topically to the nasal cavity are of particular interest. The formulation preferably contains water as the diluent or carrier for this purpose. Aqueous formulations for administration to the lung or nose may be provided with conventional excipients such as buffering agents, tonicity modifying agents and the like. Aqueous formulations may also be administered to the nose by nebulisation.
Other possible presentations include the following:
Ointments, creams and gels, may, for example, be formulated with an aqueous or oily base with the addition of suitable thickening and/or gelling agent and/or solvents. Such bases may thus, for example, include water and/or an oil such as liquid paraffin or a vegetable oil such as arachis oil or castor oil, or a solvent such as polyethylene glycol. Thickening agents and gelling agents which may be used according to the nature of the base include soft paraffin, aluminium stearate, cetostearyl alcohol, polyethylene glycols, woolfat, beeswax, carboxypolymethylene and cellulose derivatives, and/or glyceryl monostearate and/or non-ionic emulsifying agents.
Lotions may be formulated with an aqueous or oily base and will in general also contain one or more emulsifying agents, stabilising agents, dispersing agents, suspending agents or thickening agents.
Powders for external application may be formed with the aid of any suitable powder base, for example, talc, lactose or starch. Drops may be formulated with an aqueous or non-aqueous base also comprising one or more dispersing agents, solubilising agents, suspending agents or preservatives.
If appropriate, the formulations of the invention may be buffered by the addition of suitable buffering agents.
The proportion of the active compound of formula (I) in the local compositions according to the invention depends on the precise type of formulation to be prepared but will generally be within the range of from 0.001 to 10% by weight. Generally, however for most types of preparations advantageously the proportion used will be within the range of from 0.005 to 1% and preferably 0.01 to 0.5%. However, in powders for inhalation or insufflation the proportion used will usually be within the range of from 0.1 to 5%.
Aerosol formulations are preferably arranged so that each metered dose or “puff” of aerosol contains 1 μg-2000 μg e.g. 20 μg-2000 μg, preferably about 20 μg-500 μg of compound of formula (I) optionally in combination with another therapeutically active ingredient. Administration may be once daily or several times daily, for example 2, 3, 4 or 8 times, giving for example 1, 2 or 3 doses each time. Preferably the composition of the invention is delivered once or twice daily. The overall daily dose with an aerosol will typically be within the range 10 μg-10 mg e.g. 100 μg-10 mg preferably, 200 μg-2000 μg.
Topical preparations may be administered by one or more applications per day to the affected area; over skin areas occlusive dressings may advantageously be used. Continuous or prolonged delivery may be achieved by an adhesive reservoir system.
For internal administration the compound according to the invention may, for example, be formulated in conventional manner for oral, parenteral or rectal administration. Formulations for oral administration include syrups, elixirs, powders, granules, tablets and capsules which typically contain conventional excipients such as binding agents, fillers, lubricants, disintegrants, wetting agents, suspending agents, emulsifying agents, preservatives, buffer salts, flavouring, colouring and/or sweetening agents as appropriate. Dosage unit forms are, however, preferred as described below.
Preferred forms of preparation for internal administration are dosage unit forms i.e. tablets and capsules. Such dosage unit forms contain from 0.1 mg to 20 mg preferably from 2.5 to 10 mg of the compound of formula (I).
The compound according to the invention may in general may be given by internal administration in cases where systemic adreno-cortical therapy is indicated.
In general terms preparations, for internal administration may contain from 0.05 to 10% of the active ingredient dependent upon the type of preparation involved. The daily dose may vary from 0.1 mg to 60 mg, e.g. 5-30 mg, dependent on the condition being treated, and the duration of treatment desired.
Slow release or enteric coated formulations may be advantageous, particularly for the treatment of inflammatory bowel disorders.
Since the compound of formula (I) is long-acting, preferably the composition of the invention will be delivered once-per-day and the dose will be selected so that the compound has a therapeutic effect in the treatment of respiratory disorders (e.g. asthma or COPD, particularly asthma) over 24 hours or more.
The pharmaceutical compositions according to the invention may also be used in combination with another therapeutically active agent, for example, a β 2 adrenoreceptor agonist, an anti-histamine or an anti-allergic. The invention thus provides, in a further aspect, a combination comprising the composition of the invention together with another therapeutically active agent, for example, a β 2 -adrenoreceptor agonist, an anti-histamine or an anti-allergic.
Examples of β 2 -adrenoreceptor agonists include salmeterol (e.g. as racemate or a single enantiomer such as the R-enantiomer), salbutamol, formoterol, salmefamol, fenoterol or terbutaline and salts thereof, for example the xinafoate salt of salmeterol, the sulphate salt or free base of salbutamol or the fumarate salt of formoterol. Pharmaceutical compositions employing combinations with long-acting β 2 -adrenoreceptor agonists (e.g. salmeterol and salts thereof) are particularly preferred, especially those which have a therapeutic effect (e.g. in the treatment of asthma or COPD, particularly asthma) over 24 hours or more.
Since the compound of formula (I) is long-acting, preferably the composition comprising the compound of formula (I) and the long-acting β 2 -adrenoreceptor agonists will be delivered once-per-day and the dose of each will be selected so that the composition has a therapeutic effect in the treatment of respiratory disorders effect (e.g. in the treatment of asthma or COPD, particularly asthma) over 24 hours or more.
Examples of anti-histamines include methapyrilene or loratadine.
Other suitable combinations include, for example, other anti-inflammatory agents e.g. NSAIDs (e.g. sodium cromoglycate, nedocromil sodium, PDE4 inhibitors, leukotriene antagonists, iNOS inhibitors, tryptase and elastase inhibitors, beta-2 integrin antagonists and adenosine 2a agonists)) or antiinfective agents (e.g. antibiotics, antivirals).
Also of particular interest is use of the composition of the invention in combination with a phosphodiesterase 4 (PDE4) inhibitor e.g. cilomilast or a salt thereof.
The combination referred to above may conveniently be presented for use in the form of a pharmaceutical formulation and thus pharmaceutical formulations comprising a combination as defined above together with a physiologically acceptable diluent or carrier represent a further aspect of the invention.
The compound according to the invention in combination with another therapeutically active ingredient as described above may be formulated for administration in any convenient way, and the invention therefore also includes within its scope pharmaceutical formulations comprising the composition of the invention in combination with another therapeutically active ingredient together, if desirable, in admixture with one or more physiologically acceptable diluents or carriers. The preferred route of administration for inflammatory disorders of the respiratory tract will generally be administration by inhalation.
Further, there is provided a process for the preparation of such pharmaceutical compositions which comprises mixing the ingredients.
Therapeutic agent combinations may be in any form, for example combinations may comprise a single dose containing separate particles of individual therapeutics, and optionally excipient material(s), alternatively, multiple therapeutics may be formed into individual multicomponent particles, formed for example by coprecipitation, and optionally containing excipient material(s).
The individual compounds of such combinations may be administered either sequentially in separate pharmaceutical compositions as well as simultaneously in combined pharmaceutical formulations. Appropriate doses of known therapeutic agents will be readily appreciated by those skilled in the art.
The composition of the invention may be prepared by the methodology described hereinafter, constituting a further aspect of this invention.
A first process for preparing a composition of the invention comprises crystallising the composition from a solution containing a compound of formula (I) and the guest molecule. The solution containing the guest molecule could be the guest itself when this a liquid, or could be the guest dissolved in another liquid substance which substance does not act as a guest molecule.
Optionally, for better control and reproduceability, the crystallisation process may be assisted by seeding with crystals of the composition of the invention. The seed crystals of the composition of the invention need not contain the same guest molecule.
A second process for preparing a composition of the invention comprises contacting the compound of formula (I) or a composition according to the invention thereof in solid form with a liquid containing the guest molecule (for example by slurrying) and obtaining the composition therefrom. The liquid containing the guest molecule could be the guest itself when this a liquid, or could be the guest dissolved in another liquid substance which substance does not act as a guest molecule.
A third process for preparing a composition of the invention comprises contacting a compound of formula (I) or a composition according to the invention thereof in solid form with a vapour containing the guest molecule. This process is suitable when the guest has acceptable volatility e.g. when the guest is a solvent.
In the second and third processes, the compound of formula (I) may be employed in the form of a composition with a guest molecule or in a form without a guest molecule (eg as unsolvated polymorph Form 1, 2 or 3). In the first process the compound of formula (I) or a composition according to the invention may be dissolved in the solution or prepared in situ.
In one particular embodiment of this aspect of the invention the input compound of formula (I) in the first, second and third processes is in the form of a substantially amorphous solid. Preferably the compound of formula (I) in the form of a substantially amorphous solid is preferably in the form of substantially amorphous particles. For example the the compound of formula (I) in the form of substantially amorphous particles may be obtained by spray drying a solution containing the compound of formula (I). Any solvent that will dissolve the compound of formula (I) that can be evaporated safely in a spray drying process may be used. Suitable solvents for forming the solution include, but are not limited to, methyl acetate, ethyl acetate, isopropyl acetate, acetone, 2-butanone, 3-pentanone, 4-methyl-2-pentanone, ethanol, methanol, 1-propanol, propan-2-ol, acetonitrile, chloroform, dichloromethane especially methylethylketone (2-butanone). Solution concentration will typically be 0.5-50% specifically 10-40% eg 20-30%. Lower concentrations may be more suitable for preparing smaller particle sizes especially 2-4% e.g. 3.5-4%. The concentration that may be employed will be limited by the dissolution power of the solvent. Methylethylketone is preferred since it dissolves compound of formula (I) at a relatively high concentration which results in production advantages. The compound of formula (I) may be employed in non-solvated form or in the form of a composition of the invention (e.g. with acetone). Preferably it is employed as the non-solvated Form 1 polymorph. Spray drying maybe performed, for example, using apparatus supplied by Buchi or Niro. A pneumatic spray nozzle orifice of e.g. 0.04 inches is suitable, although alternate atomization methods such as rotary and pressure nozzles can be used. Solution flow rate may typically be in the range 1-100 ml/min, especially 15-30ml/min. The inlet temperature and flow rate combination should be suitable to evaporate the solvent completely to minimize the risk of solvent trapped in the particle expediting an amorphous to crystalline transition. Inlet temperatures can range from 50-250° C., typically 100-200° C.
Compound of formula (I) in unsolvated form which is itself a useful substance has been found to exist in 3 crystalline polymorphic forms, Forms 1, 2 and 3, although Form 3 may be an unstable variant of Form 2. The Forms are characterised by their XRPD patterns shown in FIG. 8 . Broadly speaking the Forms are characterised in their XRPD profiles by the absence of guest molecules and by peaks as follows:
Form 1: Peak at around 18.9 degrees 2Theta
Form 2: Peaks at around 18.4 and 21.5 degrees 2Theta
Form 3: Peaks at around 18.6 and 19.2 degrees 2Theta.
Forms 1 appears likely to be the thermodynamically most stable form since Forms 2 and 3 are converted into Form 1 on heating.
A process for preparing a compound of formula (I) as crystalline unsolvated Form 1 polymorph comprises dissolving compound of formula (I) in methylisobutylketone or ethyl acetate and producing compound of formula (I) as unsolvated Form 1 by addition of an anti-solvent such as iso-octane or toluene.
According to a first preferred embodiment of this process the compound of formula (I) may be dissolved in ethyl acetate and compound of formula (I) as unsolvated Form 1 polymorph may be obtained by addition of toluene as anti-solvent. In order to improve the yield, preferably the ethyl acetate solution is hot and once the toluene has been added the mixture is distilled to reduce the content of ethyl acetate.
According to a second preferred embodiment of this process the compound of formula (I) may be dissolved in methylisobutylketone and compound of formula (I) as crystalline unsolvated Form 1 polymorph may be obtained by addition of isooctane as anti-solvent.
A process for preparing a compound of formula (I) as unsolvated Form 2 polymorph comprises dissolving compound of formula (I) in unsolvated form in methanol or dry dichloromethane and recrystallising the compound of formula (I) as unsolvated Form 2 polymorph. Typically the compound of formula (I) will be dissolved in hot methanol or dry dichloromethane and allowed to cool.
A process for preparing a compound of formula (I) as unsolvated Form 3 polymorph comprises dissolving compound of formula (I) in particular as the composition with acetone in dichloromethane in the presence of water (typically 1-3% water by volume) and recrystallising the compound of formula (I) as unsolvated Form 3 polymorph.
As mentioned above, compositions of the invention may also find use as manufacturing intermediates in the preparation of compound of formula (I) in unsolvated form, or in the preparation of other compositions of the invention, or in pharmaceutical compositions thereof.
For example, a process for preparation of compound of formula (I) in unsolvated form (typically unsolvated polymorph Form 1) comprises removing the guest molecule from a composition of the invention.
A process for preparing a compound of formula (I) comprises alkylation of a thioacid of formula (II)
or a salt thereof.
In this process the compound of formula (II) may be reacted with a compound of formula FCH 2 L wherein L represents a leaving group (e.g. a halogen atom, a mesyl or tosyl group or the like) for example, an appropriate fluoromethyl halide under standard conditions. Preferably, the fluoromethyl halide reagent is bromofluoromethane. Preferably the compound of formula (II) is employed as a salt, particularly the salt with diisopropylethylamine.
In a preferred process for preparing the compound of formula (I), the compound of formula (II) or a salt thereof is treated with bromofluoromethane optionally in the presence of a phase transfer catalyst. A preferred solvent is methylacetate, or more preferably ethylacetate, optionally in the presence of water. The presence of water improves solubility of both starting material and product and the use of a phase transfer catalyst results in an increased rate of reaction. Examples of phase transfer catalysts that may be employed include (but are not restricted to) tetrabutylammonium bromide, tetrabutylammonium chloride, benzyltributylammonium bromide, benzyltributylammonium chloride, benzyltriethylammonium bromide, methyltributylammonium chloride and methyltrioctylammonium chloride. THF has also successfully been employed as solvent for the reaction wherein the presence of a phase transfer catalyst again provides a significantly faster reaction rate. Preferably the product present in an organic phase is washed firstly with aqueous acid e.g. dilute HCl in order to remove amine compounds such as triethylamine and diisopropylethylamine and then with aqueous base e.g. sodium bicarbonate in order to remove any unreacted precursor compound of formula (II).
Compounds of formula (II) may be prepared from the corresponding 17(X-hydroxyl derivative of formula (III):
using for example, the methodology described by G. H. Phillipps et al., (1994) Journal of Medicinal Chemistry, 37, 3717-3729. For example the step typically comprises the addition of a reagent suitable for performing the esterification e.g. an activated derivative of 2-furoic acid such as an activated ester or preferably a 2-furoyl halide e.g. 2-furoyl chloride (employed in at least 2 times molar quantity relative to the compound of formula (III)) in the presence of an organic base e.g. triethylamine. The second mole of 2-furoyl chloride reacts with the thioacid moiety in the compound of formula (III) and needs to be removed e.g. by reaction with an amine such as diethylamine.
This method suffers disadvantages, however, in that the resultant compound of formula (II) is not readily purified of contamination with the by-product 2-furoyidiethylamide. We have therefore invented several improved processes for performing this conversion.
In a first such improved process we have discovered that by using a more polar amine such as diethanolamine, a more water soluble by-product is obtained (in this case 2-furoyldiethanolamide) which permits compound of formula (II) or a salt thereof to be produced in high purity since the by-product can efficiently be removed by water washing.
Thus we provide a process for preparing a compound of formula (II) which comprises:
(a) reacting a compound of formula (III) with an activated derivative of 2-furoic acid as in an amount of at least 2 moles of the activated derivative per mole of compound of formula (III) to yield a compound of formula (IIA)
; and
(b) removal of the sulphur-linked 2-furoyl moiety from compound of formula (IIA) by reaction of the product of step (a) with an organic primary or secondary amine base capable of forming a water soluble 2-furoyl amide.
In two particularly convenient embodiments of this process we also provide methods for the efficient purification of the end product which comprise either
(c1) when the product of step (b) is dissolved in a substantially water immiscible organic solvent, purifying the compound of formula (II) by washing out the amide by-product from step (b) with an aqueous wash, or
(c2) when the product of step (b) is dissolved in a water miscible solvent, purifying the compound of formula (II) by treating the product of step (b) with an aqueous medium so as to precipitate out pure compound of formula (II) or a salt thereof.
In step (a) preferably the activated derivative of 2-furoic acid may be an activated ester of 2-furoic acid, but is more preferably a 2-furoyl halide, especially 2-furoyl chloride. A suitable solvent for this reaction is ethylacetate or methylacetate (preferably methylacetate) (when step (c1) may be followed) or acetone (when step (c2) may be followed). Normally an organic base e.g. triethylamine will be present. In step (b) preferably the organic base is diethanolamine. The base may suitably be dissolved in a solvent e.g. methanol. Generally steps (a) and (b) will be performed at reduced temperature e.g. between 0 and 5° C. In step (c1) the aqueous wash may be water, however the use of brine results in higher yields and is therefore preferred. In step (c2) the aqueous medium is for example a dilute aqueous acid such as dilute HCl.
We also provide an alternative process for preparing a compound of formula (II) which comprises:
(a) reacting a compound of formula (III) with an activated derivative of 2-furoic acid in an amount of at least 2 moles of activated derivative per mole of compound of formula (III) to yield a compound of formula (IIA); and
(b) removal of the sulphur-linked 2-furoyl moiety from compound of formula (IIA) by reaction of the product of step (a) with a further mole of compound of formula (III) to give two moles of compound of formula (II).
In step (a) preferably the activated derivative of 2-furoic acid may be an activated ester of 2-furoic acid, but is more preferably a 2-furoyl halide, especially 2-furoyl chloride. A suitable solvent for his step is acetone. Normally an organic base e.g. triethylamine will be present. In step (b) a suitable solvent is DMF or dimethylacetamide. Normally an organic base e.g. triethylamine will be present. Generally steps (a) and (b) will be performed at reduced temperature e.g. between 0 and 5° C. The product may be isolated by treatment with acid and washing with water.
This aforementioned process is very efficient in that it does not produce any furoylamide by-product (thus affording inter alia environmental advantages) since the excess mole of furoyl moiety is taken up by reaction with a further mole of compound of formula (II) to form an additional mole of compound of formula (II).
Further general conditions for the conversion of compound of formula (III) to compound of formula (II) in the two processes just described will be well known to persons skilled in the art.
According to a preferred set of conditions, however, we have found that the compound of formula (II) may advantageously be isolated in the form of a solid crystalline salt. The preferred salt is a salt formed with a base such as triethylamine, 2,4,6-trimethylpyridine, diisopropylethylamine or N-ethylpiperidine. Such salt forms of compound of formula (II) are more stable, more readily filtered and dried and can be isolated in higher purity than the free thioacid. The most preferred salt is the salt formed with diisopropylethylamine. The triethylamine salt is also of interest.
Compounds of formula (III) may be prepared in accordance with procedures described in GB 2088877B.
Compounds of formula (III) may also be prepared by a process comprising the following steps:
Step (a) comprises oxidation of a solution containing the compound of formula (V). Preferably, step (a) will be performed in the presence of a solvent comprising methanol, water, tetrahydrofuran, dioxan or diethylene glygol dimethylether. So as to enhance yield and throughput, preferred solvents are methanol, water or tetrahydrofuran, and more preferably are water or tetrahydrofuran, especially water and tetrahydrofuran as solvent. Dioxan and diethylene glygol dimethylether are also preferred solvents which may optionally (and preferably) be employed together with water. Preferably, the solvent will be present in an amount of between 3 and 10 vol relative to the amount of the starting material (1 wt.), more preferably between 4 and 6 vol., especially 5 vol. Preferably the oxidising agent is present in an amount of 1-9 molar equivalents relative to the amount of the starting material. For example, when a 50% w/w aqueous solution of periodic acid is employed, the oxidising agent may be present in an amount of between 1.1 and 10 wt. relative to the amount of the starting material (1 wt.), more preferably between 1.1 and 3 wt., especially 1.3 wt. Preferably, the oxidation step will comprise the use of a chemical oxidising agent. More preferably, the oxidising agent will be periodic acid or iodic acid or a salt thereof. Most preferably, the oxidising agent will be periodic acid or sodium periodate, especially periodic acid. Alternatively (or in addition), it will also be appreciated that the oxidation step may comprise any suitable oxidation reaction, e.g. one which utilises air and/or oxygen. When the oxidation reaction utilises air and/or oxygen, the solvent used in said reaction will preferably be methanol. Preferably, step (a) will involve incubating the reagents at room temperature or a little warmer, say around 25° C. e.g. for 2 hours. The compound of formula (IV) may be isolated by recrystallisation from the reaction mixture by addition of an anti-solvent. A suitable anti-solvent for compound of formula (IV) is water. Surprisingly we have discovered that it is highly desirable to control the conditions under which the compound of formula (IV) is precipitated by addition of anti-solvent e.g. water. When the recrystallisation is performed using chilled water (e.g. water/ice mixture at a temperature of 0-5° C.) although better anti-solvent properties may be expected we have found that the crystalline product produced is very voluminous, resembles a soft gel and is very difficult to filter. Without being limited by theory we believe that this low density product contains a large amount of solvated solvent within the crystal lattice. By contrast when conditions of around 10° C. or higher are used (e.g. around ambient temperature) a granular product of a sand like consistency which is very easily filtered is produced. Under these conditions, crystallisation typically commences after around 1 hour and is typically completed within a few hours (e.g. 2 hours). Without being limited by theory we believe that this granular product contains little or no solvated solvent within the crystal lattice.
Step (b) will typically comprise the addition of a reagent suitable for converting a carboxylic acid to a carbothioic acid e.g. using hydrogen sulphide gas together with a suitable coupling agent e.g. carbonyidiimidazole (CDl) in the presence of a suitable solvent e.g. dimethylformamide.
The advantages of the composition comprising a compound of formula (I) together with a guest compound according to the invention may include the fact that the substance appears to demonstrate excellent anti-inflammatory properties, with predictable pharmacokinetic and pharmacodynamic behaviour, with an attractive side-effect profile, long duration of action, and is compatible with a convenient regime of treatment in human patients, in particular being amenable to once-per day dosing. Further advantages may include the fact that the substance has desirable physical and chemical properties which allow for ready manufacture and storage. Alternatively it may serve as a useful intermediate in the preparation of other forms of the compound of formula (I) or compositions thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : Figure showing the spacial arrangement of 4 steroid and 8 guest molecules in the unit cell of a composition of the invention with toluene (guest molecule darkened).
FIG. 2 : Figure showing hydrogen bond interactions between steroid and guest for the composition of the invention with toluene
FIG. 3 : Figure showing the spacial arrangement of 4 steroid and 8 guest molecules in the unit cell of a composition of the invention with toluene, and hydrogen bond interactions between two steroid molecules
FIG. 4 : Enlarged XRPD profile of composition of the invention with toluene
FIG. 5 : Enlarged XRPD profile of composition of the invention with m-xylene
FIG. 6 : Enlarged XRPD profile of composition of the invention with o-xylene
FIG. 7 : Enlarged XRPD profile of composition of the invention with chlorobenzene
FIG. 8 : XRPD profiles of unsolvated polymorphs 1, 2 and 3
DETAILED DESCRIPTION
The following non-limiting Examples illustrate the invention:
EXAMPLES
General
1 H-nmr spectra were recorded at 400 MHz and the chemical shifts are expressed in ppm relative to tetramethylsilane. The following abbreviations are used to describe the multiplicities of the signals: s (singlet), d (doublet), t (triplet), q (quartet), m (multiplet), dd (doublet of doublets), ddd (doublet of doublet of doublets), dt (doublet of triplets) and b (broad). Biotage refers to prepacked silica gel cartridges containing KP-Sil run on flash 12i chromatography module. LCMS was conducted on a Supelcosil LCABZ+PLUS column (3.3 cm×4.6 mm ID) eluting with 0.1% HCO 2 H and 0.01 M ammonium acetate in water (solvent A), and 0.05% HCO 2 H 5% water in acetonitrile (solvent B), using the following elution gradient 0-0.7 min 0% B, 0.7-4.2 min 100% B, 4.2-5.3 min 0% B, 5.3-5.5 min 0% B at a flow rate of 3 ml/min. The mass spectra were recorded on a Fisons VG Platform spectrometer using electrospray positive and negative mode (ES+ve and ES−ve).
The XRPD analyses shown in the figures were performed on
a) a Phillips X'pert MPD powder diffractometer, serial number DY667. The pattern was recorded using the following acquisition conditions: Tube anode: Cu, Start angle: 2.0°2θ, End angle: 45.0°2θ, Step size: 0.02°2θ, Time per step: 1 second. XRPD profiles were collected at ambient temperature (295K) (FIG. 8 );
b) a Philips PW1710 powder diffractometer. The pattern was recorded using the following acquisition conditions: Tube anode: Cu, Start angle: 3.5°2θ, End angle: 35.0°2θ, Step size: 0.02°2θ, Time per step: 2.3 seconds. XRPD profiles were collected at ambient temperature (295K) (FIGS. 4 - 7 );
The diffractometer used in each case can be determined by the end angle in the figure.
X-ray diffraction pattern collections referred to in Table 1 were performed in the following manners:
The crystal and molecular structures and corresponding unit cell dimensions were determined from three-dimensional X-ray diffraction data collected at 120+/−2 K. All measurements were made using a Bruker SMART CCD diffractometer with graphite monochromated Mo-Kα radiation (λ=0.71073 Å) from a fine focus sealed tube source. The structure was solved by direct methods and refined using full-matrix least-squares procedures which minimized the function Sw(Fo 2 -Fc 2 ) 2 . The Bruker SHELX software was used throughout.
Intermediates
Intermediate 1: 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid diisopropylethylamine salt
A stirred suspension of 6α,9α-difluoro-11β,17α-dihydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid (prepared in accordance with the procedure described in GB 2088877B) (49.5 g) in methylacetate (500 ml) is treated with triethylamine (35 ml) maintaining a reaction temperature in the range 0-5° C. 2-Furoyl chloride (25 ml) is added and the mixture stirred at 0-5° C. for 1 hour. A solution of diethanolamine (52.8 g) in methanol (50 ml) is added and the mixture stirred at 0-5° C. for at least 2 hours. Dilute hydrochloric acid (approx 1 M, 550 ml) is added maintaining a reaction temperature below 15° C. and the mixture stirred at 15° C. The organic phase is separated and the aqueous phase is back extracted with methyl acetate (2×250 ml). All of the organic phases are combined, washed sequentially with brine (5×250 ml) and treated with di-isopropylethylamine (30 ml). The reaction mixture is concentrated by distillation at atmospheric pressure to an approximate volume of 250 ml and cooled to 25-30° C. (crystallisation of the desired product normally occurs during distillation/subsequent cooling). Tertiary butyl methyl ether (TBME) (500 ml) is added, the slurry further cooled and aged at 0-5° C. for at least 10 minutes. The product is filtered off, washed with chilled TBME (2×200 ml) and dried under vacuum at approximately 40-50° C. (75.3 g, 98.7%). NMR (CDCl 3 ) δ: 7.54-7.46 (1H, m), 7.20-7.12 (1H, dd), 7.07-6.99 (1H, dd), 6.48-6.41 (2H, m), 6.41-6.32 (1H, dd), 5.51-5.28 (1H, dddd 2 J H-F 50 Hz), 4.45-4.33(1H, bd), 3.92-3.73 (3H, bm), 3.27-3.14 (2H, q), 2.64-2.12 (5H, m), 1.88-1.71 (2H, m), 1.58-1.15 (3H, s), 1.50-1.38 (15H, m), 1.32-1.23 (1H, m), 1.23-1.15 (3H s), 1.09-0.99 (3H, d)
Intermediate 2: 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
Unsolvated Form 1
A mobile suspension of Intermediate 1 (12.61 g, 19.8 mmol) in ethyl acetate (230 ml) and water (50 ml) is treated with a phase transfer catalyst (benzyltributylammonium chloride, 10 mol %), cooled to 3° C. and treated with bromofluoromethane (1.10 ml, 19.5 mmol, 0.98 equivalents), washing in with prechilled (0° C.) ethyl acetate (EtOAc) (20 ml). The suspension is stirred overnight, allowing to warm to 17° C. The aqueous layer is separated and the organic phase is sequentially washed with 1 M HCl (50 ml), 1% w/v NaHCO 3 solution (3×50 ml) and water (2×50 ml). The ethylacetate solution is distilled at atmospheric pressure until the distillate reaches a temperature of approximately 73° C. at which point toluene (150 ml) is added. Distillation is continued at atmospheric pressure until all remaining EtOAc has been removed (approximate distillate temperature 103° C.). The resultant suspension is cooled and aged at <10° C. and filtered off. The bed is washed with toluene (2×30 ml) and the product oven dried under vacuum at 60° C. to constant weight to yield the title compound (8.77 g, 82%) LCMS retention time 3.66 min, m/z 539 MH + , NMR δ (CDCl 3 ) includes 7.60 (1H, m), 7.18-7.11 (2H, m), 6.52 (1H, dd, J 4.2 Hz), 6.46 (1H, s), 6.41 (1H, dd, J 10, 2 Hz), 5.95 and 5.82 (2H dd, J 51, 9 Hz), 5.48 and 5.35 (1H, 2m), 4.48 (1H, m), 3.48 (1H, m), 1.55 (3H, s), 1.16 (3H, s), 1.06 (3H, d, J 7 Hz).
Pharmacological Activity
In Vitro Pharmacological Activity
Pharmacological activity was assessed in a functional in vitro assay of glucocorticoid agonist activity which is generally predictive of anti-inflammatory or anti-allergic activity in vivo.
For the experiments in this section, compound of formula (I) was used as unsolvated Form 1 (Intermediate 2)
The functional assay was based on that described by K. P. Ray et al., Biochem J. (1997), 328, 707-715. A549 cells stably transfected with a reporter gene containing the NF-κB responsive elements from the ELAM gene promoter coupled to sPAP (secreted alkaline phosphatase) were treated with test compounds at appropriate doses for 1 hour at 37° C. The cells were then stimulated with tumour necrosis factor (TNF, 10 ng/ml) for 16 hours, at which time the amount of alkaline phosphatase produced is measured by a standard colourimetric assay. Dose response curves were constructed from which EC 50 values were estimated.
In this test the compound of formula (1) showed an EC 50 value of <1 nM.
The glucocorticoid receptor (GR) can function in at least two distinct mechanisms, by upregulating gene expression through the direct binding of GR to specific sequences in gene promotors, and by downregulating gene expression that is being driven by other transcription factors (such as NFκB or AP-1) through their direct interaction with GR.
In a variant of the above method, to monitor these functions, two reporter plasmids have been generated and introduced separately into A549 human lung epithelial cells by transfection. The first cell line contains the firefly luciferase reporter gene under the control of a synthetic promoter that specifically responds to activation of the transcription factor NFκB when stimulated with TNFα. The second cell line contains the renilla luciferase reporter gene under the control of a synthetic promotor that comprises 3 copies of the consensus glucocorticoid response element, and which responds to direct stimulation by glucocorticoids. Simultaneous measurement of transactivation and transrepression was conducted by mixing the two cell lines in a 1:1 ratio in 96 well plate (40,000 cells per well) and growing overnight at 37° C. Test compounds were dissolved in DMSO, and added to the cells at a final DMSO concentration of 0.7%. After incubation for 1 h 0.5 ng/ml TNFα (R&D Systems) was added and after a further 15 hours at 37° C., the levels of firefly and renilla luciferase were measured using the Packard Firelite kit following the manufacturers' directions. Dose response curves were constructed from which EC 50 values were determined.
Transactivation (GR)
Transrepression (NFκB)
ED 50 (nM)
ED 50 (nM)
Compound of Formula
0.06
0.20
(I)
Metabolite (X)
>250
>1000
Fluticasone propionate
0.07
0.16
In Vivo Pharmacological Activity
Pharmacological activity in vivo was assessed in an ovalbumin sensitised Brown Norway rat eosinophilia model. This model is designed to mimic allergen induced lung eosinophilia, a major component of lung inflammation in asthma.
For the experiments in this section, compound of formula (I) was used as unsolvated Form 1.
Compound of formula (I) produced dose dependant inhibition of lung eosinophilia in this model after dosing as an intra-tracheal (IT) suspension in saline 30 min prior to ovalbumin challenge. Significant inhibition is achieved after a single dose of 30 μg of compound of formula (I) and the response was significantly (p=0.016) greater than that seen with an equivalent dose of fluticasone propionate in the same study (69% inhibition with compound of formula (I) vs 41% inhibition with fluticasone propionate).
In a rat model of thymus involution 3 daily IT doses of 100 μg of compound (I) induced significantly smaller reductions in thymus weight (p=0.004) than an equivalent dose of fluticasone propionate in the same study (67% reduction of thymus weight with compound (I) vs 78% reduction with fluticasone propionate).
Taken together these results indicate a superior therapeutic index for compound (I) compared to fluticasone propionate.
In Vitro Metabolism in Rat and Human Hepatocytes
Incubation of compound (I) with rat or human hepatocytes shows the compound to be metabolised in an identical manner to fluticasone propionate with the 17-β carboxylic acid (X) being the only significant metabolite produced. Investigation of the rate of appearance of this metabolite on incubation of compound (I) with human hepatocytes (37° C., 10 μM drug concentration, hepatocytes from 3 subjects, 0.2 and 0.7 million cells/mL) shows compound (I) to be metabolised ca. 5-fold more rapidly than fluticasone propionate:
17-β acid metabolite production
Subject
Cell density
(pmol/h)
number
(million cells/mL)
Compound (I)
Fluticasone propionate
1
0.2
48.9
18.8
1
0.7
73.3
35.4
2
0.2
118
9.7
2
0.7
903
23.7
3
0.2
102
6.6
3
0.7
580
23.9
Median metabolite production 102-118 pmol/h for compound (I) and 18.8-23.0 pmol/h for fluticasone propionate.
Pharmacokinetics After Intravenous (IV) and Oral Dosing in Rats
Compound (I) was dosed orally (0.1 mg/kg) and IV (0.1 mg/kg) to male Wistar Han rats and pharmacokinetic parameters determined. Compound (I) showed negligible oral bioavailability (0.9%) and plasma clearance of 47.3 mL/min/kg, approaching liver blood flow (plasma clearance of fluticasone propionate=45.2 mL/min/kg).
Pharmacokinetics After Intra-tracheal Dry Powder Dosing in the Pig.
Anaesthetised pigs (2) were dosed intra-tracheally with a homogenous mixture of compound (I) (1 mg) and fluticasone propionate (1 mg) as a dry powder blend in lactose (10% w/w). Serial blood samples were taken for up to 8 h following dosing. Plasma levels of compound (I) and fluticasone propionate were determined following extraction and analysis using LC-MS/MS methodology, the lower limits of quantitation of the methods were 10 and 20 pg/mL for compound (I) and fluticasone propionate respectively. Using these methods compound (I) was quantifiable up to 2 hours after dosing and fluticasone propionate was quantifiable up to 8 hours after dosing. Maximum plasma concentrations were observed for both compounds within 15 min after dosing. Plasma half-life data obtained from IV dosing (0.1 mg/kg) was used to calculate AUC (0-inf) values for compound (I). This compensates for the plasma profile of Compound (I) only being defined up to 2 hours after an IT dose and removes any bias due to limited data between compound (I) and fluticasone propionate.
C max and AUC (0-inf) values show markedly reduced systemic exposure to compound (I) compared to fluticasone propionate:
Cmax (pg/mL)
AUC (0-inf) (hr. pg/mL)
Pig 1
Pig 2
Pig 1
Pig 2
Compound of Formula (I)
117
81
254
221
Fluticasone propionate
277
218
455
495
The pharmacokinetic parameters for both compound (I) and fluticasone propionate were the same in the anaesthetised pig following intravenous administration of a mixture of the two compounds at 0.1 mg/kg. The clearance of these two glucocorticoids is similar is this experimental pig model.
Intermediate 3: 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester, amorphous particles
Intermediate 2 (30.04 g) was dissolved in methylethylketone (850 ml) to give a 3.5% solution. The solution was spray dried using a Niro Mobile Minor spray drier (Niro Inc, Columbia, Md., USA). The spray orifice was a two fluid pneumatic nozzle with 0.04 inch orifice diameter (Spray Systems Co, Wheaton, Ill., USA). The other spray drying parameters were as follows:
Temperature: 150° C., outlet temperature 98° C.
Solution flow rate: 30 ml/min using Isco 260D syringe pump (Isco Inc, Lincoln, Nev., USA)
Atomisation Pressure: 2 Bar
Particle collection was achieved in the conventional manner using a Fisher Klosterman XQ120-1.375 high efficiency cyclone (Fisher-Klosterman Inc, Louisville, Ky., USA). A white powder was recovered. The spray drying process was successful at producing smooth, spherical particles of amorphous 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester. System yield was 61%
Intermediate 4 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
Unsolvated Form 2
EXAMPLES
Example 1
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
Composition with Toluene
Intermediate 4 (200 mg) was slurried in toluene (5 mL) for 3 hours. The solid was then recovered by filtration to afford the title compound as a white solid.
Stoichiometry of compound of formula (I): guest=1: 3.1 from 1 H nmr (CDCl 3 ).
Example 2
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
Composition with m-xylene
Intermediate 4 (200 mg) was slurried in m-xylene (6 mL) for 2 hours. The solid was then recovered by filtration to afford the title compound as a white solid.
Example 3
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
Composition with o-xylene (first alternative method)
Intermediate 3 (100 mg) was slurried in o-xylene (1 mL) at 21° C. for 16 hours. The solid was recovered by filtration to afford the title compound as a white solid. Stoichiometry of compound of formula (I): guest=1: 1.5 from 1 H nmr (CDCl 3 ).
Example 4
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
Composition with o-xylene (second alternative method)
Intermediate 2 (3.0 g) was dissolved in a mixture of o-xylene (60 mL) and acetonitrile (60 mL). The solvent was allowed to evaporate under ambient conditions until the crystallisation had proceeded sufficiently. The solid was then recovered by filtration to afford the title compound as a white solid.
Stoichiometry of compound of formula (I): guest=1: 4 from 1 H nmr (CDCl 3 ).
Example 5
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
Composition with Chlorobenzene
Intermediate 4 (200 mg) was slurried in m-xylene (5 mL) for 3 hours. The solid was then recovered by filtration to afford the title compound as a white solid.
Further characterising data on compositions of the invention:
Detailed XRPD profile peak information for various compositions of the invention is provided in Tables 2, 3, 4 and 5.
The XRPD profiles of compositions of the invention are provided in FIGS. 4, 5 , 6 and 7 .
We also claim compositions of the invention substantially by reference to their XRPD profiles as shown in the Figures and Tables.
Example A
Dry Powder Composition Containing 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester composition with toluene
A dry powder formulation may be prepared as follows:
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-
0.20 mg
hydroxy-16α-methyl-3-oxo-
androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester,
composition with
toluene prepared according to Example 1, MMD of 3 μm:
milled lactose (wherein not greater than 85% of particles
12 mg
have a MMD of 60-90 μm, and not less than 15% of particles
have a MMD of less than 15 μm):
A peelable blister strip containing 60 blisters each
filled with a formulation as just
described may be prepared.
Example B
Dry Powder Composition Containing 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester composition with toluene and a long acting β 2 -adrenoreceptor agonist
A dry powder formulation may be prepared as follows:
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-
0.20 mg
11β-hydroxy-16α-methyl-3-oxo-
androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester
composition with
toluene prepared according to Example 1, MMD of 3 μm:
Long-acting β 2 -adrenoreceptor agonist (micronised to a
0.20 mg
MMD of 3 μm):
milled lactose (wherein not greater than 85% of particles
12 mg
have a MMD of 60-90 μm, and not less than 15% of particles
have a MMD of less than 15 μm):
A peelable blister strip containing 60 blisters each filled
with a formulation as just
described may be prepared.
Example C
Aerosol Formulation Containing 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester composition with toluene prepared according to Example 1, MMD of 3 μm:
An aluminium canister may be filled with a fromulation as follows:
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-
250 μg
hydroxy-16α-methyl-3-oxo-
androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl
ester composition with
toluene prepared according to Example 1, MMD of 3 μm:
1,1,1,2-tetrafluoroethane:
to 50 μl
(amounts per actuation)
in a total amount suitable for 120 actuations and the
canister may be fitted with a
metering valve adapted to dispense 50 μl per actuation.
Example D
Aerosol formulation containing 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester composition with toluene and a long acting β 2 -adrenoreceptor agonist
An aluminium canister may be filled with a formulation as follows:
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-
250 μg
hydroxy-16α-methyl-3-oxo-
androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl
ester composition with
toluene prepared according to Example 1, MMD of 3 μm:
Long-acting β 2 -adrenoreceptor agonist (micronised to
25 μg
a MMD of 3 μm):
1,1,1,2-tetrafluoroethane:
to 50 μl
(amounts per actuation)
in a total amount suitable for 120 actuations and the
canister may be fitted with a
metering valve adapted to dispense 50 μl per actuation.
Example E
Nasal formulation containing 6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl ester composition with toluene
A formulation for intranasal delivery may be prepared as follows:
6α,9α-Difluoro-17α-[(2-furanylcarbonyl)oxy]-11β-
10 mg
hydroxy-16α-methyl-3-oxo-
androsta-1,4-diene-17β-carbothioic acid S-fluoromethyl
ester composition with
toluene prepared according to Example 1, MMD of 3 μm:
Polysorbate 20
0.8 mg
Sorbitan monolaurate
0.09 mg
Sodium dihydrogen phosphate dihydrate
94 mg
Dibasic sodium phosphate anhydrous
17.5 mg
Sodium chloride
48 mg
Demineralised water
to 10 ml
The formulation may be fitted into a spraypump capable
of delivering a plurality of
metered doses (Valois).
Throughout the specification and the claims which follow, unless the context requires otherwise, the word ‘comprise’, and variations such as ‘comprises’ and ‘comprising’, will be understood to imply the inclusion of a stated integer or step or group of integers but not to the exclusion of any other integer or step or group of integers or steps.
The patents and patent applications described in this application are herein incorporated by reference.
TABLE 2
XRPD characteristic
angles and relative intensities for 6α,9α-Difluoro-17α-
[(2-furanylcarbonyl)oxy]-
11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-
carbothioic acid S-fluoromethyl ester, composition with toluene
Angle
Rel. Intensity
2-Theta °
%
4.9
25.6
6.8
12.2
8.0
43.6
9.9
1.7
11.8
15.5
13.0
13.1
14.0
12.9
15.0
100.0
16.3
53.2
16.7
12.0
17.9
14.2
18.7
83.2
19.4
13.3
20.1
26.6
21.1
19.7
21.7
17.2
22.8
14.5
23.5
37.2
23.9
34.6
24.5
14.0
25.3
10.5
25.8
15.5
26.1
20.5
27.0
18.8
28.8
8.2
30.7
39.2
31.1
21.4
32.7
14.0
34.0
14.0
34.7
18.6
TABLE 3
XRPD characteristic
angles and relative intensities for 6α,9α-Difluoro-17α-
[(2-furanylcarbonyl)oxy]-
11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-
carbothioic acid S-fluoromethyl ester, composition with m-xylene
Angle
Rel. Intensity
2-Theta °
%
4.8
38.7
6.8
12.7
7.9
22.8
9.6
6.2
11.5
24.1
13.0
11.8
13.7
26.9
14.5
100.0
15.8
17.9
16.1
25.7
16.4
12.4
17.0
7.7
17.6
12.5
18.3
52.1
19.3
34.9
20.4
6.4
21.2
22.2
22.3
16.3
22.7
18.4
23.3
21.1
24.3
14.0
25.1
12.8
25.6
14.6
26.3
8.1
26.8
9.5
27.6
6.9
28.0
5.0
28.6
5.8
29.8
18.8
31.4
8.8
32.5
8.0
33.1
8.7
34.3
11.7
TABLE 4
XRPD characteristic
angles and relative intensities for 6α,9α-Difluoro-17α-
[(2-furanylcarbonyl)oxy]-
11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-
carbothioic acid S-fluoromethyl ester, composition with o-xylene
Angle
Rel. Intensity
2-Theta °
%
5.0
11.4
6.9
13.6
8.1
21.7
9.9
1.6
11.7
18.0
13.1
15.4
13.8
27.2
14.8
100.0
16.2
39.3
16.6
16.8
17.1
9.4
17.7
12.0
18.5
60.6
19.3
10.7
19.7
18.5
20.6
5.1
21.5
20.0
22.8
21.3
23.4
22.5
24.4
17.6
24.9
7.4
25.6
21.5
26.3
12.4
26.8
12.0
28.0
8.8
28.7
7.0
29.0
6.6
30.2
16.6
32.2
8.1
32.5
9.4
33.4
6.6
34.2
12.3
TABLE 5
XRPD characteristic
angles and relative intensities for 6α,9α-Difluoro-17α-
[(2-furanylcarbonyl)oxy]-
11β-hydroxy-16α-methyl-3-oxo-androsta-1,4-diene-17β-
carbothioic acid S-fluoromethyl ester, composition with chlorobenzene
Angle
Rel. Intensity
2-Theta °
%
4.3
34.4
6.6
12.4
10.7
10.2
12.7
11.1
13.3
10.5
13.6
23.4
14.6
22.9
15.3
24.8
16.9
43.2
17.3
44.4
17.6
100.0
19.1
26.7
19.4
12.4
20.1
32.3
20.9
24.3
22.1
15.2
23.0
47.0
23.6
20.7
24.5
10.5
25.2
9.6
27.4
12.7
28.5
6.2
29.6
28.1
31.8
17.5
33.3
6.2 | There is provided a crystalline chemical composition comprising a compound of formula (I)
in which the crystal lattice is stabilised by the presence of a guest molecule, characterised in the crystalline composition is of space group P2 1 2 1 2 1 having unit cell dimensions of about 7.6±0.6 Å, 12.7±0.7 Å, and 33±3 Å when determined at 120K. | 2 |
BACKGROUND
1. Technical Field
The present invention relates to electrical connections to photovoltaic panels and more particularly to a junction box with upper and lower portions which snap together to achieve the electrical connection.
2. Description of Related Art
A photovoltaic module or photovoltaic panel is a packaged interconnected assembly of photovoltaic cells, also known as solar cells. Since a single photovoltaic module can only produce a limited amount of power, commercial installations include several modules or panels interconnected in serial and in parallel into a photovoltaic array. Electrical connections are made in series to achieve a desired output voltage and/or in parallel to provide a desired amount of current source capability. A photovoltaic installation typically includes the array of photovoltaic modules, an inverter, batteries and interconnection wiring. Electronic modules may be integrated with the photovoltaic modules which perform electrical conversion, e.g. direct current (DC) to direct current conversion, electrical inversion, e.g. micro-inverter, or other functions such as monitoring of performance and/or protection against theft.
Bus ribbon is a common interconnect that is used to connect photovoltaic modules. Bus ribbon is made up of a copper ribbon, or flat wire, that is coated in solder. The solder protects the surface of the copper from oxidation and provides a layer of solder to form the solder joint. Bus ribbon is generally 5 mm-6 mm wide, although some applications require bus ribbon to be more than twice as wide. Bus ribbon may serve as an input/output to a conventional junction box typically mounted on the back side of the photovoltaic module.
When part of a photovoltaic module is shaded, the shaded cells do not produce as much current as the unshaded cells. Since photovoltaic cells are connected in series, the same amount of current must flow through every serially connected cell. The unshaded cells force the shaded cells to pass more current. The only way the shaded cells can operate at a higher current is to operate in a region of negative voltage that is to cause a net voltage loss to the system. The current times this negative voltage gives the negative power produced by the shaded cells. The shaded cells dissipate power as heat and cause “hot spots”. Bypass diodes are therefore integrated with the photovoltaic modules to avoid overheating of cells in case of partial shading of the photovoltaic module.
Blocking diodes may be placed in series with cells or modules to block reverse leakage current backwards through the modules such as to block reverse flow of current from a battery through the module at night or to block reverse flow down damaged modules from parallel-connected modules during the day.
The term “wire” or “electrical wire” as used herein is a piece of metal or other electrically conductive material of any cross-sectional shape used for carrying electrical currents or signals. Bus ribbon is an example of an electrical wire used to electrically connect to photovoltaic panels.
The term “cable gland” as used herein refers to a device used for the entry of electrical cables or cords into electrical equipment and is used to firmly secure an electrical cable entering a piece of electrical equipment.
BRIEF SUMMARY
According to embodiments of the present invention there is provided a junction box adapted to provide an electrical connection to an electrical wire attached to a photovoltaic panel. The junction box has a lower portion which has an entry slot to allow entry of the wire into the junction box and a raised protrusion over which the wire is bent and formed to be substantially in the same shape as the raised protrusion. The junction box may have a clamp attachable to the lower portion. The clamp holds the wire in place for providing the electrical connection. The wire is typically bus ribbon. The lower portion may have an elastic polymeric element disposed between the raised protrusion and the wire and or the raised protrusion may have an elastic polymeric element.
The junction box may have an upper portion including a terminal. The terminal connects to an electrical load. The terminal is adapted to be applied under pressure onto the wire, thereby conforming the terminal to be of substantially the same shape as the raised protrusion. The upper portion typically has a fastener which closes the upper portion to the lower portion under pressure. The terminal is typically spring loaded. The electrical load may be a direct current (DC) to DC converter, a DC to alternating current (AC) inverter, a DC motor or a battery. The upper portion preferably has a seal which is positioned between the upper and the lower portions. The seal is adapted to seal under the same pressure which effects the electrical connection between the terminal and the wire. The upper portion typically includes a diode connected to the terminal. The diode may be either a bypass diode or a blocking diode. The upper portion may be an electronic module connected to the terminal. The upper portion preferably has a cable gland.
According to embodiments of the present invention there is provided a method to provide a connection to a photovoltaic panel. A wire, e.g. bus ribbon, which connects electrical to the photovoltaic panel is passed through an entry slot of a lower portion of a junction box. The bus ribbon is bent over a raised protrusion provided in the lower portion of the junction box. The bus ribbon is formed to be substantially the same shape as the raised protrusion. The bus ribbon is typically clamped onto the protrusion of the lower portion of the junction box.
An upper portion of the junction box is inserted into the lower portion of the junction box and while inserting a terminal is loaded compressively onto the bus ribbon. The compressive loading may include spring loading. Additionally while inserting, the upper portion is sealed to the lower portion of the junction box. The terminal is typically conformed to the shape of the protrusion while electrically connecting to the bus ribbon between the terminal and the protrusion. An elastic polymeric material is typically inserted between the protrusion and the wire.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 shows a partial view of the back side (i.e. non photovoltaic side) of a photovoltaic panel according to an embodiment of the present invention.
FIG. 2 shows a lower half of a junction box assembly according to an embodiment of the present invention.
FIG. 3 a which shows a junction box assembly with clamp according to an embodiment of the present invention.
FIG. 3 b shows a partial cross sectional view of a wire ribbon mounted in a lower junction box assembly with a clamp according to an embodiment of the present invention.
FIG. 4 shows a method according to an embodiment of the present invention.
FIGS. 5 a and 5 b show isometric views of upper an junction box assembly connected/inserted into a lower junction box assembly according to an embodiment of the present invention.
FIGS. 5 c and 5 d show isometric views of the underside of an upper junction box assembly according to an embodiment of the present invention.
FIG. 5 e shows a cross section view of an upper junction box assembly inserted into a lower junction box assembly according to an embodiment of the present invention.
FIG. 5 f shows area A shown in FIG. 5 e in greater detail according to an embodiment of the present invention.
FIG. 5 g shows a method according to an embodiment of the present invention.
FIGS. 6 a and 6 b show an upper junction box assembly inserted into a lower junction box assembly according to another embodiment of the present invention.
FIG. 6 c shows an underside isometric view of an upper assembly according to an embodiment of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
Before explaining embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of design and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
By way of introduction, embodiments of the present invention are directed to enable an interconnection of photovoltaic panels with cables and/or photovoltaic panels with electronic modules such as alternating current (AC) inverters or direct current (DC) to DC converters with a minimal use of hand tools while providing electrical isolation and hermeticity.
Reference is now made to the drawings. FIG. 1 shows a partial view of the back side 104 (i.e. non photovoltaic side) of a photovoltaic panel 100 according to an embodiment of the present invention. bus ribbons are 102 located on back side 104 of panel 100 and provide electrical connections to internal photovoltaic cells of panel 100 .
Reference is now made to FIG. 2 which shows a lower half of a junction box assembly 218 according to an embodiment of the present invention. Assembly 218 is typically attached to back side 104 of panel 100 at the time of manufacture/assembly of panel 100 . Assembly 218 may be made or cast as one piece, in the form of a plastic injection molding. Assembly 218 has support rails 216 , retainer clip 214 and lower part 210 of junction box.
Reference is now also made to FIGS. 5 a and 5 b which shows isometric views of upper junction box assembly 500 connected/inserted into lower junction box assembly 218 according to an embodiment of the present invention. Assembly 500 has a lid 504 which when removed shows an upper terminal assembly 528 fixed into lower assembly 218 using screws 530 . Upper terminal assembly 528 after being inserted into lower assembly 218 provides complete electrical isolation of the electrical connection of upper assembly 528 with the lower assembly 218 . Lid 504 provides a cosmetic appearance and/or further level of isolation. Attached mechanically and electrically to upper terminal assembly 528 is electronic module 524 . Electronic module 524 is attached mechanically to panel 100 using support rails 216 and retainer clip 214 . Electronic module 524 has cable glands 526 which allow a cable entry into electronic module 524 where the cable may be terminated inside electronic module 524 .
Referring back to FIG. 2 , support rails 216 may be made from one piece of plastic as part of an injection molding process or as separate parts. Support rails 216 may be made from spring metal which may be plastic coated. Support rails 216 provide the correct distance between module 524 and backside 104 of panel 100 . Support rails 216 also provide support for module 524 along with retainer clip 214 . Retainer clip 214 may also be made from spring metal which may be plastic coated or made from one piece of plastic as part of an injection molding process.
Reference is now also made to FIG. 3 a which shows junction box assembly 218 with clamp 300 according to an embodiment of the present invention. Clamp 300 is preferably attached to the bottom side 210 a of junction box 210 with an adhesive, by screws through hole pillars 212 or by the insertion of upper junction box assembly 500 ( FIG. 5 b ) and the tightening of screws 530 into threaded pillars 212 .
Referring back to FIG. 2 , junction box 210 has gland apertures 220 to accommodate embodiment 600 and through hole pillars 212 . Through hole pillars 212 are typically used to attach junction box 210 to backside 104 of panel 100 . Through hole pillars 212 may also be used to attach clamp plate 300 to the bottom side 210 a of junction box 210 .
Junction box 210 has a slot 210 b where bus ribbons 102 are passed through and are placed into the inside of junction box 210 . Bus ribbons 102 are typically bent and formed over raised protrusion 208 . Raised protrusion 208 may have additionally a rubber or elastic material 206 placed in-between protrusion 208 and bus ribbon 102 .
Reference is now made to FIG. 3 b which shows a partial cross sectional view 302 of wire ribbon 102 mounted in lower junction box assembly 218 with clamp 300 according to an embodiment of the present invention. Cross sectional view 302 shows bus ribbon 102 clamped by clamp 300 over elastic material 206 and protrusion 208 . One of two gaskets 310 (for example an “O” ring), is shown between bottom side 210 a of junction box 210 and clamp 300 . Gasket 310 provides a level of sealing against the ingress of water and/or dust into panel 100 . Additionally the underside of clamp 300 may be coated with an elastic material to provide sealing between the elastic material and bus ribbon 102 . bus ribbon 102 passes through slot 210 b of junction box 210 . bus ribbon 102 continues through a hole in backside 204 of solar panel 100 and is connected to the photovoltaic cells inside panel 100 . Protrusion 208 is typically formed by an indentation on bottom side 210 a of junction box 210 . Bottom side 210 a of junction box 210 is located and may be attached on backside 204 of solar panel 100 .
Reference is now made to FIG. 4 which shows a method 401 according to an embodiment of the present invention. Typically, assembly 218 is attached to backside 104 of panel 100 at the time of manufacture/assembly of panel 100 whilst ensuring bus ribbon 102 is passed through entry slot 210 b of junction box 210 (step 403 ). With bus ribbon 102 located inside junction box 210 as a result of step 403 , bus ribbon 102 is bent over elasticated material 206 and protrusion 208 (step 405 ). After being bent, bus ribbon is then formed (step 407 ) to take substantially the shape of protrusion 208 and/or elasticated material 206 . The bending (step 405 ) and forming (step 407 ) of bus ribbon 102 is then held firm and clamped into place (step 409 ) in junction box 210 using clamping plate 300 . Clamp 300 is preferably attached to the bottom side 210 a of junction box 210 with an adhesive, by screws through hole pillars 212 or by the insertion of upper junction box assemblies 500 and 600 (not shown) and the tightening of screws 530
Reference is now made to FIGS. 5 c and 5 d which show isometric views of the underside of upper junction box assembly 500 according to an embodiment of the present invention. Upper junction box assembly 500 has electronic module 524 with lid 532 , when lid 532 is removed the component side of electronic circuit board 542 is shown. Circuit board 542 is typically a direct current (DC) to DC converter or a DC to alternating current (AC) inverter. Termination of interconnecting cables on circuit board 542 is provided by insertion of interconnecting cables into cable entry glands 526 . Upper terminal assembly 528 has mounting through holes 540 which along with screws 530 (not shown) are used as part of the insertion and retention of assembly 500 into lower junction box assembly 218 . Upper terminal assembly 528 also has terminals 536 which provide an electrical connection between circuit board 542 and the curved portions 536 a of terminals 536 . An indented portion of assembly 528 houses curved portions 536 a of terminals 536 and typically there may be an elastic material placed between assembly 528 and curved portions 536 a . Sufficient flexibility and movement of curved portions 536 a typically allows curved portions 536 a to conform around the bent and formed portion wire ribbon 102 when upper junction box assembly 500 inserted into lower junction box assembly 218 .
Reference is now made to FIG. 5 e which shows a cross section view of upper junction box assembly 500 inserted into lower junction box assembly 218 according to an embodiment of the present invention. Area A shows an electrical connection between upper junction box assembly 500 inserted into lower junction box assembly 218 . Upper junction box assembly 500 includes further; electronic module 524 with lid 532 and electronic circuit board 542 . Lid 532 rests and is held by support rails 216 along with module 524 held by retainer clip 214 . Terminal 536 provides the electrical connection between circuit board 542 and connection to photovoltaic cells in panel 100 (not shown) via the electrical connection between upper assembly 500 inserted into lower assembly 218 .
Reference is now made to FIG. 5 f and FIG. 5 g which show area A shown in FIG. 5 e in greater detail and a method 501 respectively according to an embodiment of the present invention. Area A shows details of the insertion (step 505 ) of upper junction box assembly 500 inserted into lower junction box assembly 218 to form an electrical connection between circuit board 542 and connection to photovoltaic cells in panel 100 (not shown). The electrical connection is formed between curved portion 536 a which may be spring loaded and bus ribbon 102 . Curved portion 536 a is held by assembly 528 . Curved portion 536 a is connected to circuit board 542 via terminal 536 . Sealing of lower assembly 218 is provided by gaskets 310 which provide a level of sealing against the ingression of water and/or dust into aperture 210 b by using clamp 300 . Sealing between upper assembly 500 and lower assembly 218 is provided by gaskets 534 . Further sealing of upper and lower assemblies by lid 504 . Protrusion 208 is formed as a part of the bottom side 210 a of junction box 210 . In between protrusion 208 and bus ribbon 102 is elastic material 206 .
Reference is now made to FIGS. 6 a and 6 b which show upper junction box assembly 600 inserted into lower junction box assembly 218 according to another embodiment of the present invention. Upper junction box assembly 600 inserted into lower junction box assembly 218 does not make use of support rails 216 and retainer clip 214 only junction box 210 of lower assembly 218 . Clamp 300 in junction box 210 is preferably attached to the bottom side 210 a of junction box 210 with an adhesive, by screws through hole pillars 212 or by the insertion of upper junction box assembly 600 and the tightening of screws 630 into threaded pillars 212 . Upper assembly 600 after being inserted into lower assembly 218 provides complete electrical isolation of the electrical connection of upper assembly 600 with the lower assembly 218 . Lid 602 provides a cosmetic appearance and/or further level of electrical isolation and sealing. Assembly 600 has cable glands 626 which allow a cable entry into assembly 600 where the cable may be terminated inside assembly 600 .
Reference is now made to FIG. 6 c which shows an underside isometric view of upper assembly 600 according to an embodiment of the present invention. Curved portions 636 a are typically held by an indented portion of assembly 600 . An elastic material may be placed between assembly 600 and curved portions 636 a . Sufficient flexibility and movement of curved portions 636 a typically allows curved portions 636 a to conform around the bent and formed portion of wire ribbon 102 when upper junction box assembly 600 is inserted into lower junction box assembly 218 . Curved portions 636 a are connected to one end of a bypass diode 642 via terminal 636 . Bypass diodes 642 are typically connected between terminals 636 . Sealing between upper assembly 600 and lower assembly 218 is provided by gasket 634 . Further sealing of upper and lower assemblies may be by lid 602 . Upper assembly 600 after being inserted into lower assembly 218 is held in place by screws 630 (not shown) which go through holes 640 . Cables are typically passed through and are held by glands 626 and terminated in clamp 638 . Clamp 638 is typically spring loaded and is moved by an insertion of a screwdriver to reveal an aperture. The aperture receives an insertion of a conductor provided by a cable which is inserted into gland 626 . The removal of the screwdriver causes the aperture to close which clamps the conductor in clamp 638 and a connection of the conductor with terminal 636 is established.
Reference is now made again method 501 shown in FIG. 5 g with respect to upper assembly 600 according to an embodiment of the present invention. Upper assembly 600 inserted (step 505 ) into lower junction box assembly 218 to form an electrical connection between cables terminated in clamp 638 and connection to photovoltaic cells in panel 100 (not shown). The electrical connection is formed between curved portion 636 a (which may be spring loaded) and bus ribbon 102 . Insertion of upper assembly 600 into lower assembly 218 further provides sealing between upper assembly 600 and lower assembly 218 by gasket 634 . Further sealing between upper 600 and lower 218 assemblies is provided by lid 602 .
The definite articles “a”, “an” is used herein, such as “a terminal”, “a junction box” have the meaning of “one or more” that is “one or more terminals s” or “one or more junction boxes”.
Although selected embodiments of the present invention have been shown and described, it is to be understood the present invention is not limited to the described embodiments. Instead, it is to be appreciated that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and the equivalents thereof. | A junction box adapted to provide an electrical connection to an electrical wire attached to a photovoltaic panel. The junction box has a lower portion which has an entry slot to allow entry of the wire into the junction box and a raised protrusion over which the wire is bent and formed to be substantially in the same shape as the raised protrusion. The junction box also has a clamp adapted to be attachable to said lower portion, whereby the clamp holds the wire in place for providing the electrical connection. The wire is preferably bus ribbon. The lower portion preferably has an elastic polymeric element disposed between the raised portion and the wire. The raised protrusion may have an elastic polymeric element. | 7 |
[0001] This nonprovisional application is a continuation application of application Ser. No. 11/338,762 filed on Jan. 25, 2006, which is a continuation application of application Ser. No. 10/653,288 filed on Sep. 3, 2003, which is a continuation application of application Ser. No. 09/701,556 filed on Mar. 16, 2001, which is a National Stage entry of International Application No. PCT/FR99/01278 filed on Jun. 1, 1999, which claims priority to French Application No. 98/07144 filed on Jun. 4, 1998. The disclosures of the prior applications are hereby incorporated herein in their entirety by reference.
[0002] The present invention relates to the technical field of paper production and the polymers used in this field.
[0003] The invention relates to a process for producing a paper or paperboard with improved retention and other properties.
[0004] During the production of paper, paperboard, or the like, it is well known to introduce into the pulp retention aids whose function is to retain a maximum of fines and fillers in the sheet. The beneficial effects that result from the utilization of a retention aid are essentially:
increased production and reduction of production costs: energy savings, more reliable operation of the machine, higher yield in terms of fibers, fines, fillers and anionic finishing products, lower acidity in the circuit linked to a decrease in the use of aluminum sulfate, and hence a reduction in corrosion problems; an improvement in quality: better formation and better look-through, an improvement in the moisture content, the opacity, the gloss, and the absorptive capacity of the sheet, and a reduction in the porosity of the paper.
[0007] Long ago, it was proposed that bentonite be added to the pulp, possibly together with other mineral products such as aluminum sulfates or even synthetic polymers, notably polyethylene imine (see for example the documents DE-A-2 262 906 and U.S. Pat. No. 2,368,635).
[0008] In the document U.S. Pat. No. 3,052,595, it was proposed to associate the bentonite with a polyacrylamide of an essentially linear nature. This process met with competition from systems that were easier to use yet performed just as well. Moreover, even with the current linear polyacrylamides, the retention capacity is still insufficient.
[0009] In the document EP-A-0 017 353, it was proposed, for the retention of low-filler pulps (less than 5% fillers), to associate the bentonite with a nonionic to slightly anionic linear copolyacrylamide. This process has not been very widely used, since these polymers perform relatively poorly in terms of retention, especially that of pulps containing fillers, no doubt as a result of insufficient synergy between these copolymers and bentonite, which does not have much of a tendency to recoagulate.
[0010] In the document EP-A-0-235 893, it was proposed to use essentially linear cationic polyacrylamides having molecular weights of greater than one million, of thirty million and higher. This results in the obtainment of a retention effect that is satisfactory, but is still deemed inadequate in the papermaking application; since the use of bentonite causes problems during the subsequent treatment of the effluents issuing from the machine, users select this system only if there are significant advantages.
[0011] In the notes presented at the lecture given in Seattle on Oct. 11-13, 1989, published under the title “Supercoagulation in the control of wet end chemistry by synthetic polymer and activated bentonite,” R. Kajasvirta described the mechanism of supercoagulation of activated bentonite in the presence of a cationic polyacrylamide, without specifying its exact nature. This process has the same drawbacks as above.
[0012] Lastly, European Patent 0 574 335 produced an important improvement by proposing the use branched polymers (particularly polyacrylamides) in powder form.
[0013] The invention eliminates the drawbacks mentioned above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1-10 are histograms showing the data obtained as a result of the analyses performed in Example 1.
[0015] FIGS. 11-20 are histograms showing the data obtained as a result of the analyses performed in Example 2.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The object of the invention is to obtain an improved process of the type in question, which is comprised of adding to the suspension or fibrous mass or paper pulp to be flocculated, as the main retention aid, an agent consisting of or comprising a branched polyacrylamide which is: characterized in that it has been prepared in reverse phase or water-in-oil emulsion, and bentonite as the second retention aid (a so-called “dual” system of the type also known as “microparticulate”).
[0017] The phrase “exists in reverse phase emulsion” or similar expressions related to the polymer used (i.e., injected or introduced into the pulp to be flocculated) according to the invention, will be understood by one skilled in the art to designate the reverse phase water-in-oil emulsion that is dissolved in water before its injection or its introduction into the mass or pulp to be flocculated (this dissolution in water results in what is known as the “reversal” of the initial reverse phase water-in-oil emulsion; these processes are well known to one skilled in the art).
[0018] The additions of the polymer and the bentonite are separated by a shearing stage, for example at the level of the mixing pump known as a “fan pump.” In this field, the reader is referred to the specification of U.S. Pat. No. 4,753,710, as well as to a vast body of prior art related to the addition point of the retention aid relative to the shearing stages existing in the machine, including U.S. Pat. No. 3,052,595; Unbehend, TAPPI Vol. 59, No. 10, October, 1976; Luner, 1984 Papermakers Conference or TAPPI, April, 1984, pp. 95-99; Sharpe, Merck and Co., Inc., Rahway, N.J., USA, around 1980, Chapter 5, “Polyelectrolyte Retention Aids”; Britt, TAPPI Vol. 56, October 1973, p. 46 ff.; and Waech, TAPPI, March, 1983, p. 137; or even U.S. Pat. No. 4,388,150 (Eka Nobel).
[0019] The reader is also referred to U.S. Pat. No. 4,753,710 for all of the generalities related to paper production, the usual additives used, and similar details.
[0020] It is possible to replace the bentonite, as the secondary retention aid, with a kaolin, as described in the Applicant's French patent application 95 13051, this kaolin preferably being pretreated with a polyelectrolyte. One skilled in the art can refer to this French patent application 95 13051.
[0021] This process makes it possible to obtain a distinctly improved retention of fines and fillers without a reverse effect. An additional characteristic of this improvement is that the drainage properties are improved.
[0022] The branched polyacrylamide (or more generally the branched (co)polymer) is introduced into the suspension, in a distinctly preferred way, in the form of a reverse phase water-in-oil emulsion at a rate of 0.03 to one per mill (0.03 to 1%, or 30 to 1,000 g/t) by weight of active material (polymer) relative to the dry weight of the fibrous suspension, preferably 0.15 to 0.5 per mill, or 150 to 500 g/t.
[0023] In a way that is known to one skilled in the art, the reverse phase emulsion polymer is diluted in water and inverted (solubized) by this dilution before its introduction, as described above.
[0024] This selection of the reverse phase emulsion form makes it possible, in the papermaking application for the retention of fillers and fines, to reach a level of performance unequalled up to now. Moreover, the utilization of branched polymers makes it possible to obtain a better retention of the bentonite in the sheet, as described in the above-mentioned European patent 0 574 335, and thus to limit its negative effects on the subsequent treatment of the effluents issuing from the machine. Furthermore, the choice of this branched polyacrylamide increases the fixation capacity of the bentonite in the sheet, consequently resulting in a synergy, and hence a recoagulation, which reduces the bentonite content in the white water.
[0025] It is understood that it is essential according to the invention that the polymer be prepared by means of a reverse phase oil-in-water emulsion polymerization. However, this polymer can then be used (i.e., injected or introduced into the mass or pulp to be flocculated) either in the form—preferably—of this reverse phase emulsion after its dissolution in water, or in the form of a powder obtained by drying (especially drying by means of “spray drying”) the reverse phase emulsion from the polymerization, and then redissolving this powder in water, for example at a concentration on the order of 5 g of active polymer/liter, the solution thus obtained then being injected into the pulp at substantially the same polymer dosages.
[0026] Advantageously, in practice, the branched (co)polyacrylamide is a cationic copolymer of acrylamide and of an unsaturated cationic ethylenic monomer, chosen from the group comprising dimethylaminoethyl acrylate (ADAME), dimethylaminoethyl methacrylate (MADAME), quaternized or salified by different acids and quaterinizing agents, benzyl chloride, methyl chloride, alkyl or aryl chloride, dimethyl sulfate, diallyldimethylammonium chloride (DADMAC), acrylamidopropyltrimethyaammonium chloride (APTAC), and methacrylamidopropyltrimethylammonium chloride (MAPTAC).
[0027] In a known way, this copolymer is branched by a branching agent constituted by a compound having at least two reagent groups chosen from the group comprising the double bonds, aldehyde bonds, or epoxy bonds. These compounds are well known and are described, for example, in the document EP-A-0 374 458 (see also the Applicant's document FR-A-2 589 145).
[0028] As is known, a “branched” polymer is a polymer that has in the chain branches, groups or branchings globally disposed in one plane and not in the three directions, unlike a “cross-linked” polymer; branched polymers of this type, of high molecular weight, are well known as flocculating agents. These branched polyacrylamides are distinguished from the cross-linked polyacrylamides by the fact that in the latter, the groups are disposed three dimensionally so as to lead to practically insoluble products of infinite molecular weight.
[0029] The branching can be carried out preferably during (or possibly after) the polymerization, for example by reaction of two soluble polymers having counter-ions, or by reaction on formaldehyde or a polyvalent metal compound. Often, the branching is carried out during the polymerization by the addition of a branching agent, and this method is clearly preferred according to the invention. These processes for polymerization with branching are well known.
[0030] The branching agents that can be incorporated comprise ionic branching agents such as polyvalent metal salts, formaldehyde, glyoxal, or even, preferably, covalent cross linkers that will copolymerize with the monomers, preferably monomers with diethylenic unsaturation (like the family of diacrylate esters such as the diacrylates of polyethylene glycol PEG) or polyethylenic unsaturation, of the type classically used for the cross-linking of water-soluble polymers, and particularly methylenebisacrylamide (MBA), or any of the other known acrylic branching agents.
[0031] These agents are often identical to the cross linkers, but cross-linking can be avoided when desiring to obtain a polymer that is branched but not cross-linked, by optimizing polymerization conditions such as the concentration of the polymerization, type and quantity of transfer agent, temperature, type and quality of initiators, and the like.
[0032] In practice, the branching agent is methylenebisacrylamide (MBA), introduced at a rate of five to two hundred (5 to 200) moles per million moles of monomers, preferably 5 to 50.
[0033] Advantageously, the quantity of branched polyacrylamide introduced into the suspension to be flocculated is between thirty and one thousand grams of active polymer/ton of dry pulp (30 and 1,000 g/t), or between 0.03 per mill and one per mill, preferably 150 to 500 g/t; it was observed that if the quantity is lower than 0.03% (0.03 per mill), no significant retention is obtained; likewise, if this quantity exceeds 1% (1 per mill), no proportional improvement is observed; however, unlike the linear cationic polyacrylamides, as described in the documents EP-A-0 017 353 and EP 0 235 893 mentioned in the preamble, there is no observed reverse dispersion effect by recirculation in the closed circuits of the excess polymer not retained in the sheet. Preferably, the quantity of branched polyacrylamide introduced is between 0.15 and 0.5 per mill (0.15 and 0.5%) of the quantity of dry pulp, or between 150 g/t and 500 g/t.
[0034] As stated above, it is important that the branched polymer be prepared in reverse phase (water-in-oil) emulsion form in order to achieve the improvement of the invention. Emulsions of this type and the process for preparing them are well known to one skilled in the art.
[0035] This approach was condemned in the above-mentioned European patent 0 574 335, in which it was indicated that if a branched polymer is used in emulsion, the indispensable presence of surfactants in these emulsions promotes the formation of foams during the production of the paper and the appearance of disparities in the physical properties of the finished paper (modification of the absorbency in the places where part of the oil phase of the emulsion is retained in the sheet).
[0036] Therefore, it was not obvious to consider a fortiori the reverse phase water-in-oil emulsions whose oil content is clearly high.
[0037] The invention was even more difficult to achieve in that it was important to stay within the field of branched polymers and not to cross over to the field of cross-linked polymers. It is known that technically, especially on an industrial production scale, the borderline between the two areas is very easily crossed, in a way that is, moreover, irreversible. Since the branched area is very limited, the difficulty of developing the invention is considerable, and the Applicant deserves credit for undertaking to use of this technology in the field of paper production, which poses particular problems and has strict quality requirements.
[0038] The risk of failure, which may explain the fact that this technology had not been used, was even greater in that cross linked emulsions are not known to provide any particular advantage in paper.
[0039] In comparison with the linear polymers, the branched polymers in powder form of the above-mentioned European patent 0 574 335 had already made substantial progress relative to the properties and the paper production process. The improvement was on the order of 20 to 40% depending on the properties.
[0040] With the present branched emulsions, an improvement on the order of 50 to 60% is obtained, which would not have been foreseeable since, on the contrary, it was known that the cross linked products did not work.
[0041] According to the invention, in a preferred but non-limiting way, a “moderately branched” polymer is used, for example with 10 ppm of branching agent relative to the active material.
[0042] As already indicated above, the polymer can be used either in the form of its synthetic reverse-phase emulsion, dissolved or “inverted” in water, or in the form of the solution in water of the powder obtained by drying said synthetic: emulsion, particularly by means of spray-drying. Spray-drying is a process that is also known to one skilled in the art. The reader is referred to the tests below in order to verify that the results are comparable.
[0043] Bentonite, also known as “smectic swelling clay,” from the montmorillonite family, is well known and there is no need to describe it in detail here; these compounds, formed of microcrystallites, comprise surface sites having a high cation exchange capacity capable of retaining water (see for example the document U.S. Pat. No. 4,305,781, which corresponds to the document EP-A-0 017 353 mentioned above, and FR-A-2 283 102).
[0044] Preferably, a semisodic bentonite is used, which is introduced just upstream from the headbox, at a rate of 0.1 to 0.5 percent (0.1 to 0.5%) of the dry weight of the fibrous suspension.
[0045] As a filler, it is possible to use kaolins, GCC or ground CaCO 3 , precipitated CaCO 3 or PCC, and the like.
[0046] The branched polymer in reverse phase emulsion according to the invention is injected or introduced prior to a shearing stage into the paper pulp (or fibrous mass to be flocculated), which is more or less diluted according to the experience of one skilled in the art, and generally into the diluted paper pulp or “thin stock,” i.e. a pulp diluted to about 0.7 to 1.5% solid matter such as cellulose fibers, possible fillers, and the various additives commonly used in papermaking.
[0047] According to a variant of the invention with fractionated introduction, some of the branched polymer in emulsion according to the invention is introduced at the level of the stage for preparing the “thick stock” with about 5% or more solid matter, or even at the level of the preparation of the thick stock before a shearing stage.
[0048] The following examples illustrate the invention without limiting its scope.
Example 1
Production of a Branched Polymer in the Form of a Reverse Phase Water-in-Oil Emulsion
[0049] In a reactor A, the constituents of the organic phase of the emulsion to be synthesized are mixed at the ambient temperature.
a) Organic phase
252 g of Exxsol D100 18 g of Span 80 4 g of Hypermer 2296
b) In a beaker B, the aqueous phase of the emulsion to be produced is prepared by mixing:
385 g of acrylamide at 50% 73 g of ethyl acrylate trimethyl ammonium chloride 80% 268 g of water 0.5 g of methylenebisacrylamide at 0.25% 0.75 ml of sodium bromate at 50 g 1 −1 20 ppm of sodium hypophosphite relative to the active material 0.29 ml of Versenex at 200 g 1 −1
[0062] The contents of B are mixed into A under agitation. After the mixing of the phases, the emulsion is sheared in the mixer for 1 minute in order to create the reverse phase emulsion. The emulsion is then degassed by means of a nitrogen bubbling; then after 20 minutes the gradual addition of the metabisulfite causes the initiation followed by the polymerization.
[0063] Once the reaction is finished, a “burn out” (treatment with the metabisulfite) is carried out in order to reduce the free monomer content.
[0064] The emulsion is then incorporated with its inverting surfactant in order to subsequently release the polymer in the aqueous phase. It is necessary to introduce 2 to 2.4% ethoxylated alcohol. The standard Brookfield viscosity of said polymer is 4.36 cps (viscosity measured at 0.1% in a 1 M NaCl solution at 25° C. at sixty rpm).
[0065] In accordance with a variation of the MBA content from 5 to 20 ppm, the results in terms of UL viscosity are the followings
Table of Example 1:
[0066]
[0000]
IR
MBA
NaH 2 PO 2
UL
(1)
IVR (2)
Test
ppm
ppm (*)
Viscosity
(%)
(%)
State
R 52
5
20
4.56
12.8
0
Branched
R 102
10
20
3.74
28.9
0
Branched
SD 102
10
20
3.70
26
0
Branched
X 104
10
40
2.31
45
50
Cross-
linked
X 204
20
40
2.61
54.8
50
Cross-
linked
EM 140CT
0
15
4.5
0
<0
Linear
EM 140L
0
30
3.82
0
0
Linear
EM 140LH
0
40
3.16
0
<0
Linear
EM 140BD
5
0
1.85
80
100
Cross-
linked
FO 4198
5
20
3.2
5
<0
Branched
FO 4198: a branched powder containing 20 ppm transfer agent and 5 ppm branching agent.
(*) sodium hypophosphite, transfer agent
(1) ionic regain in %
(2) intrinsic viscosity regain in %
EM140CT: a standard emulsion of very high molecular weight containing no branching agent
EM 140L: a standard emulsion of high molecular weight containing no branching agent
EM140LH: an emulsion of average molecular weight containing no branching agent
EM140BD: a cross-linked emulsion containing no transfer agent and 5 ppm cross linker
SD 102: the emulsion R 102 dried by spray-drying, and the powder obtained dissolved in water to 5 g of active polymer/liter
[0067] It is noted that the linear products do not develop any ionic regain IR, and their intrinsic viscosity IV decreases under the effect of an intense shearing (two of the IV values are negative); the branched products in emulsion develop an ionic regain IR, but no IV (values <=0); the cross-linked products develop a high ionic regain and a very high IV regain.
DEFINITIONS OF THE IONIC REGAINS AND INTRINSIC VISCOSITY REGAINS
[0068] Ionic regain IR=(X−Y)/Y×100
with X: ionicity after shearing in meq/g.
Y: ionicity before shearing in meq/g.
Intrinsic viscosity regain IVR=(V1−V2)/V2×100
with V1: intrinsic viscosity after shearing in dl/g
V2: intrinsic viscosity before shearing in dl/g
[0069] Some of the emulsions cited above will be the subjects of a study of effectiveness in retention and drainage in an automated sheet former at the Center for Paper Technology.
Procedure for Testing the Emulsions
Pulp Used:
[0070]
[0000]
mixture of 70% bleached hardwood kraft
KF
10% bleached softwood kraft
KR
20% mechanical pulp
PM
20% natural calcium carbonate.
Sizing in a neutral medium with 2% of an alkyl ketene dimer emulsion.
[0072] The pulp used is diluted to a consistency of 1.5%. A sample of 2.24 dry g of pulp, or 149 g of pulp at 150%, is taken, then diluted to 0.4% with clear water.
[0073] The 560 ml volume is introduced into the plexiglass cylinder of the automated sheet former, and the sequence is begun.
[0000]
t = 0 s,
start of agitation at 1500 rpm.
t = 10 s,
addition of the polymer.
t = 60 s,
automatic reduction to 1000: rpm and, if necessary, addition
of the bentonite.
t = 75 s,
stopping of the agitation, formation of the sheet with vacuum
under the wire, followed by reclamation of the white water.
[0074] The following operations are then carried out:
measurement of the turbidity of the water under the wire. dilution of a beaker of thick stock for a new sheet with the reclaimed water under the wire. drying of the so-called 1st pass sheet. start of a new sequence for producing the so-called 2nd pass sheet.
[0079] After 3 passes, the products to be tested are changed.
[0080] The following analyses are then performed:
measurement of the matter in suspension in the water under the measurement of the ash in the sheets (TAPPI standard: T 211 om-93) measurement of turbidity 30′ after the fibers are deposited in order to learn the state of the ionic medium. measurement of the degree of drainability of the pulp with a Canadian Standard Freeness (CSF; TAPPI standard T 227 om-94).
Notes for FIGS. 1-20 Below:
[0085] X=so-called first-pass measurement
R1=so-called second pass-measurement (1st recycling)
R2=so-called third pass measurement (2nd recycling)
Ash %=% by weight of ash retained (=filler retention) in the sheet/weight of the sheet.
Comments on the Results:
[0086] The cross-linked polymers have no advantage as to the flocculation and the retention of fines and fillers in spite of the high rate of shear applied during the process to the fibrous mass (and not applied to the polymer itself), in this case 1,500 rpm, which is characteristic of this type of microparticulate retention systems They show a poor capture of fillers and colloidal matter, since no reduction in turbidity is observed.
[0087] The combination with bentonite does not significantly improve the effectiveness in terms of retention and only slightly improves the effectiveness in terms of drainage.
[0088] As for the linear polymer, its behavior follows the tendency to improve the retention of fillers and fines.
[0089] The combination according to the invention of a branched polymer in reverse phase emulsion and bentonite provides a net gain in filler retention and in total retention, and is revealed to be superior to the known linear polymer/bentonite system.
[0090] The coagulation capacity is better for a branched polymer in emulsion, which translates into an excellent reduction in the turbidity at 30′ (30 min.).
[0091] The R 52 test and the R 102 test show that the invention makes it possible to obtain branched products having UL viscosities higher than those accessible through gel polymerization as described in European patient 0 574 335. Any attempt to reach such highly advantageous UL viscosity values using a gel polymerization process with drying into a powder would result in a product that was totally insoluble and therefore totally unusable in the industry.
[0092] The SD 102 test shows that the polymer used in the form of a solution in water of the powder obtained by drying the reverse phase emulsion from the synthesis of the polymer behaves like the polymer used in the form of the solution in water of said synthetic reverse phase emulsion. In particular, no degradation of the polymer is observed during the stage for drying by means of spray-drying.
[0093] It is useful to compare the R 52 test to the FO 4198 test (powder), since the polymers have the same chemistry, hence the same cationicity, and the same % of MBA, while the R52 of the invention is far superior to the powder in terms of drainage and retention (96.3 as compared to 87.6); compare also the turbidity in NTU after 30 minutes, 32 as compared to 75 NTU units.
[0094] Such UL viscosity values specifically result in substantially improved drainage.
[0095] The invention also relates to a novel retention aid for the production of a sheet of paper, paperboard or the like, which is comprised of a branched acrylic (co)polymer as described above, in reverse phase emulsion, which is characterized in that its UL viscosity is >3, or >3.5 or >4. Said agent can be used either in emulsion, inverted in water, or in a solution of the powder obtained by drying the emulsion, as described above.
Example 2
Production of a Branched Acrylamidopropyltrimethylammonium Chloride (APTAC) Based Polymer in the (Corm of a Reverse Phase Oil-in-Water Emulsion
[0096] In a reactor A, the constituents of the organic phase of the emulsion to be synthesized are mixed at the ambient temperature.
a) Organic phase
252 g of Exxsol D100 18 g of Span 80 4 g of Hypermer 2296
b) In a beaker B, the phase of the emulsion to be produced is prepared by mixing:
378 g of acrylamide at 50% 102.2 g of acrylamidopropyltrimethylamonium chloride (60%) 245.7 g of water 0.5 g of methylenebisacrylamide at 0.25% 0.75 ml of sodium bromate at 50 g/1 20 ppm of sodium hypophosphite relative to the active material 0.29 ml of Versenex at 200 g/1
[0109] The contents of B are mixed into A under agitation. After the mixing of the phases, the emulsion is sheared in the mixer for 1 minute in order to create the reverse-phase emulsion. The emulsion is then degassed by means of a nitrogen bubbling; then after 20 minutes, the gradual addition of the metabisulfite causes the initiation followed by the polymerization.
[0110] Once the reaction is finished, a “burn out” is carried out in order to reduce the free monomer content.
[0111] The emulsion is then incorporated with its inverting surfactant in order to subsequently free the polymer in the aqueous phase.
Table of Example 2:
[0112]
[0000]
MBA
NaH 2 PO 2
UL
IR (1)
IVR (2)
Test
PPM
ppm (*)
viscosity
(%)
(%)
State
M 52
5
20
4.20
14.2
0
Branched
M 102
10
20
3.34
21.3
0
Branched
XM 104
10
40
2.11
37
50
Cross-
linked
XM 204
20
40
1.94
58
55
Cross-
linked
EK 190
0
15
4.35
0
0
Linear
EK 190
5
0
1.85
78
60
Cross-
BD
linked
EK 190: a standard emulsion of a copolymer of acrylamide and crylamidopropyltrimethylammonium chloride, linear.
Procedure for Testing the Emulsions
[0000]
(identical to that of Example 1)
Comments on the Results:
[0114] The results invite the same comments as those of Example 1 and confirm the great advantage of the present invention.
[0115] The invention also relates to the novel retention aids described above, characterized in that they consist of, or comprise, at least one branched (co)polymer of the type described, prepared in reverse phase emulsion, intended to cooperate with a secondary retention aid after an intermediate stage for shearing the paper pulp, as well as to the processes for producing sheets of paper, paperboard or the like using the agents according to the invention or the process according to the invention, and the sheets of paper, paperboard and the like thus obtained.
[0116] Said agent can be used either in emulsion inverted in water, or in a solution of the powder obtained by drying the emulsion, as described above. | The invention concerns an improved method for making paper, which uses a branched polymer prepared in invert emulsion as the main retention agent, and bentonite as a secondary retention agent (dual type system). The two additions are separated by a step for shearing the fibrous suspension (or mass). The invention results in highly improved retention and also highly improved dewatering. Moreover, it enables the bentonite content in white water to be reduced. | 3 |
RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 10/631,474, filed on Jul. 31, 2003 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for molding garments and the garments made. More particularly, the present invention relates to a method for molding a lofted material having a laminated support layer and the resultant garment.
2. Description of the Prior Art
Various methods and mechanisms for molding different types and assemblies of material have been developed and are known. For example, U.S. Pat. No. 3,464,418 provides an apparatus and method for making brassiere pads from bonded non-woven fibrous batting material, U.S. Pat. No. 4,025,597 provides a method of making a brassiere cup from a soft fibrous board material, U.S. Pat. No. 4,080,416 provides a method for making multi-layered seamless brassiere pads, and U.S. Pat. No. 4,250,137, which provides a process for preparing breast pads or fronts such that the pads are centrally soft and peripherally firmer.
Notwithstanding that which is known, there remains a continuing need for improved methods for molding lofted material having a laminated support layer to provide a three dimensional shape thereto without compromising the loft characteristics associated with such material. Problems heretofore associated with various processes of molding a lofted material include at least the following: (1) thinning of material at points of increased pressure or applied heat, or both, such as for example, the apex of a bra cup or pad, (2) requiring relatively complicated or additional structural elements, or both to facilitate a desired result, for example, spacer devices or vacuum systems, and (3) requiring that heat, pressure or both be avoided at relatively substantial portions of the material being molded, which can complicate the molding process.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide method for molding lofted material having a nylon laminated support layer.
It is another object of the present invention to provide a garment that is made from a lofted material that has a nylon laminated support layer that is molded to maintain the loft characteristics of such lofted material.
It is yet another object of the present invention to provide a garment that is molded from a lofted material that has a laminated synthetic support layer.
It is still yet another object of the present invention to provide a brassiere that is molded from a lofted assembly having a lofted material and a laminated synthetic support layer that is deeply molded to provide support for a large sized brassiere.
These and other objects and advantages of the present invention are achieved by a molding apparatus with at least a first die or mold with a projecting element and a first level portion, and a second die or mold with a recessed element and a second level portion. The projecting element and the recessed element are formed such that when the first level portion of the first mold and the second level portion of the second mold are brought into relatively close relation, a uniform preset distance or gap is created between the projecting element and the recessed element. The gap is preferably adjustable to accommodate the loft of different materials. The first mold and second mold each are preferably selectively and/or independently heatable and configured as appropriate to facilitate the following material molding method.
The method for molding the lofted material essentially comprises the steps of first, placing pre-cut piece of nylon support fabric that is in a pre-determined position on a piece of lofted material, laminating the two materials together to form a lofted assembly, and positioning the lofted assembly in the molding apparatus. Then, closing the first mold in relation to the second mold, or vice-versa, sandwiching the lofted assembly therebetween such that the portion of the lofted assembly situated between the first and second level portions is compressed and the portion of the lofted assembly situated between the projecting element and recessed element is compressed only to the extent desired or not at all. The extent of compression being adjustable. Following this closing step is a step of opening the first mold in relation to the second mold after a period of selectively providing pressure and/or heat as appropriate for the desired molding result. The resulting molded lofted assembly preferably providing a balance of comfort, support and durability.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference characters denote like elements of structure.
FIG. 1 is a top view of the lofted material that is to be molded in accordance with an illustrative embodiment of the present invention;
FIG. 2 is a top view of the pre-cut piece of synthetic support fabric that is to be laminated to the lofted material in accordance with the present invention;
FIG. 3 is top view of the laminated assembly of lofted material and the synthetic support fabric in accordance with the present invention;
FIG. 4 is a cross-sectional side view of an apparatus for molding a lofted assembly in accordance with an illustrative embodiment of the present invention with the apparatus shown in open position;
FIG. 5 is a cross-sectional side view of the apparatus of FIG. 4 with the apparatus shown in a closed position;
FIG. 6 is a side sectional view of the apparatus of FIG. 4 , reflecting a forming step in accordance with an illustrative embodiment of the present invention;
FIG. 7 is a side sectional view of an alternative apparatus for molding a lofted assembly;
FIG. 8 is a side sectional view of another alternative apparatus for molding a lofted assembly;
FIG. 9 is a plan view of yet another alternative apparatus for molding a lofted assembly;
FIG. 10 is a plan view of still another alternative apparatus for molding a lofted assembly;
FIG. 11 is a side sectional view of yet still another alternative apparatus for molding a lofted assembly; and
FIG. 12 is a front perspective view of a brassiere with the lofted assembly molded in the form of a breast-receiving cup.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and, in particular to FIG. 1 , there is shown an illustrative embodiment of the lofted material generally represented by reference numeral 30 . In this disclosure, the term lofted material 30 includes foam and circularly knitted and/or warp knitted single ply materials that can be a variety of materials or combination of materials (batting, spacer fabric, etc.). Spacer fabric could be a polyester and/or nylon fabric. Lofted material 30 is sized to form a deep breast-receiving cup for a brassiere after being molded.
Referring to FIG. 2 , support fabric 32 is shown. Support fabric 32 is cut in the shape of a crescent to ensure a comfortable and close fit at the lower lateral portion of the finished breast-receiving cup. Although the shape of support fabric 32 is shown as a crescent, other shapes capable of offering comfort and support to the wearer could also be used. Support fabric 32 can be any synthetic material. Preferably, the support fabric 32 is a warp knit material, such as, nylon Jacquard, lace, woven, or knitted material. In all instances, support fabric 32 provides the level of comfort and support to the breasts of the wearer that would otherwise not be available without the enhanced support. Support fabric 32 can have any design such as for example a floral design although any design such as a geometric pattern could also be used.
In FIG. 3 , support fabric 32 is pre-positioned on lofted material 30 before the two pieces of fabric are laminated together. A layer of adhesive is placed on support fabric 32 before it is placed on lofted material 30 . The adhesive is a glue that is heat activated and can be a film, a web or polyester. The temperature that is required to laminate support fabric and lofted material 30 is approximately 320° F. to 360° F. The lamination process is of a temperature that will preserve the loft and the aesthetic appeal of the lofted material 30 and the support fabric. After the lamination process, lofted material 30 and the support fabric 32 together form lofted assembly 36 .
Referring to the drawings and, in particular to FIG. 4 , there is shown an illustrative embodiment of an apparatus for molding lofted assembly 36 . The apparatus 1 preferably has at least two mold elements, a first mold 10 and a second mold 20 . Preferably, the first mold 10 and the second mold 20 are complementary to one another.
Preferably, first mold 10 and second mold 20 cooperate to mold or form a lofted assembly 36 positioned therebetween into a three-dimensional shape, such as, for example, that required by molded brassiere pads. Preferably, lofted assembly 36 can be any of a variety of materials or combination of materials and can be fashioned into a variety of forms, such as for example, a garment.
First mold 10 preferably has at least one first contact surface 40 with at least one projecting element 50 in the form of a dome. First contact surface 40 preferably also has a first level portion 42 about projecting element 50 . First contact surface 40 may also have any of a variety of other surface elements 43 associated therewith, such as for example, one or more nodes, dimples, and/or teeth as shown in FIGS. 9 through 11 . First contact surface 40 can be interchangeably associated with first mold 10 . First mold 10 can be interchangeably associated with apparatus 1 . The interchangeability of first contact surface 40 and/or first mold 10 preferably provides apparatus 1 with further diversity in application or use.
Preferably, first mold 10 , first contact surface 40 , projecting element 50 , and/or first level portion 42 can be heatable. This heating can be accomplished in any of a variety of ways, such as for example, via electric heating wires or rods associated with first mold 10 . These heating wires or rods could preferably conduct or transmit heat, via first mold 10 , as appropriate, to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. First mold 10 can preferably have any shape, size, and/or configuration suitable for accomplishing one or more different molding operations. See, for example, FIGS. 7 and 8 , which show alternative embodiments of first mold 10 . It is noted that the present invention is not limited to those configurations discussed and/or shown and that other configurations are also within the scope of the present invention.
It is also noted, with regard to surface elements 43 discussed above, that surface elements 43 are preferably suitable for achieving a variety of different molding effects. For example, surface elements 43 can be on either and/or both projecting element 50 and first level portion 42 to interact with lofted assembly 36 during a molding process. Surface elements 43 can be, for example, one or more piercing elements, heating or cooling elements, cushioning or insulating elements, or any combination of the same. Other similar types of elements may also be used and are within the scope of the present invention.
Referring again to FIG. 4 , second mold 20 has at least one second contact surface 60 with at least one recessed element 70 in the form of a dish. Preferably, recessed element 70 is complementary to and cooperative with projecting element 50 of first mold 10 . Second contact surface 60 preferably also has a second level portion 62 about recessed element 70 . Second contact surface 60 may also have surface elements 43 associated therewith. Second contact surface 60 can be interchangeably associated with second mold 20 , and, the second mold can be interchangeably associated with apparatus 1 . The interchangeability of second contact surface 60 and/or second mold 20 preferably provides apparatus 1 with further diversity in application or use.
Preferably, second mold 20 , second contact surface 60 , recessed element 70 , and/or second level portion 62 can be heatable. Such heating can be accomplished in any of a variety of ways, such as, for example, by electric heating wires or rods associated with second mold 20 . These heating wires or rods could preferably conduct or transmit heat, via second mold 20 , as appropriate to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. Second mold 20 can preferably have any shape, size, and/or configuration suitable for accomplishing one or more different molding operations in cooperation with mold 10 . See, for example, FIGS. 7 and 8 , which show alternative embodiments of second mold 20 . It is noted that the present invention is not limited to those configurations discussed and/or shown and that other configurations are also within the scope of the present invention.
As with the first mold 10 , surface elements 43 for providing a variety of different molding effects that can be on either and/or both recessed element 70 and second level portion 62 to interact with lofted assembly 36 during the molding process.
Referring to FIGS. 5 and 6 , having described some of the preferred elements of an illustrative embodiment of the present invention, first and second molds 10 , 20 , respectively, are preferably configured to engage one another such that when first level portion 42 of first mold 10 and second level portion 62 of second mold 20 are brought into relatively close relation, a uniform preset distance or gap 80 is created between projecting element 50 and recessed element 70 . Gap 80 preferably has an extent of about 0.1 inches. However, gap 80 can also have any extent appropriate for accomplishing a desired molding operation. Hence, gap 80 can preferably be adjusted to accommodate the loft characteristics associated with a variety of different materials. This adjusting feature can be accomplished in different ways, such as, for example, via the preferred interchangeability of first and second molds 10 , 20 and/or first and second contacting surfaces 42 , 62 . Gap 80 may also be adjusted to influence the degree of loft associated with a material. That is, gap 80 can be reduced to provide a desired finish or effect to a lofted assembly 36 . Thus, it is apparent the preservation of the inherent loft characteristics associated with a lofted assembly is preferably independent of the heat, pressure and/or time associated with a particular molding process. The present invention efficiently and effectively preserves the inherent loft characteristics associated with a lofted assembly during the molding process.
The process of molding lofted assembly 36 preferably includes at least the following steps. Referring to FIG. 1 , lofted assembly 36 is first positioned in apparatus 1 between first mold 10 and second mold 20 . On lofted assembly 36 , support fabric 32 is positioned so that after the molding process, support fabric 32 will be positioned at the lower side edge of lofted assembly. Referring to FIG. 2 , first mold 10 is then closed in relation to second mold 20 , or vice-versa, to sandwich lofted assembly 36 therebetween. Preferably, at least a portion of lofted material 30 is situated in gap 80 so that the inherent loft characteristics thereof are substantially preserved while at least another portion of lofted assembly 36 is substantially compressed between first and second level portions 42 , 62 of first and second contact surfaces 40 , 60 , respectfully. Next, first mold 10 is opened in relation to second mold 20 , or vice-versa, after an appropriate amount of heat and/or pressure has been applied for an appropriate period of time. Then, the molded lofted assembly is removed from apparatus 1 to perform any additional operations required for obtaining a desired effect, such as for example, eliminating any excess or unwanted material as appropriate to leave lofted assembly 36 with a three dimensional shape.
Referring to FIGS. 1 through 3 and 12 , the molding process is capable of producing a three-dimensional lofted assembly 36 , in the form of a breast-receiving cup 90 having at the lower lateral position, the support fabric 32 . The breast-receiving cup 90 is shown in a brassiere 100 in FIG. 12 . An advantage of the molding process is that cup 90 can be very deeply molded to accommodate wearers having large breasts. The material of support fabric 32 is of such stitch pattern and material that it limits the elasticity of the lofted material 30 from which cup 90 is made. By limiting the elasticity of the lofted material 30 , wearers that require substantial breast support can wear cup 90 with comfort and confidence.
The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined herein. | A method for molding a lofted assembly having a lofted material and a laminated nylon support material the garment produced are provided. The method includes the steps of positioning a support fabric on a lofted material; laminating the support fabric to the lofted material to form a lofted assembly; positioning the lofted assembly in a molding apparatus having at least a first mold and a second mold, closing together the first mold and the second mold thereby sandwiching the lofted assembly therebetween and while maintaining a uniform preset gap between said first mold and the second mold so that the inherent loft characteristics of the lofted assembly are substantially preserved. | 0 |
TECHNICAL FIELD
The present invention relates generally to a control system to adapt a sewing machine for semi-automatic operation. More particularly, this invention is directed to an adaptive sewing machine control system incorporating a microprocessor controller in combination with a stitch counter, an edge sensor and stitch length control apparatus to achieve more precise seam lengths and end points.
BACKGROUND OF THE INVENTION
In the sewn goods industry, where various sections of material are sewn together to fabricate products, precise seam lengths and end points are often necessary for proper appearance and function of the finished products. For example, the top stitch seam of a shirt collar must closely follow the contour of the collar and terminate at a precise point which matches the opposite collar. Accurate seam lengths must similarly be maintained in the construction of shoes when sewing together vamps and quarter pieces to achieve strength as well as pleasing appearance. Achieving consistently accurate seam lengths and end points at high rates of production has, however, been a long standing problem in the industry.
Microprocessor controllers have been developed which convert manually operated sewing machines into semi-automatic sewing systems. U.S. Pat. Nos. 4,108,090; 4,104,976; 4,100,865; and 4,092,937, assigned to the Singer Company are representative of such devices. Each of those patents discloses a programmable sewing machine with three operational modes: manual, teach and auto. Control parameters are programmed into the system for subsequent control of the sewing machine in the auto mode. Those microprocessors control all sewing machine functions such as sewing speed, presser foot position, thread trimmer, reverse sew mechanism and the number of stitches sewn in each individual seam. Accurate control of seam lengths is one of the important aspects of those systems.
U.S. Pat. No. 4,404,919, issued Sept. 20, 1983, entitled "Control System for Providing Stitch Length Control of a Sewing Machine", and assigned to assignor describes a microprocessor controlled sewing system which improves upon the seam length accuracy of those systems. The described system controls seam length accuracy using a combination of stitch counting, edge detection and stitch length control techniques. Control of seam lengths and end points is achieved in the system by initiating countdown of a variable number of final whole and partial stitches responsive to detection of the end of the material being sewn by sensors located ahead of the needle. Though the system disclosed in U.S. Pat. No. 4,404,919 provides improved accuracy over the previous systems which relied solely upon stitch counting to determine seam lengths and end points, the system does not account for variations in stitch length with respect to sewing speed. It is known, for example, that stitches sewn at higher speeds are generally longer than stitches sewn at lower speeds. Thus, in a system where a combination of edge sensing and stitch counting is used to accurately control seam margins, stitch length changes due to speed variances may nonetheless cause inaccurate results.
A need has thus arisen for an improved adaptive sewing machine control system which includes a stitch length control technique which compensates for sewing speed.
SUMMARY OF INVENTION
The present invention comprises an adaptive sewing machine control system which substantially improves seam length accuracy by including means for compensating for stitch length changes attributable to speed variances.
In accordance with the invention, there is provided a system including a microprocessor controller which can be programmed with or taught a sequence of sewing operations by the operator in one mode for automatically controlling the machine during subsequent sewing of similar pieces of the same or different sizes in another mode. The semi-automatic system uses a combination of stitch counting and material edge detection techniques to achieve more accurate seam length and end point control.
More specifically, this invention comprises a microprocessor-based control system for an industrial sewing machine. The system has manual, teach and auto modes of operation. In the preferred embodiment, one or more sensors are mounted in front of the presser foot for monitoring edge conditions of the material at the end of each seam. In the teach mode, operating parameters are programmed into the controller by the operator. For each seam, the number of whole and partial stitches x sewn after the desired status change in the sensors are recorded along with sewing machine and auxiliary control inputs. In the auto mode, the number of stitches sewn in each seam is monitored until the characteristic sensor pattern indicating edge detection is seen, at which time x additional stitches are sewn to complete the seam.
The actual number of additional stitches sewn is determined by monitoring the speed of the sewing machine at the time the material edge is detected and comparing that speed to a predetermined reference speed. The number x of stitches remaining to be sewn is then dynamically adjusted to compensate for the speed variance from the reference speed.
BRIEF DESCRIPTION OF DRAWINGS
A more complete understanding of the invention can be had by reference to the following detail description taken in conjunction with the accompanying Drawing, in which:
FIG. 1 is a perspective view of a programmable sewing system incorporating the invention;
FIG. 2 is a front view illustrating placement of the edge sensor relative to the sewing needle;
FIG. 3 is a sectional view taken along lines 3--3 of FIG. 2 in the direction of the arrows;
FIG. 4 is an end view of the sewing system illustrating the automatic control apparatus of the sewing machine reverse mechanism;
FIG. 5 illustrates the variations in stitch length caused by speed differences; and
FIG. 6 is a flow chart of the technique of the present invention to dynamically alter the number of stitches sewn after the material edge is detected.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the Drawing, wherein like reference numerals designate like or corresponding parts throughout, FIG. 1 illustrates a semi-automatic sewing system 10 incorporating the invention. System 10 is a microprocessor-based system adapted to extend the capabilities of a sewing machine to enable the operator to perform sewing procedures on a manual or semi-automatic basis.
System 10 includes a conventional sewing machine 12 mounted on a work stand 14 consisting of a table top 16 supported by four legs 18. Sewing machine 12, which is of conventional construction, includes a spool 20 containing a supply of thread for stitching by a reciprocable needle 22 to form a seam in one or more pieces of material. Surrounding needle 22 is a vertically movable presser foot 24 for cooperation with movable feed dogs (not shown) positioned within table top 16 for feeding material past the needle.
A number of standard controls are associated with sewing machine 12 for use by the operator in controlling its functions. A handwheel 26 is attached to the drive shaft (not shown) of machine 12 for manually positioning needle 22 in the desired vertical position. Sewing speed is controlled by a speed sensor 15 which is actuated by a foot treadle 28, which functions as an accelerator. Vertical positioning of presser foot 24 can be controlled by heel pressure on foot treadle 28 which closes a switch 19 in speed sensor 15, which in turn causes the presser foot lift actuator 30 to operate. A leg switch 32 is provided for controlling the sewing direction of machine 12 by causing operation of a reverse sew mechanism 17. A toe switch 34 located adjacent to foot treadle 28 controls a conventional thread trimmer (not shown) disposed underneath the throat plate 36 of machine 12. Foot switch 38 on the other side of foot treadle 28 comprises a one-stitch switch for directing machine 12 to sew a single stitch.
Sewing machine 12 and its associated manual controls are of substantially conventional construction, and may be obtained from several commercial sources, e.g., Singer, Union Special, Pfaff, Consew, Juki, Columbia, Brother or Durkopp Companies.
In addition to the basic sewing machine 12 and its manual controls, system 10 includes several components for adapting the sewing machine for semi-automatic operation. One or more sensors 40 are mounted in laterally spaced-apart relationship in front of needle 22 and presser foot 24. A drive unit 42 comprising a variable speed direct drive motor, sensors for stitch counting and an electromagnetic brake for positioning of needle 22, is attached to the drive shaft of sewing machine 12. A main control panel 44 supported on a bracket 46 is provided above one corner of work stand 14. A pneumatic control chassis 48 containing an air regulator, filter and lubricator for the sewing machine control sensors, pneumatic actuators and other elements of system 10 is provided on one side of work stand 14. All of these components are of known construction and are similar to those shown in U.S. Pat. Nos. 4,108,090; 4,104,976; 4,100,865 and 4,092,937, the disclosures of which are incorporated herein by reference.
A controller chassis 50 is located on the opposite side of work stand 14 for housing the electronic components of system 10. Chassis 50 includes a microprocessor controller 51, appropriate circuitry for receiving signals from sensors and carrying control signals to actuators, and a power module for providing electrical power at the proper voltage levels to the various elements of system 10. The microprocessor controller 51 may comprise a Zilog Model Z-80 microprocessor or any suitable unit having read only memory (ROM) and random access memory (RAM) of adequate storage capacities. An auxiliary control panel 52 is mounted for sliding movement in one end of chassis 50.
Referring now to FIGS. 2 and 3, further details of edge sensors 40 and their cooperation with needle 22 can be seen. Sensors 40 may be mounted directly on the housing of sewing machine 12, or supported by other suitable means. Each sensor 40 comprises a lamp/photosensor which projects a spot of light 40a onto a reflective tape strip 54 on throat plate 36. The status of each sensor 40 is either "on" or "off" depending upon whether or not the light beam thereof is interrupted, such as by passage of the trailing edge or discontinuity of the particular piece of material.
Sensors 40 are positioned in mutually spaced relationship ahead of needle 22 of sewing machine 12. The condition of at least one sensor 40 changes as the trailing material edge passes thereunder to indicate approach of the seam end point. Sensors such as the Model 10-0672-02 available from Clinton Industries of Carlstadt, N.J., have been found satisfactory as sensors 40, however, infrared sensors and emitters, or pneumatic ports in combination with back pressure sensors could also be utilized, if desired.
Circuitry is provided in chassis 50 which detects the output of sensors 40 to generate electrical signals representative of the material edge. Controller 51 is responsive to such edge detection for allowing a selected number of stitches to be sewn after the edge detection.
As described in U.S. Pat. No. 4,404,919, the system may first be operated in a teach mode and thereafter operate in an auto mode. The system may be taught in the teach mode to sew x stitches after the material edge is detected where x can be a combination of whole and partial stitches. Thereafter, when the system is operated in the auto mode, the edge of the material will be automatically detected by the sensor and the machine will then automatically sew x stitches before terminating the seam. In this manner, automatic operation of the system is provided to increase the speed and accuracy of the system without human intervention. The present system operates in essentially the same manner as the system described in U.S. Pat. No. 4,404,919 the disclosure of which is incorporated herein by reference with additional improvement and accuracy being provided by the present invention as will be subsequently described.
In operation of the system thus described, as a seam is sewn by the machine, the number of stitches from the starting point are counted by the encoder within drive unit 42. The reflective tape 54 will be covered by the material and the beams of the sensors 40 are blocked by the material. When the edge of the material moves past the reflective tape 54, the sensor beams are reflected from the reflective tape 54 and sensed. This provides the system with an indication of the location of the edge of the material so that the seam length can be stopped at a given distance from the material edge. The system is originally taught by the operator to sew a given number of whole and partial stitches x in a seam after the edge of the material is detected, and will then sew x stitches before terminating the seam. Depending upon the percentage of the stitch which has been sewn at the time of detection of the material edge, the reverse sew mechanism is positioned to vary the length of the last stitch sewn to provide increased accuracy to the seam termination.
Referring to FIG. 4, an enlarged view of the reverse sew assembly is illustrated. A stepper motor 21 is actuated to pivot reverse sew mechanism 17 about a pivot point 23. Mechanism 17 is illustrated in the solid line position in its normal operating position in the forward sew mode. When the stepper motor 21 is actuated, mechanism 17 is pivoted about pivot point 23 to reduce the length of the last stitch in the seam. It will be understood too that other techniques may be used to vary the length of the last stitch. For example, the material feeding mechanism, known as feed dogs, may be retracted by an air cylinder while the last stitch is being formed. The air cylinder may be operated by a solenoid control actuated by the microprocessor to accurately vary the length of the last stitch formed.
Though the combination of edge detection technique, stitch counting and last stitch variation will theoretically ensure accurate seam margins, stitch length changes due to speed variances may nonetheless cause inaccurate results. In most sewing machines the stitch length will vary with respect to sewing speed, with stitches sewn at higher speed being generally longer than stitches sewn at lower speeds. That phenomenon is illustrated in FIG. 5, which shows two seams, A and B. Seam A is sewn at a higher sewing speed than is seam B and its stitches are therefore longer than the stitches of seam B. Thus, if in this example, the stitches of Seam A are 10% longer than Seam B and if in both instances the system sews 4.15 additional stitches after the sensor detects the edge of the material being sewn at the "sensor-on" point, the end of seam A will be approximately 0.41 stitch closer to the edge of the material than will the end of seam B because of the differences in stitch length.
The system of the present invention eliminates that source of inaccuracy by providing a technique which dynamically alters the number of additional stitches sewn after the sensor detects the material edge to compensate for the sewing speed. FIG. 6 is a flow chart illustrating the operation of the present invention. The steps are implemented by suitable programming of microprocessor controller 51. The program is suitable for adaptation to the Zilog Z-80 microprocessor and may be written into Z-80 assembly language in a manner known to the art.
In accordance with the invention, the system sews until the edge of the material is detected at 60. The sewing speed at edge detection is then determined at 62 and compared to a predetermined reference speed at 64. The reference speed may be input by the operator through control panel 44 and stored in the microprocessor memory. If the detected sewing speed equals the reference speed, no adjustment is required and the system will then sew "N" additional stitches, where "N" represents the x stitches programmed to be sewn after edge detection. If the sewing speed is not equal to the reference speed, the number of additional stitches, "N", will be adjusted at 66 to compensate for the speed variance from the reference speed. In FIG. 6, the number of additional stitches sewn is adjusted at 66 by the ratio of the sewing speed to the reference speed. Controller 51 may alternatively be programmed to apply a constant factor of adjustment or to apply a variable factor depending upon only the type of sewing machine or only upon the sewing speed at edge detection. If either of the last two techniques is used, a "look-up" table containing the adjustment factors required for the various sewing machines or sewing speeds is stored in memory and provided as data to controller 51. It will be understood that such stored tables will vary in accordance with different sewing machines and operating conditions. For example, a needle feed sewing machine will typically have less variation in stitch length due to speed than does a drop feed sewing machine.
By adjusting the number of stitches sewn after the sensor detects the material edge to compensate for sewing speed at the time the sensor detects the material edge, accurate seam margins are maintained without regard to sewing speed.
Whereas the present invention has been described with respect to the preferred embodiment thereof, it should be understood that various changes and modifications will be suggested to one skilled in the art, and can be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | An adaptive semi-automatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed motor and encoder for counting stitches sewn and for sensing the rotation of the motor, at least one material edge sensor (40) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edge of the sensors (40). The speed of the sewing machine at the time the material edge is detected is monitored and compared to a reference speed. The number of final stitches is then dynamically adjusted to compensate for the speed variance from the reference speed. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/236,819, filed Sep. 20, 2011, which issued as U.S. Pat. No. 8,224,363 on Jul. 17, 2012, which is a continuation of U.S. patent application Ser. No. 12/552,779, filed Sep. 2, 2009, which issued as U.S. Pat. No. 8,032,164 on Oct. 4, 2011, which claims the benefit of U.S. Provisional Application No. 61/099,097 filed Sep. 22, 2008, the contents of which are hereby incorporated by reference herein.
TECHNICAL FIELD
This application is related to wireless communications.
BACKGROUND
Current efforts in the third generation partnership project (3GPP) long term evolution (LTE) program aim to bring new technology, new architecture, and new methods to provide improved spectral efficiency, reduced latency, and better utilization of radio resource to bring faster user experiences and richer applications and services with lower cost. Enabling the traditional commercially viable wireless services, especially the short message service (SMS), would greatly enhance the acceptance of the LTE technology in the wireless service product market.
In the current LTE specification, the SMS service is either not fully defined or it depends on the Internet protocol (IP) multimedia service (IMS) based SMS service or the circuit switched (CS) fallback methodology, such that the overhead of development cost is large, the network service interactions are complex and the transport efficiency is low. For supplementary services (SS) in LTE, the supportability has yet to be defined and enabled.
It would be desired to provide methods and apparatus that enable SMS and SS in LTE with implementation and backbone routing simplicity, while achieving overall data transport efficiency.
SUMMARY
Methods and apparatus for communicating SMS and SS messages in an LTE network via evolved packet system (EPS) mobility management (EMM) over the LTE control plane are described. A radio resource control (RRC) connection signaling radio bearer (SRB)-2 may be used for SMS and SS transport over the LTE control plane between a wireless transmit/receive unit (WTRU) and a mobility management entity (MME). EMM interfaces and primitives are defined for actions towards SMS and SS entities for enabling SMS and SS services in LTE via the LTE control plane media. Message formats for SMS and SS message transport are also disclosed for sending SMS and SS messages within EMM uplink (UL) non-access stratum (NAS) transport and downlink (DL) NAS transport messages.
BRIEF DESCRIPTION OF THE DRAWINGS
A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:
FIG. 1 shows a wireless communication system including a WTRU having a protocol entity architecture;
FIG. 2 shows a wireless communication system with a WTRU having an alternate protocol entity architecture;
FIG. 3 shows a procedure for supporting an outgoing SMS;
FIG. 4 shows a procedure for supporting an incoming SMS;
FIG. 5 shows call independent supplementary services supported using the systems of FIGS. 1 and 2 ;
FIG. 6 shows an overall NAS message header format for EMM;
FIG. 7 shows an EMM message UL/DL transport format;
FIG. 8 shows an SMS and SS message header plus payload format;
FIG. 9 shows an EMM message format supporting SMS and SS in LTE;
FIG. 10 is a signaling diagram for a mobile terminated (MT) SMS procedure; and
FIG. 11 is a signaling diagram for an MT SS procedure.
DETAILED DESCRIPTION
When referred to hereafter, the terminology “wireless transmit/receive unit (WTRU)” includes but is not limited to a user equipment (UE), a mobile station, a fixed or mobile subscriber unit, a pager, a cellular telephone, a personal digital assistant (PDA), a computer, or any other type of user device capable of operating in a wireless environment.
When referred to hereafter, the terminology “evolved Node-B (eNodeB)” includes but is not limited to a base station, a site controller, an access point (AP), or any other type of interfacing device capable of operating in a wireless environment.
Enabling SMS and SS Over EMM
FIG. 1 shows a wireless LTE communication system 100 including a WTRU 105 , an evolved universal terrestrial radio access network (E-UTRAN) 110 , an MME 115 and a mobile switching center (MSC)/visitor location register (VLR) 120 . The E-UTRAN includes a plurality of eNodeBs. The system 100 provides EMM functionality in the WTRU 105 and the MME 115 , and supports SMS and SS by accessing an EMM interface over an LTE C-plane media. The MSC/VLR 120 may be part of a global system for mobile communications (GSM) network or universal mobile telecommunications system (UMTS) network, and is considered to be in the CS domain. The E-UTRAN 110 and the MME 115 are part of an LTE network, which is considered to be in a packet switch (PS) domain. SMS traffic may be transferred over the control plane of the LTE network using a CS fallback mechanism.
As shown in FIG. 1 , the WTRU 105 includes an SMS protocol entity 125 , an SS protocol entity 130 , a mobility management (MM) protocol entity 135 , an EMM protocol entity 140 and an LTE RRC protocol entity 145 . The EPS EMM protocol entity 140 in the WTRU 105 will forward SMS and SS requests/messages towards the LTE network via the LTE RRC protocol entity 145 and SRB 150 .
A corresponding functionality may exist on the LTE network side, (e.g., in a base station or a core network component). An LTE EMM protocol entity 155 in the MME 115 handles the forwarding and receiving of SMS and SS messages towards/from the traditional SMS or SS processing center, such as the MSC/VLR 120 , via a serving gateway (SG) interface between the MME 115 and the MSC/VLR 120 , and towards a service center (SC) (not shown) for SMS.
Logically, the SG interface is defined between the MME and VLR functional entities. The interface defined herein is between the existing connection management (CM) protocol entities (SMS and SS) and the new MM protocol entity, EMM, for LTE.
FIG. 2 shows a wireless LTE communication system 200 including a WTRU 205 with an alternate protocol entity architecture. The WTRU 205 includes an SMS protocol entity 225 , an SS protocol entity 230 , an MM protocol entity 235 , an EPS EMM protocol entity 240 and an LTE RRC protocol entity 245 . However, unlike the protocol entity architecture of the WTRU 105 shown in FIG. 1 , the SMS protocol entity 225 and the SS protocol entity 230 do not communicate directly with the EMM protocol entity 240 , but instead only communicate with the MM protocol entity 235 .
The protocol entity architecture of FIG. 2 also differs from that of FIG. 1 by the direct interface between the MM protocol entity 235 and the EMM protocol entity 240 . This direct interface provides SMS and SS in LTE and legacy access networks. When an SMS/SS message is created, it will be sent to the MM protocol entity 235 in order to be delivered. Upon reception of the SMS/SS message, the MM protocol entity 235 checks for the existing radio access technology (RAT) of the terminating WTRU. If the existing RAT is either GSM/enhanced data rates for GSM evolution (EDGE) radio access network (GERAN) or UTRAN, the MM protocol entity 235 continues according to known procedures. However, in case the existing RAT is E-UTRAN/LTE, the MM protocol entity 235 contacts the EMM protocol entity 240 and delivers the higher layer information (the SMS/SS message). From this point forward, the defined procedures for EMM SMS/SS delivery are then followed.
The interface between the MM protocol entity 235 and the EMM protocol entity 240 may have a set of control primitives and data carriage containers (i.e., data primitives). The control primitives may be used for translating SMS and MM primitives sent to the EMM protocol entity 240 for session/connection establishment and error indication.
Enhanced EMM (E-EMM) Interface for SMS
The SMS protocol entities 125 and 225 , (also referred to herein as an enhanced SMS (E-SMS) since the underlying RAT is LTE), communicate with a corresponding peer entity, (in the WTRU and the MME), using an EMM interface over an LTE control plane.
When an SMS message is to be sent and an EMM connection (through the LTE RRC connection) does not exist at the time, one must be established at the request of the E-SMS on the originating end.
The primitives and interactions used for SMS/EMM state manipulation between the E-SMS and the EMM include:
1) SMS-EMM-Conn-Est-Req (from E-SMS to EMM for requesting establishment of a connection for outgoing SMS if no connection currently exists); 2) SMS-EMM-Conn-Est-Cnf (from EMM to E-SMS to confirm the connection establishment request); 3) SMS-EMM-Conn-Est-Ind (from EMM to E-SMS for indicating incoming SMS message); and 4) SMS-EMM-Conn-Est-Rsp (from E-SMS to EMM for responding to the incoming SMS message indication).
Connection release primitives are also defined and include the following:
1) SMS-EMM-Rel-Req (from E-SMS to EMM for requesting release of established connection); 2) SMS-EMM-Rel-Cnf (from EMM to E-SMS for confirming the release request); 3) SMS-EMM-Rel-Ind (from EMM to E-SMS for indicating a connection release); and 4) SMS-EMM-Rel-Rsp (from E-SMS to EMM for responding to the connection release indication).
The data primitives between the E-SMS and EMM are also defined and include the following:
1) SMS-EMM-Data-Req (a primitive for carrying an SMS message from E-SMS to EMM); and 2) SMS-EMM-Data-Ind (a primitive for carrying an SMS message from EMM to E-SMS).
The following control protocol (CP) messages are used to transparently support the transportation of the SMS messages between the E-SMS and the EMM: CP-Data, CP-ACK and CP-Error messages.
FIG. 3 shows signaling that occurs between an E-SMS protocol entity 305 and an EMM protocol entity 310 in a wireless communication system 300 . As shown in FIG. 3 , when originating an SMS, the E-SMS 305 entity checks with the EMM 310 sending an SMS-EMM-Conn-Est-Req message 315 to the EMM protocol entity 310 . The EMM protocol entity 310 in turn checks to see if it already has an EMM-connection over the LTE RRC connection. If that is the case, the EMM protocol entity 310 responds with an SMS-EMM-Conn-Est-Cnf message 320 back to the E-SMS protocol entity 305 . If no EMM connection exists over the LTE RRC connection, the EMM protocol entity 310 triggers the LTE RRC to establish an RRC connection towards the currently attached E-UTRAN for “service request”. When the RRC connection is successfully established, the EMM protocol entity 310 will then send an SMS-EMM-Conn-Est-Cnf message 320 back to the E-SMS 305 . The outgoing SMS data activity may then proceed using Data-Req message 325 and Data-Ind message 330 to transport SMS messages.
FIG. 4 shows signaling that occurs between an E-SMS protocol entity 405 and an EMM protocol entity 410 in a wireless communication system 400 . As shown in FIG. 4 , in the case of an incoming SMS, the EMM protocol entity 410 will be paged if no EMM/RRC connection towards the E-UTRAN exists. As the EMM protocol entity 410 responds to the page for establishing an RRC connection, the EMM protocol entity 410 will indicate the SMS event to the E-SMS protocol entity 405 via an SMS-EMM-Conn-Est-Ind message 415 and the E-SMS protocol entity 405 will respond with an SMS-EMM-Conn-Est-Rsp message 420 . The incoming SMS data activity may then proceed using Data-Req message 425 and Data-Ind message 430 to transport SMS messages.
E-EMM Interface for SS
The SS protocol entities 130 and 230 , (also referred to herein as an enhanced SS (E-SS) since the underlying RAT is LTE), communicate with a corresponding peer entity, (in the WTRU and the MME), using an EMM interface over an LTE control plane.
When an SS message is to be sent and an EMM session (through the LTE RRC connection) does not exist at the time, one must be established at the request of the E-SS on the originating end.
The primitives and interactions used for SS/EMM state manipulation between the E-SS and the EMM include:
1) SS-EMM-Sess-Est-Req (from E-SS to EMM for requesting establishment of a session for outgoing SS if no session currently exists); 2) SS-EMM-Sess-Est-Cnf (from EMM to E-SS to confirm of the session establishment request); 3) SS-EMM-Sess-Est-Ind (from EMM to E-SS for indicating an incoming SS message); and 4) SS-EMM-Sess-Est-Rsp (from E-SS to EMM for responding to the incoming SS message indication).
Session release primitives are also defined and include the following:
1) SS-EMM-Rel-Req (from E-SS to EMM for requesting release of established session); 2) SS-EMM-Rel-Cnf (from EMM to E-SS for confirming the release request); 3) SS-EMM-Rel-Ind (from EMM to E-SS for indicating a session release); and 4) SS-EMM-Rel-Rsp (from E-SS to EMM for responding to the session release indication).
The data primitives between the E-SS and the EMM are also defined and include the following:
1) SS-EMM-Data-Req (a primitive for carrying a SS message from E-SS to EMM); and 2) SS-EMM-Data-Ind (a primitive carrying a SS message from EMM to E-SS).
For SS in LTE, only the call independent SS messages will be supported for the LTE standard, since CS call service is not supported in release-8 LTE. Currently, the following call independent SS are supported and shown in FIG. 5 .
Given that the SS message header construction is the same as those for SMS (see FIG. 8 ), the above supported call independent SS messages will be inserted at the octet-9 (with the SS message header) in the EMM message shown in FIG. 9 .
Encapsulation Mechanism for SMS and SS Transport with EMM
Base EMM Message Format for Encapsulation
The EMM message for transporting the SMS or SS is generated by including the SMS message or the SS message (shown in FIG. 8 ) in an information element (IE) of the EMM UL NAS transport message or DL NAS transport message (shown in FIG. 7 ), which is then encapsulated into the NAS message header of the EMM message shown in FIG. 6 .
The NAS message shown in FIG. 7 is either a UL NAS transport message or a DL NAS transport message that carries the SMS or SS message for the intended service. Additional details of the header and body of the NAS transport message are shown in FIG. 9 .
SMS and SS Message Header
The currently used CM level SMS messages, (CP-Data, CP-ACK and CP-Error), as well as the SS messages may have the header format shown in FIG. 8 .
In FIG. 8 , the transaction-identifier field may be used for SMS and SS as a field for their original transaction identifiers. The protocol discriminator field may be used to identify the encapsulated SMS or SS or others. The message type field may be used to indicate a type of each individual SMS or SS messages.
EMM Message Format for Encapsulating SMS and SS Messages
The combined header on EMM to support SMS or SS plus the message body, (i.e., the payload), is illustrated in FIG. 9 . With this message format, the LTE access stratum control plane bearers are used to carry the SMS or the SS traffic between the WTRU and the network. In a first scenario, a direct interface between the SMS/SS entities and the EMM entity at the WTRU exist. Once the EMM session/connection is established with the E-UTRAN and MME via the LTE RRC connection, the WTRU may use the EMM and RRC interface through to the LTE SRB-2 as the SMS/SS transporting media. The SRB-2 (signal radio bearer 2) is mapped over the bidirectional logical channel DCCH (dedicated control channel), which is over the UL/DL transport channel UL-SCH (uplink shared channel)/DL-SCH (downlink shared channel), which is then mapped over the physical channel PUSCH (physical uplink shared channel)/PDSCH (physical downlink shared channel) in LTE. If an RRC connection does not exist in a mobile originated (MO) SMS scenario, the EMM protocol entity triggers the RRC protocol entity to establish an RRC connection.
In one scenario, the SMS protocol entity 125 in the WTRU 105 shown in FIG. 1 generates an SMS message using the header and payload shown in FIG. 8 , and sends the SMS message to the EMM protocol entity 140 . The EMM protocol entity 140 then formats a UL/DL NAS transport message using the header format shown in FIG. 7 , whereby the SMS message is inserted in the NAS message body IE of the UL/DL NAS transport message. The UL/DL NAS transport message is then encapsulated in the NAS message field of the EMM message shown in FIG. 6 , and is forwarded to the RRC protocol entity 145 . The RRC protocol entity 145 then formats an UL/DL information transfer message to include the EMM message, and transmits the UL/DL information transfer message over the SRB 150 .
In another scenario, the SS protocol entity 130 in the WTRU 105 shown in FIG. 1 generates an SS message using the header and payload shown in FIG. 8 , and sends the SS message to the EMM protocol entity 140 . The EMM protocol entity 140 then formats a UL/DL NAS transport message using the header format shown in FIG. 7 , whereby the SS message is inserted in the NAS message body IE of the UL/DL NAS transport message. The UL/DL NAS transport message is then encapsulated in the NAS message field of the EMM message shown in FIG. 6 , and is forwarded to the RRC protocol entity 145 . The RRC protocol entity 145 then formats an UL/DL information transfer message to include the EMM message, and transmits the UL/DL information transfer message over the SRB 150 .
FIG. 10 shows a signaling diagram for an MT SMS procedure using the primitives defined above. As shown in FIG. 10 , a WTRU 1000 includes an SMS protocol entity 1005 , an EMM protocol entity 1010 and an RRC protocol entity 1015 . A network 1020 is illustrated as a single entity for simplicity.
In an MT SMS scenario, the network 1020 may send the WTRU 1000 a page 1025 while the WTRU 1000 is in an idle state, and the WTRU 1000 may respond with a service-request 1030 (with paging response) for establishing the RRC connection. The EMM protocol entity 1010 may then send and receive the SMS message using the EMM DL NAS transport message and UL NAS transport message. The RRC protocol entity 1015 uses an RRC DownlinkInformationTransfer message 1135 and an RRC UplinkInformationTransfer message 1140 for the transportation.
FIG. 11 shows a signaling diagram for an MT SS procedure using the primitives defined above. As shown in FIG. 11 , a WTRU 1100 includes an SS protocol entity 1105 , an EMM protocol entity 1110 and an RRC protocol entity 1115 . A network 1120 is illustrated as a single entity for simplicity.
In an MT SMS scenario, the network 1120 may send the WTRU 1100 a page 1125 while the WTRU 1010 is in an idle state, and the WTRU 1100 may respond with a service request 1130 (with paging response) for establishing the RRC connection. The EMM protocol entity 1110 may then send and receive the SS message using the EMM DL NAS transport message in an RRC DownlinkInformationTransfer message 1135 , or an EMM UL NAS transport message in the RRC UplinkInformationTransfer message 1140 .
The features described above will be now summarized by referring to FIG. 1 .
In one scenario, the WTRU 105 of FIG. 1 communicates SMS messages by using the SMS protocol entity 125 to request the EMM protocol entity 140 to send an SMS message. The EMM protocol entity 140 then initiates a procedure to send a UL NAS transport message including an IE containing the SMS message. The SMS protocol entity 125 may send the SMS message to the EMM protocol entity 140 . The EMM protocol entity 140 formats the UL NAS transport message to include the SMS message, encapsulates the UL NAS transport message in an EMM message, and sends the EMM message to the LTE RRC protocol entity 145 . The LTE RRC protocol entity 145 formats a UL information transfer message to include the EMM message, and transmits the UL information transfer message over an SRB. The UL information transfer message may be transmitted to the MME 115 .
In another scenario, the WTRU 105 of FIG. 1 communicates SMS messages by using the EMM protocol entity 140 to receive a DL NAS transport message including an IE containing an SMS message. The EMM protocol entity 140 forwards the SMS message to the SMS protocol entity 125 . The RRC protocol entity 145 may receive a DL information transfer message, remove the DL NAS transport message from the DL information transfer message, and forward the DL NAS transport message to the EMM protocol entity 140 . The EMM protocol entity 140 then removes at least one NAS message header from the DL NAS transport message. The RRC protocol entity may receive the DL information transfer message from an MME.
In yet another scenario, the WTRU 105 of FIG. 1 communicates SS messages by using the SS protocol entity 130 to request the EMM protocol entity 140 to send an SS message. The EMM protocol entity 140 then initiates a procedure to send a UL NAS transport message including an IE containing the SS message. The SS protocol entity 130 may send the SS message to the EMM protocol entity 140 . The EMM protocol entity 140 formats the UL NAS transport message to include the SS message, encapsulates the UL NAS transport message in an EMM message, and sends the EMM message to the LTE RRC protocol entity 145 . The LTE RRC protocol entity 145 formats a UL information transfer message to include the EMM message, and transmits the UL information transfer message over an SRB. The UL information transfer message may be transmitted to the MME 115 .
In yet another scenario, the WTRU 105 of FIG. 1 communicates SS messages by using the EMM protocol entity 140 to receive a DL NAS transport message including an IE containing an SS message. The EMM protocol entity 140 forwards the SS message to the SS protocol entity 130 . The RRC protocol entity 145 may receive a DL information transfer message, remove the DL NAS transport message from the DL information transfer message, and forward the DL NAS transport message to the EMM protocol entity 140 . The EMM protocol entity 140 then removes at least one NAS message header from the DL NAS transport message. The RRC protocol entity may receive the DL information transfer message from an MME.
Although features and elements are described above in particular combinations, each feature or element can be used alone without the other features and elements or in various combinations with or without other features and elements. The methods or flow charts provided herein may be implemented in a computer program, software, or firmware incorporated in a computer-readable storage medium for execution by a general purpose computer or a processor. Examples of computer-readable storage mediums include a read only memory (ROM), a random access memory (RAM), a register, cache memory, semiconductor memory devices, magnetic media such as internal hard disks and removable disks, magneto-optical media, and optical media such as CD-ROM disks, and digital versatile disks (DVDs).
Suitable processors include, by way of example, a general purpose processor, a special purpose processor, a conventional processor, a digital signal processor (DSP), a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs) circuits, any other type of integrated circuit (IC), and/or a state machine.
A processor in association with software may be used to implement a radio frequency transceiver for use in a wireless transmit receive unit (WTRU), user equipment (UE), terminal, base station, radio network controller (RNC), or any host computer. The WTRU may be used in conjunction with modules, implemented in hardware and/or software, such as a camera, a video camera module, a videophone, a speakerphone, a vibration device, a speaker, a microphone, a television transceiver, a hands free headset, a keyboard, a Bluetooth® module, a frequency modulated (FM) radio unit, a liquid crystal display (LCD) display unit, an organic light-emitting diode (OLED) display unit, a digital music player, a media player, a video game player module, an Internet browser, and/or any wireless local area network (WLAN) or Ultra Wide Band (UWB) module. | Methods and apparatus for enabling short message service (SMS) and supplementary services (SS) in a long term evolution (LTE) network via evolved packet system (EPS) mobility management (EMM) over the LTE control plane are described. In one embodiment, the radio resource control (RRC) connection signaling radio bearer (SRB) is used for SMS and SS transport over the LTE control plane between a wireless transmit/receive unit (WTRU) and a mobility management entity (MME). EMM interfaces and primitives are defined for actions towards SMS and SS entities for enabling SMS and SS services in LTE via the LTE control plane media. Message formats for SMS and SS message transport are also disclosed for sending SMS and SS messages within EMM uplink (UL) non-access stratum (NAS) transport and downlink (DL) NAS transport messages. | 7 |
FIELD OF THE INVENTION
The present application relates to thickening water-in-oil latices, to a process for their preparation and to their application as thickeners and/or emulsifiers for skincare products and haircare products or for the manufacture of cosmetic, dermopharmaceutical or pharmaceutical preparations.
BACKGROUND OF THE INVENTION
Various thickeners exist and are already used for these purposes. Natural products such as guar gum or corn starch are known in particular, the drawbacks of which are those inherent to natural products, such as price fluctuations, supply difficulties and random quality.
Synthetic polymers in powder form, mainly polyacrylic acids, are also widely used but have the drawback of requiring neutralization when they are used, since they only develop their viscosity from a pH >6.5 and they are often difficult to dissolve.
Synthetic thickening polymers in the form of an inverted latex, that is to say one in which the continuous phase is an oil, are also known. These latices dissolve extremely quickly; the polymers contained in these inverted latices are usually acrylamide/alkali metal acrylate copolymers or acrylamide/sodium 2-acrylamido-2-methylpropane-sulphonate co-polymers; they are already neutralized and when they are dissolved in water, for example to a concentration of 1%, it is observed that the pH is generally above 6.
However, acrylamide/sodium acrylate copolymers do not develop any appreciable thickening properties when the pH is lowered below 6; on the other hand, the acrylamide/sodium 2-acrylamido-2-methylpropane-sulphonate copolymers described in EP 0,503,853 retain an appreciable thickening capacity even at pH 4.
However, such copolymers have monoacrylamide contents which, although extremely low, could result in making them impossible to use in cosmetics in the near future, following changes in the European legislation on hazardous substances.
The Applicant has thus been concerned with the synthesis and development of polymers that thicken, even at acidic pH, in the form of an inverted latex, without using monoacrylamide.
SUMMARY OF THE INVENTION
One subject of the invention is a composition comprising an oil phase, an aqueous phase, at least one emulsifier of water-in-oil (W/O) type, at least one emulsifier of oil-in-water (O/W) type, characterized in that the composition is an inverted latex comprising from 20% to 60% by weight, and preferably from 25% to 45% by weight, of a branched or crosslinked anionic polyelectrolyte based on at least one monomer possessing a strongly acidic function, copolymerized either with at least one monomer possessing a weakly acidic function or with at least one neutral monomer.
The expression “emulsifier of the water-in-oil type” is understood to denote emulsifiers having an HLB value that is low enough to give water-in-oil emulsions, such as the surfactant polymers sold under the name Hypermer™ or such as sorbitan extracts, for instance sorbitan monooleate sold by the company SEPPIC under the tradename Montane 80™, or sorbitan isostearate sold by SEPPIC under the name Montane 70™.
The expression “emulsifier of the oil-in-water type” is understood to denote emulsifiers having an HLB value that is high enough to give oil-in-water emulsions, such as ethoxylated sorbitan esters, for instance sorbitan oleate ethoxylated with 20 mol of ethylene oxide, sold by SEPPIC under the name MONTANOX 80™.
The term branched polymer is understood to denote a non-linear polymer which has pendant chains so as to obtain, when this polymer is dissolved in water, a high degree of entangling leading to very high low-gradient viscosities.
The term crosslinked polymer is understood to denote a non-linear polymer in the form of a three-dimensional network which is insoluble in water but swellable in water and thus leading to the production of a chemical gel.
The composition according to the invention can contain crosslinked units and/or branched units.
The subject of the invention is, in particular, a composition as defined above, characterized in that the anionic polyelectrolyte is the result of a copolymerization of its precursor monomers, which is carried out at a pH below 4.
The subject of the invention is also a composition as defined above, characterized in that 30% to 90% of the monomer units which comprise the anionic polyelectrolyte have a strongly acidic function.
The strongly acidic function of the monomer containing it is, in particular, a sulphonic acid function or a phosphonic acid function, partially or totally salified. The monomer can be for instance, styrenesulfonic acid partially or totally salified. It is preferably 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulphonic acid partially or totally salified in the form of an alkali metal salt or an ammonium salt. The weakly acidic function of the monomer containing it is, in particular, a carboxylic acid function, and the monomer is preferably chosen from acrylic acid, methacrylic acid, itaconic acid and maleic acid. The neutral monomer is chosen in particular from 2-hydroxyethyl acrylate, 2,3-dihydroxypropyl acrylate, 2-hydroxyethyl methacrylate and 2,3-dihydroxypropyl methacrylate, or an ethoxylated derivative, with a molecular weight between 400 and 1000, of each of these esters.
According to a specific aspect of the present invention, it relates to a composition comprising an oil phase, an aqueous phase, at least one emulsifier of water-in-oil (W/O) type and at least one emulsifier of oil-in-water (O/W) type, characterized in that the said composition is a reverse latex comprising from 20% to 60% by weight, and preferably from 25% to 45% by weight, of a branched or crosslinked, anionic polyelectrolyte based on partially or totally salified 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid, copolymerized with 2-hydroxyethyl acrylate, more particularly, a composition as defined above, characterized in that 30% to 90%, preferably 50% to 90%, in molar proportions, of the monomer units comprised by the anionic polyelectrolyte is 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid (MPSA) partially or totally salified, and in particular a composition as defined above, for which the anionic polyelectrolyte contains, in molar proportions, from 60% to 90% of sodium salt or of ammonium salt of 2-methyl-2[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid and from 10% to 40% of 2-hydroxyethyl acrylate.
According to another specific aspect of the present invention, it relates to a composition as defined above, characterized in that the composition is a reverse latex comprising from 20% to 60% by weight, and preferably from 30% to 45% by weight, of a branched or crosslinked, anionic polyelectrolyte based on a 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid, which is partially or totally salified in the form of sodium salt or of ammonium salt, copolymerized with acrylic acid, partially salified in the form of the sodium salt or of ammonium salt.
The subject of the invention is, more particularly, a composition as defined above, characterized in that the anionic polyelectrolyte is crosslinked and/or branched with a diethylenic or polyethylenic compound in a molar proportion, expressed relative to the monomers used, of from 0.005% to 1% and preferably from 0.01% to 0.2%, and more particularly from 0.01% to 0.1%, and preferably that for which the crosslinking agent and/or the branching agent is chosen from ethylene glycol dimethacrylate, sodium diallyl-oxyacetate, ethylene glycol diacrylate, diallylurea, trimethylolpropane triacrylate or methylene-bisacrylamide.
The latex according to the invention generally contains from 2.5% to 15% by weight, and preferably from 4% to 9% by weight, of emulsifiers, among which from 20% to 50%, in particular from 25% to 40%, of the total weight of the emulsifiers present are of the water-in-oil (W/O) type and in which from 80% to 50%, in particular from 75% to 60%, of the total weight of the emulsifiers are of the oil-in-water (O/W) type.
According to a specific aspect, the composition as defined above is characterized in that the oil phase represents from 15% to 40%, preferably from 20% to 25%, of its total weight.
This oil phase either consists of a commercial mineral oil containing saturated hydrocarbons such as paraffins, isoparaffins or cycloparaffins having, at room temperature, a density of between 0.7 and 0.9 and a boiling point above 180° C., such as, for example, Exxsol™ D 100 S or Marcol™ 52 sold by Exxon Chemical, isohexadecane or isododecane, or consists of a plant oil or a synthetic oil or of a mixture of several of these oils.
According to a preferred aspect of the present invention, the oil phase consists of Marcol™ 52 or of isohexadecane; isohexadecane, which is identified in Chemical Abstracts by the number RN=93685-80-4, is a mixture of C 12 , C 16 and C 20 isoparaffins containing at least 97% of C 16 isoparaffins, among which the main constituent is 2,2,4,4,6,8,8-heptamethylnonane (RN=4390-04-9). It is marketed in France by the company Bayer. Marcol™ 52 is a commercial oil corresponding to the definition of liquid petroleum jellies in the French Codex. This is a white mineral oil in accordance with the FDA Regulations 21 CFR 172.878 and CFR 178.3620 (a) and it is listed in the USA Pharmacopoeia, US XXIII (1995) and in the European Pharmacopoeia (1993).
The latices contain between 20% and 50% water. The latices according to the invention can also contain various additives such as completing agents, transfer agents or chain-limiting agents.
According to another aspect of the present invention, its subject is a process for preparing the composition as defined above, characterized in that:
a) an aqueous solution containing the monomers and the optional additives is emulsified in an oil phase in the presence of one or more emulsifiers of water-in-oil type,
b) the polymerization reaction is initiated by introducing a free-radical initiator into the emulsion formed in a), after which the reaction is left to proceed,
c) when the polymerization reaction is complete, one or more emulsifiers of oil-in-water type are introduced at a temperature below 50° C.
According to a variant of this process, the reaction medium obtained after step b) is concentrated by distillation before step c) is carried out.
According to a preferred embodiment of the process as defined above, the polymerization reaction is initiated by a redox couple, such as the cumene hydroperoxide/sodium metabisulphite couple, at a temperature below or equal to 10° C., and is then carried out either in a virtually adiabatic manner up to a temperature above or equal to 40° C., more particularly above or equal to 50° C., or by controlling the temperature evolution.
According to another preferred embodiment of the process, the starting aqueous solution is adjusted to a pH below or equal to 4 before step c) is carried out.
The subject of the invention is also the use of the composition as defined above for preparing a cosmetic, dermo-pharmaceutical or pharmaceutical topical composition.
A topical composition according to the invention, intended to be applied to the skin or mucous membranes of humans or animals can consist of a topical emulsion comprising at least one aqueous phase and at least one oil phase. This topical emulsion can be of the oil-in-water type. More particularly, this topical emulsion can consist of a fluid emulsion, such as a fluid gel or milk. The oil phase of the topical emulsion can consist of a mixture of one or more oils.
A topical composition according to the invention can be intended for cosmetic use or can be used to prepare a medical product intended for the treatment of mucous and skin diseases. In the latter case, the topical composition then contains an active principle which can consist, for example, of an anti-inflammatory agent, a muscle relaxant, an antifungal agent or an antibacterial agent.
When the topical composition is used as a cosmetic composition intended to be applied to the skin or mucous membranes, it may or may not contain an active principle, for example a moisturizer, a tanning agent, a sunscreen, an anti-wrinkle agent, a slimming agent, an anti-radical agent, an antiacne agent or an antifungal agent.
A topical composition according to the invention usually contains between 0.1% and 10% by weight of the thickener defined above. The pH of the topical composition is preferably above or equal to 5.
The topical composition can also contain compounds conventionally included in compositions of this type, for example fragrances, preserving agents, dyes, emollients or surfactants.
According to yet another aspect, the invention relates to the use of the novel thickener mentioned above, in accordance with the invention, to thicken and emulsify a topical composition comprising at least one aqueous phase.
The composition according to the invention is an advantageous substitute for those sold under the name Sepigel™ 305 or Sepigel™ 501 by the Applicant, since it also has good compatibility with the other excipients used for the preparation of formulations such as milks, lotions, creams, soaps, baths, balms, shampoos or conditioners. It can also be employed with the Sepigel™.
In particular, the composition is compatible with the concentrates described and claimed in the international publications WO 92/06778, WO 95/04592, WO 95/13863, WO 96/37285, WO 98/22207, WO 98/47610 or in FR 2,734,496, and with the surfactants described in WO 93/08204.
The composition is particularly compatible with Montanov™ 68, Montanov™ 82, Montanov™ 202 or Sepiperl™ N. It can also be used in emulsions of the type described and claimed in EP 0,629,396 and in cosmetically or physiologically acceptable aqueous dispersions with an organopolysiloxane compound chosen, for example, from those described in WO 93/05762 or in WO 93/21316.
The composition can also be used to form cosmetically or physiologically acceptable gels that are aqueous at acidic pH, such as those described in WO 93/07856; it can also be used in combination with nonionic celluloses in order to form, for example, styling gels, such as those described in EP 0,684,024, or alternatively in combination with fatty acid esters of a sugar, in order to form compositions for treating the hair or the skin, such as those described in EP 0,603,019, or alternatively in shampoos or conditioners as described and claimed in WO 92/21316, or, lastly, in combination with an anionic homopolymer such as Carbopol™ in order to form hair-treatment products, such as those described in DE 195 23596.
The composition according to the invention is also compatible with active principles such as, for example, self-tanning agents, for instance dihydroxyacetone (DHA) or antiacne agents, and it can thus be introduced into self-tanning compositions such as those claimed in EP 0,715,845, EP 0,604,249, EP 0,576,188 or in WO 93/07902.
The composition is also compatible with N-acylated derivatives of amino acids, which allows it to be used in soothing compositions especially for sensitive skin, such as those described or claimed in WO 92/21318, WO 94/27561 or WO 98/09611.
DETAILED DESCRIPTION OF THE INVENTION
The examples which follow are intended to illustrate the present invention.
EXAMPLE 1
Preparation and Properties of the Inverted Latex According to the Invention
A] Preparation
a) The following are loaded into a beaker, with stirring
200 g of deionized water
112.1 g of aqueous 48% (by weight) sodium hydroxide solution
278.4 g of 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulphonic acid
73.1 g of acrylic acid
0.18 g of sodium diethylenetriaminepentaacetate
0.182 g of methylenebisacrylamide
The pH of the aqueous phase described above is adjusted to 3.5 and the amount of aqueous phase is made up to 682 g by adding deionized water.
In parallel, an organic phase is prepared by introducing the following ingredients successively into a stirred beaker:
220 g of isohexadecane
25 g of Montane 80 VG (sorbitan oleate sold by SEPPIC)
0.2 g of azobisisobutyronitrile
The aqueous phase is introduced gradually into the organic phase and is then subjected to vigorous mechanical stirring of ultra-turrax™ type sold by IKA.
The emulsion obtained is then transferred into a polymerization reactor. A large amount of nitrogen is bubbled through the emulsion so as to remove the oxygen, and the resulting emulsion is cooled to about 5-6° C.
5 ml of a solution containing 0.42% (by weight) of cumene hydroperoxide in isohexadecane are then introduced.
After a period which is sufficient to obtain good homogenization of the solution, aqueous sodium metabisulphite solution (0.2 g in 100 ml of water) is then introduced at a rate of 0.5 ml/minute. The introduction is carried out over about 60 minutes.
During this introduction, the temperature in the polymerization reactor is allowed to rise to the final polymerization temperature.
The reaction medium is then held at this temperature for about 90 minutes.
The mixture is cooled to a temperature of about 35° C. and 50 g of sorbitan oleate ethoxylated with 20 mol of ethylene oxide are introduced slowly.
The desired emulsion is obtained.
Evaluation of the properties:
+ viscosity 25° C. of the latex (Brookfield RVT, No. 3 spindle, speed 20): =650 mPa.s
+ viscosity in water containing 2% latex (Brookfield RVT, No. 6 spindle, speed 20): =33,800 mPa.s.
(Brookfield, No. 6 spindle, speed 5): =74,000 mPa.s.
It is observed that the final product is free of acrylamide.
b) Working in the same manner as in paragraph a), starting with:
200 g of deionized water
121.8 g of aqueous 48% (by weight) sodium hydroxide solution
302.66 g of 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid
49.54 g of acrylic acid
0.18 g of sodium diethylenetriaminepentaacetate, and
0.163 g of methylenebisacrylamide.
The desired emulsion is obtained, which has the following characteristics:
+ viscosity in water containing 2% latex
(Brookfield RVT, No. 6 spindle, speed 20): =29,000 mPa.s
(Brookfield, No. 6 spindle, speed 5): =66,000 mPa.s.
It is observed that the final product is also free of acrylamide.
c) The following are loaded into a beaker, with stirring:
608.8 g of a commercial 50% solution of the sodium salt of 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid,
72.6 g of 2-hydroxyethyl acrylate,
0.18 g of sodium diethylenetriamine pentaacetate, and
0.121 g of methylenebis(acrylamide),
the pH of the aqueous phase described above is adjusted to 3.5, by adding 0.7 g of 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid.
In parallel, an organic phase is prepared by introducing the following successively into a stirred beaker:
220 g of isohexadecane,
25 g of Montano X80 VG (sorbitan oleate ethoxylated with 20 mol of ethylene oxide, sold by SEPPIC) and
0.2 g of azobis(isobutyronitrile).
The aqueous phase is introduced gradually into the organic phase and is then subjected to vigorous mechanical stirring with an Ultra-Turrax™ machine sold by IKA.
The emulsion obtained, characterized by a viscosity at 25° C. of 2600 mPa.s (Brookfield RVT, No. 4 spindle, speed 20), is then transferred into a polymerization reactor. The emulsion is subjected to bubbling with nitrogen at a substantial rate so as to remove the oxygen, and is cooled to about 5-6° C.
10 g of a solution containing 1.1% by weight of cumene hydroperoxide active material in isohexadecane are then introduced. After a sufficient time for good homogenization of the solution, 25 g of aqueous sodium metabisulfite solution (0.2% solution) are introduced over about 25 minutes. During this introduction, the temperature in the polymerization reactor is allowed to rise to the final polymerization temperature and the reaction mixture is then maintained for about 90 minutes at this temperature. The mixture is then cooled to a temperature of about 35° C. and 50 g of Montanov™ 80 VG are then introduced slowly.
The desired emulsion is obtained.
Evaluation of the properties:
Viscosity at 20° C. of the latex at 3% in water (Brookfield RVT, No. 6 spindle, speed 20): =36,700 mPa.s; the pH is 5.1.
The pH is lowered to 3.7 and the following result is then obtained: =31,000 mPa.s.
It is observed that the final product is free of acrylamide.
d) Working in the same way as in paragraph a), by lowering the amount of methylenebis(acrylamide) from 0.121 g to 0.091 g, an emulsion is obtained which has the following viscosity characteristics:
Viscosity at 20° C. of the latex at 3% in water (Brookfield RVT, No. 6 spindle, speed 20): =33,000 mPa.s; the pH is 5.2.
After lowering the pH, the following results are obtained:
at pH=4.0, =31,000 mpa.s;
at pH=2.8, =18,300 mPa.s.
It is observed that the final product is free of acrylamide.
e) Working in the same way as in paragraph A), by lowering the amount of methylenebis(acrylamide) from 0.121 g to 0.084 g and that of the 2-hydroxyethyl acrylate from 72.6 g to 53 g, and by increasing the amount of commercial 50% solution of the sodium salt of 2-methyl-2-[(1-oxo-2-propenyl)amino]-1-propanesulfonic acid from 608.8 g to 628 g, an emulsion is obtained which has the following viscosity characteristics:
viscosity at 20° C. of the latex at 3% in water (Brookfield RVT, No. 6 spindle, speed 20): =27,400 mPa.s; the pH is 5.2.
After lowering the pH, the following results are obtained:
at pH=4.0, =27,400 mPa.s;
at pH=2.8, =18,200 mpa.s.
It is observed that the final product is free of acrylamide.
It is observed that the emulsions obtained have a very specific feel sensation at and above 1% polymer in the solution, and that this difference increases as the concentration increases; it is a very fresh feel sensation at the start, which melts completely on the skin, this feel sensation not being experienced at all with the latices of the prior art.
The examples which follow use, without distinction, the emulsions prepared according to one of paragraphs A a) to A e) (which are referred to in the following examples—compound of Example 1).
B] Properties
a) “Emulsifying” Power of Fatty Phases
The inverted latex prepared in paragraph A] b) (composition 1) was used to prepare emulsions with different types of a polar or polar fatty substances of plant or synthetic origin. The cream-gels obtained in the various cases are stable and have an entirely homogeneous appearance. Their viscosity is given in the following table:
Oil used for the fatty phase of
the cream-gel
Viscosity at 20° C., in
(3% of composition 1; fatty
mPa · s
phase: 10%)
Brookfield LVT 6 rpm
distilled water: 87%
≈80,000
Jojoba oil
≈100,000
Sweet almond oil
≈80,000
Squalane
≈100,000
Dimethicone
≈65,000
Isohexadecane
≈100,000
Isononyl isononanoate
≈100,000
Cetearyl octanoate
≈100,000
C 12 —C 15 benzoate
≈100,000
TG Caprylic/capric
≈90,000
Liquid paraffin
Composition 1 thus makes it possible to disperse and stabilize the fatty phases in an aqueous medium, by simple dilution without a neutralization step being necessary.
b) Heat Stability
A cream-gel comprising 2.5% of composition 1 and 20% of cetearyl octanoate was prepared and the viscosity was measured. The results are as follows:
Brookfield LVT viscosity,
6 rpm (in mpa · s)
(measured at Ta)
After 1 day at 40° C.
≈69,000
After 7 days at 40° C.
≈68,000
After 1 month at 40° C.
≈66,000
c) Influence of the PH on the Viscosity
The viscosity of the cream-gel prepared with composition 1 is very stable to pH in the range pH=6 to pH=9.
d) Compatibility With Solvents
The viscosity (in mPa.s) of gels containing 3% of composition 1 was measured in various cosmetic solvents at several concentrations.
The results given in the following table show that the viscosity of these gels is not affected by the presence of solvents.
Solvent
20%
40%
60%
Hexylene glycol
≈100,000
≈10,000
5000
Ethanol
≈100,000
100,000
40,000
Dipropylene glycol
≈100,000
100,000
90,000
Butylene glycol
≈100,000
≈100,000
≈100,000
Propylene glycol
≈100,000
≈100,000
≈100,000
Glycerol
≈100,000
≈100,000
≈100,000
e) Cosmetic formulae are prepared with each of the latices prepared in paragraphs A]c), A]d) and A]e), these formulae comprising:
0.5%, 1%, 1.5%, 2%, 2.5% or 3% latex
5% Simulsol 165,
20% Lanol 1688,
0.5% Sepicide HB
water qs 100%.
It is observed that the feel sensation of the emulsions obtained is very specific at and above 1% polymer in the solution and this difference increases as the concentration increases; it is a very fresh feel sensation at the start, which melts completely on the skin, this feel sensation not being experienced at all with the latices of the prior art.
EXAMPLE 2
Care Cream
Cyclomethicone:
10%
Compound of Example 1:
0.8%
Montanov ™ 68:
4.5
Preserving agent:
0.65%
Lysine:
0.025%
EDTA (disodium salt):
0.05%
Xanthan gum:
0.2%
Glycerol:
3%
Water:
qs 100%
EXAMPLE 3
Care Cream
Cyclomethicone:
10%
Compound of Example 1:
0.8%
Montanov ™ 68:
4.5%
Perfluoropolymethyl
0.5%
Isopropyl ether:
Preserving agent:
0.65%
Lysine:
0.025%
EDTA (disodium salt):
0.05%
Pumulen ™ TR:
0.2%
Glycerol:
3%
Water:
qs 100%
EXAMPLE 4
Aftershave Balm
FORMULA
A
Compound of Example 1:
1.5%
Water:
qs 100%
B
Micropearl ™ M100:
5.0%
Sepicide ™ CI:
0.50%
Fragrance:
0.20%
95° ethanol:
10.0%
PROCEDURE
Add B to A.
EXAMPLE 5
Satin Body Emulsion
FORMULA
A
Simusol ™ 165:
5.0%
Lanol ™ 1688:
8.50%
Karite butter:
2%
Liquid paraffin:
6.5%
Lanol ™ 14M:
3%
Lanol ™ S:
0.6%
B
Water:
66.2%
C
Micropearl ™ M100:
5%
D
Compound of Example 1:
3%
E
Sepicide ™ CI:
0.3%
Sepicide ™ HB:
0.5%
Monteine ™ CA:
1%
Fragrance:
0.20%
Vitamin E acetate:
0.20%
PROCEDURE
Add C to B, emulsify B in A at 70° C. and then add D at 60° C., followed by E at 30° C.
EXAMPLE 6
Body Milk
FORMULA
A
Simusol ™ 165:
5.0%
Lanol ™ 1688:
12.0%
Lanol ™ 14M:
2.0%
Cetyl alcohol:
0.3%
Schercemol ™ OP:
3%
B
Water:
qs 100%
C
Compound of Example 1:
0.35%
D
Sepicide ™ CI:
0.2%
Sepicide ™ HB:
0.5%
Fragrance:
0.20%
PROCEDURE
Emulsify B in A at about 75° C.; add C at about 60° C., followed by D at about 30° C.
EXAMPLE 7
O/W Cream
FORMULA
A
Simulsol ™ 165:
5.0%
Lanol ™ 1688:
20.0%
Lanol ™ P:
1.0% (stabilizing
additive)
B
Water:
qs 100%
C
Compound of Example 1:
2.50%
D
Sepicide ™ CI:
0.20%
Sepicide ™ HB:
0.30%
PROCEDURE
Introduce B into A at about 75° C.; add C at about 60° C., followed by D at 45° C.
EXAMPLE 8
Non-greasy Antisun Gel
FORMULA
A
Compound of Example 1:
3.00%
Water:
30%
B
Sepicide ™ CI:
0.20%
Sepicide ™ HB:
0.30%
Fragrance:
0.10%
C
Dye:
q.s.
Water:
30%
D
Micropearl ™ M100:
3.00%
Water:
q.s. 100%
E
Silicone oil:
2.0%.
Parsol ™ MCX:
5.00%
PROCEDURE
Introduce B into A; add C, followed by D and then E.
EXAMPLE 9
Antisun Milk
FORMULA
A
Sepiperl ™ N:
3.0%
Sesame oil:
5.0%
Parsol ™ MCX:
5.0%
λ-Carrageenan
0.10%
B
Water:
q.s. 100%
C
Compound of Example 1:
0.80%
D
Fragrance:
q.s.
Preserving agent:
q.s.
PROCEDURE
Emulsify B in A at 75° C., then add C at about 60° C., followed by D at about 30° C., and adjust the pH if necessary.
EXAMPLE 10
Massage Gel
FORMULA
A
Compound of Example 1:
3.5%
Water:
20.0%
B
Dye:
2 drops/100 g
Water:
q.s.
C
Alcohol:
10%
Menthol:
0.10%
D
Silicone oil:
5.0%
PROCEDURE
Add B to A; then add C to the mixture, followed by D.
EXAMPLE 11
Massage Care Gel
FORMULA
A
Compound of Example 1:
3.00%
Water:
30%
B
Sepicide ™ CI:
0.20%
Sepicide ™ HB:
0.30%
Fragrance:
0.05%
C
Dye:
q.s.
Water:
q.s. 100%
D
Micropearl ™ SQL:
5.0%
Lanol ™ 1688:
2%
PROCEDURE
Prepare A; add B, followed by C and then D.
EXAMPLE 12
Radiant-effect Gel
FORMULA
A
Compound of Example 1:
4%
Water:
30%
B
Elastine HPM:
5.0%
C
Micropearl ™ M100:
3%
Water:
5%
D
Sepicide ™ CI:
0.2%
Sepicide ™ HB:
0.3%
Fragrance:
0.06%
50% sodium pyrrolidinonecarboxylate:
1%
Water:
q.s. 100%
PROCEDURE
Prepare A; add B, followed by C and then D.
EXAMPLE 3
Body Milk
FORMULA
A
Sepiperl ™ N:
3.0%
Glyceryl triheptanoate:
10.0%
B
Water:
q.s. 100%
C
Compound of Example 1:
1.0%
D
Fragrance:
q.s.
Preserving agent:
q.s.
PROCEDURE
Melt A at about 75° C. Emulsify B in A at 75° C. and then add C at about 60° C., followed by D.
EXAMPLE 14
Make-up-removing Emulsion Containing Sweet Almond Oil
FORMULA
Montanov ™ 68:
5%
Sweet almond oil:
5%
Water:
q.s. 100%
Compound of Example 1:
0.3%
Glycerol:
5%
Preserving agent:
0.2%
Fragrance:
03%
EXAMPLE 15
Moisturizing Cream for Greasy Skin
FORMULA
A
Montanov ™ 68:
5%
Cetylstearyl octanoate:
8%
Octyl palmitate:
2%
Water:
q.s. 100%
Compound of Example 1:
0.6%
Micropearl ™ M100:
3.0%
Mucopolysaccharides:
5%
Sepicide ™ HB:
0.8
Fragrance:
03%
EXAMPLE 16
Alcohol-free, Soothing After-shave Balm
FORMULA
Mixture of laurylamino acids
0.1% to 5%
Magnesium potassium aspartate:
0.002% to 0.5%
Lanol ™ 99:
2%
Sweet almond oil:
0.5%
Water:
q.s. 100%
Compound of Example 1:
3%
Sepicide ™ HB:
0.3%
Sepicide ™ CI:
0.2%
Fragrance:
0.4%
EXAMPLE 17
Cream Containing AHAs for Sensitive Skin
FORMULA
Mixture of laurylamino acids:
0.1% to 5%
Magnesium potassium aspartate:
0.002% to 0.5%
Lanol ™ 99:
2%
Montanov ™ 68:
5.0%
Water:
q.s. 100%
Compound of Example 1:
1.50%
Gluconic acid:
1.50%
Triethanolamine:
0.9%
Sepicide ™ HB:
0.3%
Sepicide ™ CI:
0.2%
Fragrance:
0.4%
EXAMPLE 18
Aftersun Soothing Care Product
FORMULA
Mixture of lauryl amino acids:
0.1% to 5%
Magnesium potassium aspartate:
0.002% to 0.5%
Lanol ™ 99:
10.0%
Water:
q.s. 100%
Compound of Example 1:
2.50%
Sepicide ™ HB:
0.3%
Sepicide ™ CI:
0.2%
Fragrance:
0.4%
Dye:
0.03%
EXAMPLE 19
Make-up-removing Milk
FORMULA
Sepiperl ™ N:
3%
Primol 352:
8.0%
Sweet almond oil:
2%
Water:
q.s. 100%
Compound of Example 1:
0.8%
Preserving agent:
0.2%
EXAMPLE 20
Body Milk
FORMULA
Sepiperl ™ N:
3.5%
Lanol ™ 37T:
8.0%
Solagum ™ L:
0.05%
Water
q.s. 100%
Benzophenone:
2.0%
Dimethicone 350cPs:
0.05%
Compound of Example 1:
0.8%
Preserving agent:
0.2%
Fragrance:
0.4%
EXAMPLE 21
Alkaline-pH Fluid Emulsion
Marcol ™ 82:
5.0%
NaOH:
10.0%
water:
q.s. 100%
Compound of Example 1:
1.5%
EXAMPLE 22
Fluid Foundation
FORMULA
Simusol ™ 165:
5.0%
Lanol ™ 84D:
8.0%
Lanol ™ 99:
5.0%
Water:
q.s. 100%
Inorganic fillers and pigments:
10.0%
Compound of Example 1:
1.2%
Preserving agent:
0.2%
Fragrance:
0.4%
EXAMPLE 23
Antisun Milk
FORMULA
Sepiperl ™ N:
3.5%
Lanol ™ 37T:
10.0%
Parsol NOX ™ :
5.0%
Eusolex ™ 4360:
2.0%
Water:
q.s. 100%
Compound of Example 1:
1.8%
Preserving agent:
0.2%
Fragrance:
0.4%
EXAMPLE 24
Gel for Around the Eyes
FORMULA
Compound of Example 1:
2.0%
Fragrance:
0.06%
Sodium pyrrolidinonecarboxylate:
0.2%
Dow Corning ™ 245 Fluid
2.0%
Water:
q.s. 100%
EXAMPLE 25
Leave-in Care Composition
FORMULA
Compound of Example 1:
1.5%
Fragrance:
q.s.
Preserving agent:
q.s.
Dow Corning ™ X2 8360:
5.0%
Dow Corning ™ Q2 1401:
15%
Water:
q.s. 100%
EXAMPLE 26
Slimming Gel
Compound of Example 1:
5%
Ethanol:
30%
Menthol:
0.1%
Caffeine:
2.5%
Extract of butcher's-broom:
2%
Extract of ivy:
2%
Sepicide ™ HP:
1%
Water:
q.s. 100%
EXAMPLE 27
Alcohol-free, Soothing After-shave Balm
FORMULA
A
Lipacide ™ PVB:
1.0%
Lanol ™ 99:
2.0%
Sweet almond oil:
0.5%
B
Compound of Example 1
3.5%
C
Water:
q.s. 100%
D
Fragrance:
0.4%
Sepicide ™ HB:
0.4%
Sepicide ™ CI:
0.2%
EXAMPLE 28
Refreshing After-shave Gel
FORMULA
A
Lipacide ™ PVB:
0.5%
Lanol ™ 99:
5.0%
Compound of Example 1
2.5%
B
Water:
q.s. 100%
C
Micropearl ™ LM:
0.5%
Fragrance:
0.2%
Sepicide ™ HB:
0.3%
Sepicide ™ CI:
0.2%
EXAMPLE 29
Care Product for Greasy Skin
FORMULA
A
Micropearl ™ M310:
1.0%
Compound of Example 1
5.0%
Octyl isononanoate:
4.0%
B
Water:
q.s. 100%
C
Sepicontrol ™ A5:
4.0%
Fragrance:
0.1%
Sepicide ™ HB:
0.3%
Sepicide ™ CI:
0.2%
D
Capigel ™ 98:
0.5%
Water:
10%
EXAMPLE 30
Cream Containing AHAs
FORMULA
A
Montanov ™ 68:
5.0%
Lipacide ™ PVB:
1.05%
Lanol ™ 99:
10.0%
B
Water:
q.s. 100%
Gluconic acid:
1.5%
TEA (triethanolamine):
0.9%
C
Compound of Example 1
1.5%
D
Fragrance:
0.4%
Sepicide ™ HB:
0.2%
Sepicide ™ CI:
0.4%
EXAMPLE 31
Non-greasy Self-tanning Product for the Face and the Body
FORMULA
A
Lanol ™ 2681:
3.0%
Compound of Example 1
2.5%
B
Water:
q.s. 100%
Dihydroxyacetone:
3.0%
C
Fragrance:
0.2%
Sepicide ™ HB:
0.8%
NaOH (sodium hydroxide):
q.s. pH = 5%
EXAMPLE 32
Antisun Milk Containing Monoï de Tahiti
FORMULA
A
Monoï de Tahiti:
10%
Lipacide ™ PVB:
0.5%
Compound of Example 1
2.2%
B
Water:
q.s. 100%
C
Fragrance:
0.1%
Sepicide ™ HB:
0.3%
Sepicide ™ CI:
0.1%
Octyl methoxycinnamate:
4.0%
EXAMPLE 33
Antisun Care Product for the Face
FORMULA
A
Cyclomethicone and dimethiconol:
4.0%
Compound of Example 1
3.5%
B
Water:
q.s. 100%
C
Fragrance:
0.1%
Sepicide ™ HB:
0.3%
Sepicide ™ CI:
0.21%
Octyl methoxycinnamate:
5.0%
Titanium mica:
2.0%
Lactic acid:
q.s. pH = 6.5
EXAMPLE 34
Self-tanning Emulsion
FORMULA
A
Lanol ™ 99:
15%
Montanov ™ 68:
5.0%
Octyl para-methoxycinnamate:
3.0%
B
Water:
q.s. 100%
Dihydroxyacetone:
5.0%
Monosodium phosphate:
0.2%
C
Compound of Example 1
0.5%
Fragrance:
0.3%
Sepicide ™ HB:
0.8%
NaOH:
q.s. pH = 5
EXAMPLE 35
Sheen Gel
Compound of Example 1
1.5%
Volatile silicone
25%
Monopropylene glycol
25%
Demineralized water
10%
Glycerol
q.s. 100%
EXAMPLE 36
Slimming Gel
Compound of Example 1
1.5%
Isononyl isononanoate
2%
Caffeine
5%
Ethanol
40%
Micropearl ™ LM
2%
Demineralized water
q.s. 100%
Preserving agent, fragrance
q.s.
EXAMPLE 37
Make-up-removing Milk
Simulsol ™ 165
4%
Montanov ™ 202
1%
Triglyceride caprylate caprate
15%
Pecosil ™ DCT
1%
Demineralized water
q.s.
Capigel ™ 98
0.5%
Compound of Example 1
1%
Proteol ™ oat
2%
NaOH
q.s. pH 7
EXAMPLE 38
Antisun Cream
Simulsol ™ 165
3%
Montanov ™ 202
2%
C 12 —C 15 benzoate
8%
Pecosil ™ PS 100
2%
Dimethicone
2%
Cyclomethicone
5%
Octyl methoxycinnamate
6%
Benzophenone-3
4%
Titanium oxide
8%
Xanthan gum
0.2%
Butylene glycol
5%
Demineralized water
q.s. 100%
Compound of Example 1
1.5%
Preserving agent, fragrance
q.s.
EXAMPLE 39
Care Gel for Mixed Skin
Compound of Example 1
4%
Plant squalane
5%
Dimethicone
1.5%
Sepicontrol ™ A5
4%
Xanthan gum
0.3%
Water
q.s. 100%
Preserving agent, fragrance
q.s.
EXAMPLE 40
Perfumed Body Mask
Compound of Example 1
1.5%
Cyclomethicone
5%
Fragrance
2%
Micropearl ™ M100
5%
Glycerol
5%
Demineralized water
q.s. 100%
EXAMPLE 41
Cream with Vitamins
Simulsol ™ 165
5%
Montanov ™ 202
1%
Caprylic/capric triglycerides
20%
Vitamin A palmitate
0.2%
Vitamin E acetate
1%
Micropearl ™ M305
1.5%
Compound of Example 1
0.7%
Water
q.s. 100%
Preserving agent, fragrance
q.s.
Montanov™ 68 (cetearyl glucoside) is a self-emulsifying composition as described in WO 92/06778, sold by the company SEPPIC.
Micropearl™ M100 is an ultra-fine powder with a very soft feel sensation and a matt effect, sold by the company Matsumo.
Sepicide™ CI, imidazolinurea, is a preserving agent sold by the company SEPPIC.
Pemulen™ TR is an acrylic polymer sold by Goodrich.
Simulsol™ 165 is self-emulsifying glyceryl stearate, sold by the company SEPPIC.
Lanol™ 1688 is a non-greasy emollient ester sold by the company SEPPIC.
Lanol™ 14M and Lanol™ S are consistency factors sold by the company SEPPIC.
Sepicide ™ HB, which is a mixture of phenoxyethanol, methylparaben, ethylparaben, propylparaben and butylparaben, is a preserving agent sold by the company SEPPIC.
Monteine™ CA is a moisturizer sold by the company SEPPIC.
Schercemol™ OP is a non-greasy emollient ester.
Lanol™ P is a stabilizing additive sold by the company SEPPIC.
Parsol™ MCX is octyl para-methoxycinnamate, sold by the company Givaudan.
Sepiperl™ N is a pearlescent agent, sold by the company SEPPIC, based on a mixture of alkylpolyglucosides such as those described in WO 95/13863.
Micropearl™ SQL is a mixture of microparticles containing squalane, which is released under the action of massaging; it is sold by the company Matsumo.
Lanol™ 99 is isononyl isononanoate, sold by the company SEPPIC.
Lanol™ 37T is glyceryl triheptanoate, sold by the company SEPPIC.
Solagum™ L is a carrageenan sold by the company SEPPIC.
Marcol™ 82 is a liquid paraffin sold by the company ESSO.
Lanol™ 84D is dioctyl malate, sold by the company SEPPIC.
Parsol™ NOX is a sunscreen sold by the company Givaudan.
Eusolex™ 4360 is a sunscreen sold by the company Merck.
Dow Corning™ 245 Fluid is cyclomethicone, sold by the company Dow Corning.
Lipacide™ PVB is a palmitoylated wheat protein hydrolysate sold by the company SEPPIC.
Micropearl™ LM is a mixture of squalane, poly(methyl methacrylate) and menthol, sold by the company SEPPIC.
Sepicontrol™ A5 is a mixture of capryloylglycine, sarcosine and extract of Cinnamon zylanicum, sold by the company SEPPIC, such as those described in International patent application PCT/FR 98/01313 filed on Jun. 23, 1998.
Capigel™ 98 is an acrylate copolymer sold by the company SEPPIC.
Lanol™ 2681 is a coconut caprylate/caprate mixture sold by the company SEPPIC.
Montanov™ 202 is an APG/fatty alcohol composition as described in W09 98/47610, sold by the company SEPPIC. | Composition comprising an oil phase, an aqueous phase, at least one emulsifier of water-in-oil (W/O) type, at least one emulsifier of oil-in-water (O/W) type, characterized in that the composition is an inverted latex comprising from 20% to 60% by weight, and preferably from 25% to 45% by weight, of a branched or crosslinked anionic polyelectrolyte based on at least one monomer possessing a strongly acidic function, copolymerized either with at least one monomer possessing a weakly acidic function or with at least one neutral monomer. The compositions have cosmetic applications. | 8 |
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a semiconductor memory device and, more particularly, to a semiconductor memory device provided with a test performing section capable of executing memory tests in a plurality of test modes.
(b) Description of the Related Art
In semiconductor integrated circuit devices including semiconductor memory devices, a function test is executed in a plurality of test modes. The test modes include one executed when a memory device is finished to a product and another executed when the product is installed in service. Hence, when a memory device is to be tested, it is necessary to input to the memory device a test mode selecting signal for selecting one of predetermined test modes as well as a test commanding signal for switching the memory device to a test operation mode.
In general, switching a memory device from a normal operation mode to a test operation mode is effected by inputting a predetermined address assigned to a test operation mode of the memory device via an address bus, simultaneously with inputting a test mode selecting signal via one of external test mode pins each corresponding to one of several test modes. However, with an increasing higher integration and finer pattern of a memory device, it is requested that the number of external pins be decreased.
In some memory devices, selection of one of several test modes is effected by inputting data for designating the one of the test modes through data bus instead of providing a test mode selecting signal via a corresponding external pin. In this ease, however, there is a drawback that the number of data items to be input for performing a test is large resulting in a complicated sequence of a memory tester for testing the memory device.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a semiconductor memory device in which a reduced number of data items is required for performing a test and in which number of external pins is not increased for the test.
The present invention provides a semiconductor memory device comprising a substrate, a plurality of memory cells arrayed on the substrate and each having an address included in a first address group, an address bus composed of a plurality of bits for receiving an address signal designating one of addresses included in the first address group or one of addresses included in a second address group assigned to a plurality of test modes, a first address decoder operatively connected between the address bus and the memory cells for decoding addresses included in the first address group for the memory cells, a second address decoder, operatively connected to the address bus, for decoding addresses included in the second address group, and a test performing section, operatively connected to the second address decoder, for executing a memory test in one of the test modes based on the output of the second decoder.
In accordance with the semiconductor memory device according to the present invention, when an address included in the second address group and corresponding to one of test modes is input, one of the test modes corresponding to the input address is transmitted to the test performing section, which then executes a test for the memory device in accordance with the designated test mode. Since only address data are required for executing the test, the number of data items to be input can be reduced while the number of external pins is not increased.
The memory device according to the present invention is suitable for a video display unit. In typical memory devices used for image processing in a video display unit, the capacity of the memory device is generally determined based on the number of pixels of the display unit. Accordingly, the capacity of the memory device does not correspond to a power of 2, in contrast to an ordinary DRAM the capacity of which generally corresponds to a power of 2, e.g., 1 Mb or 4 Mb. On the other hand, most of such memory devices for image processing have a large number of address lines including word lines and data lines capable of designating addresses in number corresponding to a power of 2, in consideration of benefits in the circuit structure of the address decoder. In this case, there are many addresses which are not actually used in the memory cell array of the memory devices. The present invention can utilize the excess capacity of the address lines by providing a second decoder assigned to a plurality of test mode.
In the semiconductor memory device according to the present invention, both a signal for commanding execution of a test and a signal for selecting one of a plurality of test modes can be transmitted by inputting only a single address. Accordingly, a reduced number of data items need be input for executing a test without increasing the number of external pins, so that a test sequence can be simplified in a test for a memory device of a higher integration and a finer pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and further objects as well as features and advantages of the present invention will be more apparent from the following description, taken in conjunction with accompanying drawings in which:
FIG. 1 is a block diagram of a conventional semiconductor memory device in a simplified model;
FIG. 2 is a timing diagram showing signals generated for a test operation mode in the memory device of FIG. 1;
FIG. 3 is a block diagram of a semiconductor memory device in a simplified model according to a first embodiment of the present invention;
FIG. 4 is a circuit diagram of a test commanding section used in the memory device of FIG. 3;
FIG. 5 is a timing diagram showing signals in the memory device of FIG. 3; and
FIG. 6 is a circuit diagram of another test commanding section used in a memory device according to a second embodiment of the present invention; and
FIG. 7 is a timing diagram showing signals in the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before describing embodiments of the present invention, a conventional semiconductor memory device will be described for the sake of understanding of the present invention.
FIG. 1 shows a conventional semiconductor memory device in a simplified model utilizing data bus for inputting a test mode selecting signal. The memory device comprises an address bus 1, an address decoder 2, data bus 4, a test mode register 5, a memory cell array 27 and a test performing section 28. When the address decoder 2 receives an input address 101 composed of a plurality of bits A 2 , A 1 and A 0 , together with an address enabling signal 1001, the address decoder 2 decodes the input address 101 to thereby select one of a plurality of output lines 301 to 308 including a plurality of address lines for the memory cell array 27 and a single line 301 called a test commanding line. The test commanding line 301 is connected to a control terminal of the test mode register 5 for providing a test commanding signal thereto.
The test mode register 5 is activated by an active level (for example, H-state) on the test commanding line 301 so as to receive and store an input data 401, which has been separately input from the data bus 4 and is composed of a plurality of bits including D 2 , D 1 and D 0 for designating one of a plurality of test modes. Subsequently, the test mode register 5 selects one of the test mode selecting signal lines 601, 602 and 603 based on input data 401. In this example, it is determined that the test commanding line 301 is selected when the bits A 2 , A 1 and A 0 of the input address 101 are such that (A 2 , A 1 , A 0 )=(1, 1, 1), considering that the memory cell array does not include a memory cell assigned to the address (1, 1, 1). In the following description, addresses or data are expressed such that the address or data (1, 1, 1) is simply expressed as "111", for example.
FIG. 2 is a timing diagram showing signals in the semiconductor memory device of FIG. 1 during a test mode. When an address "111" for the input address 101 is supplied for commanding execution of a test, synchronously with the address enabling signal 1001, the address decoder 2 selects the test commanding line 301 so as to drive the line 301 up to an H-state. If a data "101" for the input data 401 are supplied simultaneously with the input address "111", the data "101" is stored in the test mode register 5. The signal transmitted through the three test mode selecting lines 601-603 corresponds to the respective bits of the data "101". That is, the line 601 is driven to an H-state, the line 602 to an L-state, and the line 603 to an H-state. The test mode selecting signals are input to the test performing section 28 so that a memory test is performed in the semiconductor memory device in accordance with the designated one of the test modes.
As described above, in the conventional memory device, the data designating one of plurality of test modes is input through the data bus in addition to an address signal. Hence, memory tester should provide all of the necessary data to the memory device, so that the test sequence of a memory tester is complicated.
Now, embodiments of the present invention will be described with reference to the drawings.
FIG. 3 is block diagram of a semiconductor memory device in a simplified model according to a first embodiment of the present invention. The semiconductor memory device comprises an address bus 1 for transmitting an address 101 for commanding execution of a test and for designating addresses of a memory cell array, a first address decoder 16 for decoding input address 101 for memory cells in the memory cell array 17, a test commanding section 7 for generating a test commanding signal responsive to any one of addresses corresponding to a plurality of test modes, and a second address decoder (test mode selecting section) 8 for selecting one of the test modes responsive to input address 101 designating the one of the test modes. The output from the first address decoder 16 is supplied to the memory cell array 17, while the output from the test mode selecting section 8 is supplied to a test performing section 18.
When an input address "A 2 A 1 A 0 " corresponding to an address within an address space assigned to the memory cell array 17, i.e., an address in the first group is received via the address bus 1, one of output lines 1301-1306 is selected so that a unique memory cell in the memory cell array 17 is accessed. In this case, the semiconductor memory device operates in a normal operation mode.
When an address "A 2 A 1 A 0 " designating an address included in the second group is received via the address bus a test commanding signal 901 is output from the test commanding section 7 in response to the receipt of the input address 101, so that the test mode selecting section 8 is activated. The test mode selecting section 8 latches the address "A 2 A 1 A 0 " which has been input in the activated state thereof, and decodes the address so that a signal of H-level is output through one of a plurality of test mode selecting lines, for example, lines 1201 and 1202 as shown in the drawing. The signal of H-level on one of the test mode selecting lines 1201 and 1202 is maintained during the test operation mode due to a latching function of the test mode selecting section 8.
FIG. 4 shows an example of the test commanding section 7 in the semiconductor memory device according to the first embodiment. In semiconductor memory devices according to the present embodiment and a second embodiment which will be described later, it is assumed that the address space for the memory cell array corresponds to the address "A 2 A 1 A 0 "="000"-"101", and the addresses A 2 A 1 A 0 ="110"and "111" are assigned to the second group.
The test commanding section 7 of FIG. 4 is implemented by a combination circuit composed of a NAND gate 10 having two input terminals receiving bits A 1 and A 2 of input address, and an inverter (INV) gate 11 for receiving the output from the NAND gate 10. When the NAND gate 10 is supplied with an address A 2 =1 and A 1 =1, the address are subjected to a logical operation in the test commanding section 7 so that signal "H" is output as the test commanding signal from the INV gate 11 through the line 901. In this embodiment, the memory device according to the present invention is implemented such that the test mode register in the conventional memory device of FIG. 1 is replaced by a second address decoder and the test commanding section.
FIG. 5 is a timing diagram showing signals generated in the semiconductor memory device of FIG. 3 having the test commanding section 7 of FIG. 4. Address "110" for designating the first test mode among two test modes (or address "111" for designating the second test mode) are input synchronously with an address enabling signal. Then, the test commanding signal on the line 901 becomes an active level (H-state). The test mode selecting section 8 in FIG. 3 is activated by the active level on the test commanding line 901 so that a test mode selecting line 1201 (or 1202) is driven up to an H-state. The test performing section 18, after receiving the test mode selecting signal, executes a test inside the memory device in accordance with the first (or second) test mode.
order to stop the execution of the test, one of the addresses "000"-"101" assigned to the memory cell array 17, for example "000" as shown in FIG. 5, is input synchronously with the address enabling signal 101. Then, the test commanding signal on the line 901 becomes an inactive level (L-state), and both test mode selecting lines 1201 and 1202 become in an L-state. Hence, the test performing section 18 stops the test, and the memory device turns from the test operation mode to a normal operation mode.
The test mode selecting section 8 can be implemented by a combinational circuit, if the test performing section 18 has a function for latching the test mode selecting signal and a function for stopping a test when the output of the test commanding section is deactivated.
FIG. 6 is a circuit diagram showing a second test commanding section 7' for replacing the first test commanding section 7 in the memory device of FIG. 3, according to the second embodiment of the present invention. In this embodiment, the test commanding section 7' is comprised of a sequential circuit including a NAND gate 10, an INV gate 11, and two D-type flip-flops 14 and 15 which are cascaded in sequence. The test commanding section 7' of FIG. 6 generates a test commanding signal 901 in response to bits A 1 and A 2 of an input address 101 supplied synchronously with a clock signal (CLK) 2001 FIG. 7 shows a timing diagram for the second embodiment.
When an address A 2 =1 and A 1 =1 are input, a signal "1" is supplied from the INV gate 11 to the first flip-flop 14. After the same address is again input synchronously with the next clock signal 2001, an active level "H" is output on the output line 901 from the second flip-flop 15. In this manner, when an address assigned to the second group, for example address "110", is input twice synchronously with the clock signal 2001, the test commanding signal line 901 becomes in an H-state so that the test mode selecting section 18 of FIG. 3 is activated.
Further, when an address assigned to the first group, for example address "000" as shown in FIG. 7, is successively input twice, the test commanding signal line 901 becomes in an L-state so that the test mode selecting section 8 in FIG. 3 is inactivated. As a result, both of the output lines 1201 and 1202 of the test mode selecting section 8 become in an L-state to thereby inform the test performing section 18 of the end of the test operation mode.
In the second embodiment, the test commanding signal is transmitted to the test mode selecting section 8 by successively inputting the same address twice. If a surge pulse of a high level enters through the address bus 1 to the test commanding section 7', the AND gate 10 and the INV gate 11 may output a wrong signal. However, the wrong signal is not output from the test commanding section 7' so long as the surge pulse does not remain high during two clock cycles. In this manner, switching between the test operation mode and the normal operation mode is performed with certainty, so that it is possible to avoid an error in the semiconductor memory device more effectively than the first embodiment.
Although the present invention is described with reference to the preferred embodiments, the present invention is not limited to such embodiments and it will be obvious for those skilled in the art that various modifications or alterations can be easily made based on the above embodiments within the scope of the present invention. | A semiconductor memory device comprises an address bus having plural bits for designating addresses included in a first address group assigned to a memory cell array and in a second address group assigned to plural test modes, a first address decoder for decoding addresses in the first address group, and a second address decoder for decoding addresses in the second address group. A test commanding section generates a test commanding signal responsive to any one of addresses assigned to plural test modes. The second decoder acting as a test mode selecting section is activated by the test commanding signal to generate a test mode selecting signal from addresses assigned to the test modes. A test performing section tests inside the memory device in one of the test modes based on the test mode selecting signal. Number of data items to be input for executing a test inside the memory device is reduced without increasing an external pins. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The present invention relates generally to communication systems of coded data and, more specifically, to an improvement in the first interleaver of a two interleaver transmitter.
[0002] Although the present invention will be described with respect to code division multiple access (CDMA) system, the same method can be used on other interleavers in other systems. General and specific references will also be made to the CDMA standard 3GPP TS 25.212: “Multiplexing and channel coding (FDD)”.
[0003] Interleaving is an important function specific to the most digital communication protocols. It provides the means to undermine the burst noise that frequently affects the quality of reception in the digital communication systems as discussed by K. S. Andrews, C. Heegard, and D. Kozen in A Theory of Interleavers , Technical Report TR97-1634, Department of Computer Science, June 1997; and Chris Heegard and Stephen B. Wicker in Turbo Coding , Kluwer Academic Publishers, 2000.
[0004] Bit wise block interleavers represent a tremendous challenge for programmable micro-computing machines. An efficient software implementation for the interleavers offers multiple advantages, such as re-programmability, power and computation efficiency, fast development time, and eliminating the need for dedicated hardware block.
[0005] Specific to CDMA communication protocol, the first block interleaver function deals with block sizes containing a variable number of bits depending on the propagation conditions. Although padding bits in the second interleaver followed by pruning is common, there is no discussion of padding bits in the first interleaver.
[0006] The present invention involves padding the bit sequence in the first interleaver. The present method adds to an end of the bit sequence a sufficient number of padded bits L to permit modulus 16 operation of the bit sequence. After performing the interleaving, L bits are removed from an end of the interleaved sequence. This allows the interleaving to be performed in 16-bit segments simultaneously.
[0007] The adding can include adding randomly alternating zero and one bits. The number of L bits is determined by:
L= 16−Mod 16 ( X i )
[0008] where, Mod 16 represent modulus sixteen operation, and X i is the input bit sequence.
[0009] The method applies to any block size and executes 16 bits or multiples of 16 bits interleaving at once. The interleaving is performed in software and without forming a matrix of the bit sequence. The toll paid is a small number of errors introduced by this method. The errors are corrected at the receiver by the forward error correcting (FEC) function.
[0010] These and other aspects of the present invention will become apparent from the following detailed description of the invention, when considered in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a block diagram of a general multiplexing structure of the prior art.
[0012] [0012]FIG. 2 is a flow chart of a method of first interleaving incorporating the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] A typical receiver is shown in FIG. 1. A cycle redundant check (CRC) processes the bit sequence a and produces the bit sequence b. A transport block (TrBk) concatenation and code block segmentation is performed after signal coding producing sequences c and o, respectively. Radio frame equalization produces sequence t. There is a first interleaver whose output d is processed by radio frame segmentation and rate matching producing sequences e and f, respectively. Next, transport channel (TrCH) multiplexing produces a sequence s, which is a coded composite transport channel (CCTrCH). Next, physical channel segmentation produces sequence u, which is transmitted through a second interleaver to produce sequence v. Finally, physical channel mapping is performed to produce physical channels PhCH.
[0014] A method for the first interleaver suitable for efficient software implementation is presented. The method takes advantage of the integer unit of the micro-computing machine by performing 16-bit interleaving at once. The interleaving is performed in software and without forming a matrix of the bit sequence. By employing this method, a small error, inverse proportional with the number of interleaved bits will be introduced. At the receiver end, the errors will be corrected by the FEC (Forward Error Correction) unit.
[0015] The method, as illustrated in FIG. 2, begins with the bit sequence X i at input 10 . First, a determination of the number of padding bits to be added to the sequence X i must be made at 12 . The number of bits L to be added brings the total sequence to a number of bits which is divisible by 16 without a remainder. For example, if the bit sequence X i is 324 bits, the remainder is 4 when 324 is divided by 16. Thus, the number of padded bits is 12 or 16 minus 4.
[0016] Next, L padding bits are added to an end of the bit sequence at 14 to produce a bit sequence X i +L. Next, interleaving is performed on the padded sequence at 16 and produces sequence Y i . Next, L bits are removed from an end of the sequence Y i at 18. The resulting output bit sequence is Y i −L at 20. The sequence is farther processed through the flow chart of FIG. 1 and transmitted.
[0017] It should be noted that the L bits may be added at the beginning or the end of the sequence to X i , and L number bits may be removed from either end. The removed bits may be at the same or at a different end of the sequence, as was added to X i . This makes no difference in that the results are the same. There is no attempt to prune the added bits from the interleave sequence Y i at the exact location of the padded bits. Pruning would remove the bits in the interleave sequence Y i where they occurred after interleaving. This takes time and requires shuffling of the data bit sequence to make it continuous and, therefore, is wasteful in time and calculations.
[0018] The maximum number of padding bits L is 15. Thus, in the worst case, there will be 15 erroneous bits in the output bit sequence Y i −L. Because of the interleaving process moving the padded bits from one end of the bit sequence to different positions throughout the bit sequence, it is very unlikely that all padding bits will be left in the interleave sequence after L bits are removed. The padded bits are preferably random alternating zero and one bits, which reduces the possible number of incorrect bits. All zero or all one bits may also be used as the padded bits. Statistically, 8 of the 15 would probably be incorrect.
[0019] The number of padding bits L may be expressed or determined by the following formula:
L= 16 −Mod 16 ( X i )
[0020] where, Mod 16 represent modulus sixteen operation, and X i is the input bit, sequence.
[0021] By employing this method, a small error, inverse proportional with the number of interleaved bits will be introduced. At the receiver end, the errors will be corrected by the FEC (Forward Error Correction) unit.
[0022] Interleaver operation of step 16 may be that as described in the CDMA standard 3GPP TS 25.212: “Multiplexing and channel coding (FDD)” as follows:
[0023] The input bit sequence to the block interleaver is denoted by x i,1 ,x i,2 ,x i,3 , . . . , x i,X i , where i is the transport channel TrCH number, and X i is the number of bits. Here, X i is guaranteed to be an integer multiple of the number of radio frames in the TTI. The output bit sequence from the block interleaver is derived as follows:
[0024] (1) Select the number of columns C1 from table 4 depending on the TTI. The columns are numbered 0, 1, . . . , C1−1 from left to right.
[0025] (2) Determine the number of rows of the matrix, R1 defined as:
R 1= X i /C1.
[0026] The rows of the matrix are numbered 0, 1, . . . , R1−1 from top to bottom.
[0027] (3) Write the input bit sequence into the R1×C1 matrix row by row starting with bit x i,1 in column 0 of row 0 and ending with bit X i,(R1×C1) in column C1−1 of row R1−1:
[ x i , 1 x i , 2 x i , 3 … x i , C 1 x i , ( C 1 + 1 ) x i , ( C 1 + 2 ) x i , ( C 1 + 2 ) … x i , ( 2 × C 1 ) ⋮ ⋮ ⋮ … ⋮ x i , ( ( R 1 - 1 ) × C 1 + 1 ) x i , ( ( R 1 - 1 ) × C 1 + 2 ) x i , ( ( R 1 - 1 ) × C 1 + 3 ) … x i , ( R 1 × C 1 ) ]
[0028] (4) Perform the inter-column permutation for the matrix based on the pattern <P1 C1 (j)> jε{0, 1, . . . , C1−1} shown in table 1, where P1 C1 (j) is the original column position of the j-th permuted column. After permutation of the columns, the bits are denoted by y ik :
[ y i , 1 y i , ( R 1 + 1 ) y i , ( 2 × R 1 + 1 ) … y i , ( ( C 1 - 1 ) × R 1 + 1 ) y i , 2 y i , ( R 1 + 2 ) y i , ( 2 × R 1 + 2 ) … y i , ( ( C 1 - 1 ) × R 1 + 2 ) ⋮ ⋮ ⋮ … ⋮ y i , R 1 y i , ( 2 × R 1 ) y i , ( 3 × R 1 ) … y i , ( C 1 × R 1 ) ]
[0029] (5) Read the output bit sequence Y i,1 , Y i,2 , Y 1,3 , . . . , Y i,(C1×R1) of the block interleaver column by column from the inter-column permuted R1×C1 matrix. Bit Y i,1 corresponds to row 0 of column 0 and bit Y i,(R 1×C1) corresponds to row R1−1 of column C1−1.
TABLE 1 Inter-column permutation patterns for 1st interleaving Inter-column permutation patterns Number of <P1 C1 (0), P1 C1 (1), . . . , TTI columns C1 P1 C1 (C1 − 1)> 10 ms 1 <0> 20 ms 2 <0, 1> 40 ms 4 <0, 2, 1, 3> 80 ms 8 <0, 4, 2, 6, 1, 5, 3, 7>
[0030] In summary, the present method for the first interleaver is suitable for efficient software implementation. The method takes advantage of the integer unit of the micro-computing machine by performing 16-bit interleaving at once. By employing this method, a small error, inverse proportional with the number of interleaved bits will be introduced. At the receiver end, the errors will be corrected by the FEC unit.
[0031] Although the present invention has been described and illustrated in detail, it is to be clearly understood that this is done by way of illustration and example only and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims. | The present invention involves padding the bit sequence in the first interleaver. The present method adds to an end of the bit sequence a sufficient number of padded bits L to permit modulus 16 operation of the bit sequence. After performing the interleaving, L bits are removed from an end of the interleaved sequence. This allows the interleaving to be performed in 16-bit segments simultaneously. | 7 |
RELATED APPLICATION
[0001] The present application is a continuation-in-part of U.S. Patent Application Ser. No. 11/257,140, entitled “Switch Proxy for Providing Emergency Stand Alone Service in Remote Access Systems,” filed on Oct. 24, 2005. The present application also claims priority to U.S. Provisional Patent Application 60/694,146, filed on Jun. 27, 2005.
BACKGROUND OF THE INVENTION
[0002] This invention relates to access systems as used in wireline telephony and, more specifically, to a switch proxy for use in conjunction with an access system remote terminal to route telephone calls when communications between a remote terminal of an access system and its controlling switching system is lost.
[0003] Wireline telephone service providers use access systems to serve telephone subscribers that are not economically or practically served directly from the nearest local switching system. Examples of access systems of this type include subscriber loop carriers and digital loop carriers (or DLC's). An access system consists of a remote terminal that is connected to a local switching system (or central office or CO) by one or more digital trunk groups. The remote terminal can be located in a field cabinet, where the telephone subscriber's traditional copper pair is created in nearer proximity to the subscriber's premises. This capability improves the service that the subscriber receives and provides the telephone service provider with an economic alternative to long cable runs from the local switching system.
[0004] For engineering simplicity, remote terminals are typically designed to have very little independent operational capability. They rely on the host switching system for essentially all of the intelligence that would normally be associated with origination, routing and completion of a telephone call. The subscriber lines terminate at the remote terminal, which converts the voiceband signals into digital signals that are, in turn, multiplexed over digital channels on the trunk lines between the local switching system and the remote terminal. The trunk lines also carry separate digital channels for control information. The local switching system controls the remote terminal as if it were an extension of the switching system. For example, dial tone is sourced from the local switch and the dialed digits are collected by it.
[0005] In this manner, service providers are afforded more options in providing telephone service to subscribers. In particular, these access systems provide a much more economical approach to serve a small remote community of subscribers than the use of expensive local switching systems or proprietary remote switching modules. Typically DLC systems support between 100 and 2000 subscribers.
[0006] The simplicity of aggregating all of the call control functionality in the host switching system creates a problem in the art. That is, when the host switching system is unable to communicate with the remote terminal, either through failure of components of the digital trunks or of the switching system itself, subscribers served by the remote terminal no longer have any telephone service. Even though the connectivity with the greater network is lost and the remote terminal may be otherwise fully functional, the subscribers terminated on this remote system still cannot communicate with one another. The severity of this problem may be confounded by the fact that these subscribers are frequently served by this technology precisely because they are remote. These remote settings necessitate the use of local emergency responders and limit other communications options (e.g., cellular telephony). Therefore, the ability to continue to locally switch calls between subscribers served by remote systems that have lost communications with a host switching system is an important public safety consideration.
[0007] In urban deployments, the loss of connectivity to an access system may be only a minor inconvenience; nearby neighbors may be served from another system and cellular service will probably be available. Furthermore, urban densities allow for engineering the transport facilities with extra capacity that allows for “fail over” to protection facilities.
[0008] In rural settings, the remote terminal may provide the telephone services for an entire community. These rural communities could be very isolated from other communities and cellular service may be non-existent. Loss of communications between the host switch and the remote terminal in these circumstances could result in more serious consequences than in urban scenarios.
[0009] To mitigate the potential negative impact on public safety and communication among members of the community during such service outages, some rural public utility commissions and other agencies have promoted inclusion of Emergency Stand Alone (ESA) capabilities in telephone access systems. ESA capabilities typically include the ability for subscribers to dial 9-1-1 to reach public safety personnel and to complete telephone calls among the members of the local community isolated by the service outage.
[0010] The Public Safety Answering Point (PSAP) is normally the location where operators answer emergency calls and dispatch first responders. Usually, telephone services to a PSAP are provided directly from a central office and not from a DLC system. This is for a variety of reasons, including the fact that PSAPs generally require special trunks (e.g., CAMA trunks) to carry Automatic Number Identification (ANI) and Automatic Location Identification (ALI) information to emergency operators, and DLC systems typically do not support such special trunks. Therefore, isolated ESA systems (in emergency mode) will usually need to direct 9-1-1 calls to an alternative location, to a 9-1-1 designate, rather than to a PSAP. The 9-1-1 designate will, of course, need to be a subscriber served by the ESA system while in emergency mode, a sheriff's substation or a local fireman's home, for example, may be chosen for this responsibility.
[0011] Other suggestions in the prior art pertain to installation of a “miniature” switching system in the proximity of the remote terminal to serve as a local host. This approach is not only expensive but impractical on several counts:
i) it changes the basic architecture of the exchange network, ii) it increases the number of switches to administer and maintain, iii) it actually increases the probability of a service outage by putting another switching system into the chain, and iv) these remote terminals are frequently installed in field cabinets where it may be impossible to install an additional complex system.
[0016] Thus, there currently does not exist an economical or practical scheme for providing emergency stand alone service to subscribers served by the installed base of access systems. In addition, this invention discloses methods by which a 9-1-1 designate may be informed when incoming calls are emergency calls and be provided with information related to the caller similar to that available to a PSAP operator to insure proper handling of the call. In particular, the present invention addresses these issues by providing a ESA-capable system that enables 9-1-1 designates to be informed of the name, telephone number and address of emergency callers during these service outages.
SUMMARY OF THE INVENTION
[0017] This problem is solved and a technical advance is achieved in the art by a system and method that provides a switch proxy to control one or more remote terminals when connection to a host switching system is lost. A switch proxy in accordance with this invention comprises a controller, a translations database and a switching fabric, which are connected to the trunk group between the remote terminals and the local switching system. The controller, translations database and switching fabric are so adapted and configured that: a translations database maintains translations for its associated remote terminal(s) and the switching fabric has a capacity to switch calls among subscribers served by that switch proxy and its subtended remote terminals. Thus, no modification of existing infrastructure, either in the switching system or the remote terminal, is needed, except to introduce this switch proxy in the trunk group between the local switching system and the remote terminal. Indeed, neither the host switching system nor the remote terminal need be aware of the existence of this switch proxy for proper operation.
[0018] In accordance with one aspect of this invention, the switch proxy monitors control signals on the trunk group between the remote terminal and its controlling switching system. In the event of loss of communication of control signals on the trunk group, the switch proxy seizes control of all or a subset of the trunk group and re-establishes the interface with the remote terminal with itself acting as the “host switching system” thereby becoming the proxy for the actual host system. To the remote terminal, it appears as though a short outage with the switching system has occurred followed by restoration of some or all of the services from the switching system. The switch proxy intercepts requests for service, etc., from a calling telephone connected to the remote terminal and performs a look up in the translation database. If the call can be completed within the isolated remote system (i.e., the call is for a telephone also connected to the remote terminal or another subtended remote terminal), the controller of the switch proxy causes the switching fabric to loop the call back to the remote terminal and the causes the remote terminal to perform ringing and other such functions as required to establish the call. The switch proxy continues to monitor the transmission links towards the host switching system and when it ascertains that stable communications with that system have been restored, it initiates the process of dropping calls that it is carrying and reverts to monitoring, thus allowing the host switching system to resume providing service to the remote terminal. The switch proxy again takes up the role of monitoring the trunk group between the host switching system and the remote terminal.
[0019] Importantly, the switch proxy's translation database is maintained by a switch proxy management system, this translation database as a minimum maintains correspondence between a telephone subscriber's physical appearance (port address) on the remote terminal and its telephone number. Advantageously, as subscribers are rearranged by the telephone service provider, change orders for several remote terminals may be received and processed by the same switch proxy management system. The switch proxy management system forwards relevant changes to each switch proxy's translation database. Further, maintenance and updates to the switch proxy itself may be made in the same fashion. In this manner, a low-cost switch proxy may be used to maintain telephone service on a remote terminal when the remote terminal is disconnected from its host switching system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A more complete understanding of this invention may be obtained from a consideration of this specification taken in conjunction with the drawings, in which:
[0021] FIG. 1 is a block diagram of a wireline telephone system in which an exemplary embodiment of this invention is implemented;
[0022] FIG. 2 is a block diagram expanding on the details of FIG. 1 ;
[0023] FIG. 3 is a block diagram of an exemplary embodiment of the switch proxy of FIG. 1 and FIG. 2 ;
[0024] FIG. 4 is a state diagram illustrating the operational modes of a switch proxy;
[0025] FIG. 5 is a flow chart describing an exemplary embodiment of the control functions of a switch proxy of FIG. 3 ;
[0026] FIG. 6 is a flow chart describing an exemplary embodiment of call processing functions of a switch proxy;
[0027] FIG. 7 is a block diagram illustrating the functional components of a switch proxy management system; and
[0028] FIG. 8 is a flow chart illustrating the operation of the switch proxy management system of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 1 is a block diagram of a wireline local telephone network 100 in which an exemplary embodiment of this invention operates. In the wireline local telephone network 100 of FIG. 1 , a local switching system 102 (also referred to herein as local switch 102 or switching system 102 ), typically residing in a central office 104 is connected through trunk group 106 to the public switched telephone network (PSTN) 108 which provides for interconnectivity with subscribers worldwide. This configuration is used herein for convenience and clarity in describing the invention; it is well known in the art that local switching system 102 is part of PSTN 108 . A plurality of telephone subscribers 110 , 112 may be connected directly to the local switching system through subscriber lines. Additionally, a plurality of subscribers 114 , 116 , 118 , and 120 may be supported from remote terminals 122 and 124 which interconnect to the local switch through trunk groups 126 and 128 respectively. In the present context, a trunk group (also referred to herein as a trunk or trunks) consists of one or more physical transmission media (e.g., fiber optical cables or T 1 lines) transporting a multiplicity of digital channels between network elements such as, but not limited to, trunk group 126 between local switching system 102 and remote terminal 122 . In general, remote terminals 122 and 124 consolidate and concentrate signals to and from the customer telephones 114 , 116 , 118 , and 120 and connect these distant telephone subscribers to the local switch 102 over trunks 126 and 128 that have a capacity to support many voice and data channels over long distances. Such access system remote terminals as 122 and 124 are also known in the art as subscriber loop carriers (“SLCs”) and digital loop carriers (“DLCs”) and are functionally referred to as remote terminals. In accordance with this invention, a switch proxy 130 (illustrated herein in heavy block line and described in more detail in conjunction with FIG. 3 ) residing logically between the remote terminal 124 and the trunk 128 maintains telephone services between subscribers 118 and 120 served by remote terminal 124 when communications with local switch 102 is lost, for whatever reason. In this manner, some basic services that formerly were not provided when remote terminal 124 was isolated from local switching system 102 are now available. For illustration purposes, assume that remote terminal 124 provides service to a rural community many miles from local switching system 102 . Further, assume that telephone 120 is a telephone at a local public safety provider, such as (but not limited to) a local fire department or county sheriff's office. In the prior art, should communications with the local switch fail, a caller at telephone 118 could not contact telephone 120 in an emergency, even though both telephones are in the same community and the remote terminal is fully functional. In accordance with this invention, switch proxy 130 takes over during an outage and provides at least limited local service. Thus, telephone 118 can be connected to telephone 120 in accordance with this invention, even when local switching system 102 cannot provide service.
[0030] FIG. 2 further illustrates some interface details of subscribers 110 and 112 supported directly from switch 102 , and subscribers 114 , 116 , 118 and 120 deployed behind remote terminals 122 and 124 hosted by local switch 102 . Local switch 102 contains a switching fabric 202 that interconnects, on a channel-by-channel basis, a plurality of line units, herein represented by line units 204 and 206 and trunk units, herein represented by trunk unit 208 . These trunk and line unit subsystems serve to adapt the circuits useful to the network, such as telephone lines, to a format that can be switched by switching fabric 202 . Switching system 102 , as is well known in the art, provides many other functions such as billing and operator services, etc., which do not contribute to the understanding of this invention and are thus not described. Switching fabric 202 , line units 204 , 206 and trunk unit 208 are all well known in the art, do not form part of the invention and thus are not further described.
[0031] A control unit 210 causes switching fabric 202 to connect a particular line (or member of a trunk group) to another based on information contained in translations database 212 which associates an internal physical port address to a designation useful to the network, such as, a telephone number. When interfacing to access systems a special line unit called an integrated digital terminal (“IDT”) 214 can be used to interface directly with digital trunks 126 to communicate with and control remote terminal 122 . An alternative approach is represented by the use of a central office terminal 216 to convert a plurality of subscriber lines originating on line unit 206 into a multiplexed digital signal carried by digital trunk 128 that communicates to the remote terminal 124 . One skilled in the art will appreciate that the control signals embedded in trunks 126 and 128 must provide similar services and may, in fact, be identical regardless of the methodology (e.g., integrated digital terminal 214 or central office terminal 216 ) used to interface to switch 102 . These cases illustrate that the subscriber lines deployed using access systems do not differ significantly from those supported directly from switch line units in that they rely on the local switch for dialed digit collection, switching, translation, and other services.
[0032] As is standard in the art, control unit 210 of local switch 102 controls all remote terminals (herein 122 and 124 ). Thus, when a telephone (such as telephone 114 ) goes off-hook, remote terminal 122 detects the off-hook condition and reports the off-hook condition to integrated digital terminal 214 . Integrated digital terminal 214 forwards the information to control unit 210 . Control unit 210 causes switching fabric 202 to provide dial tone through integrated digital terminal 214 , digital trunk 126 and remote terminal 122 to telephone 114 . Telephone 114 then sends dual-tone, multifrequency signals (or dial pulses) back to control unit 210 , which decodes the signals into dialed digits and performs a look-up in translations database 212 to determine how to handle the call. As is well known in the art, the local switch 102 , by means of controller 210 controls the setup and tear down of all calls, whether originating or terminating on subtended remote terminals 122 and 124 . Signaling protocols are used between the access system remote terminal and the central office components (e.g., remote terminal 122 and integrated digital terminal 214 , and remote terminal 124 and central office terminal 216 , respectively) to coordinate the connection and signal the status of both ends. For example, GR-303 and GR-08, both generic requirements (GR) published by Telcordia, Inc. and well known in the art, are commonly used standards-based signaling protocols for providing telephone service through remote terminals. While some remote terminals (especially older remote terminals) use proprietary protocols, it is within the ability of one skilled in the art to build a switch proxy in accordance with whatever protocol may be used after studying this specification. The signaling uses bandwidth within the trunks interconnecting the remote terminal and the host switch (e.g., trunk 126 connecting host switch 102 and remote terminal 122 ) for messaging to convey status and cause actions, these messaging channels are also referred to as control signals.
[0033] FIG. 3 is a block diagram of switch proxy 130 illustrating certain exemplary aspects of this invention. In general, switch proxy 130 comprises a trunk monitoring unit 314 , a switching fabric 302 interconnected with a trunk interface unit 304 by connections 305 and interconnected with tones and receivers unit 318 by connections 316 , a bypass switch 312 , and a controller 306 which coordinates the operations of all of the subsystems. In this exemplary embodiment, switching fabric 302 comprises a time slot interchange unit. One skilled in the art will appreciate that other types of switching fabrics (e.g., space division solid state or metallic switches) may be employed to the same end.
[0034] In this exemplary embodiment, bypass circuit 310 is connected around the operational units of switch proxy 130 . Bypass circuit 310 includes a normally closed switch 312 . That is, during normal operation of remote terminal 124 under control of local switching system 102 , bypass switch 312 is closed and the switch proxy 130 is logically bypassed until such time as intervention is required. Thus, advantageously, failures within the switch proxy 130 are unlikely to affect normal operation of the remote terminal. A skilled practitioner of the art can suggest other embodiments in which this bypass circuit is not required, such as, but not limited to, passing the traffic actively from trunk 128 to trunk 132 through switch proxy 130 .
[0035] A trunk monitoring unit 314 is connected to trunk 128 in parallel with bypass circuit 310 on the central office terminal 216 side of switch proxy 130 . Trunk monitoring unit 314 monitors trunk 128 for control signals from local switching system 102 and/or responses from remote terminal 124 as well as alarm indications related to the serviceability of the trunk. When a service interruption is detected, trunk monitoring unit 314 notifies controller 306 while continuing to monitor trunk 128 . Controller 306 causes switch 312 to open and begins to supervise trunk 132 from remote terminal 124 by means of trunk interface unit 304 . Controller 306 sends and receives control signals to/from telephones connected to remote terminal 124 by means of the control channels embedded in trunks 132 in the same manner as local switch 102 does during normal operation. Based on information in these control signals, controller 306 causes switch fabric 302 to interconnect channels associated with subscribers in trunk 132 with the appropriate tones, dialed digit receivers and/or recorded announcements in tones and receivers unit 318 . After collection of the dialed information either through interpretation of rotary digits or from dual tone multi-frequency digits received by the tones and receivers unit 318 , the controller 306 consults the translation database 308 to determine if the call can be completed within the subscriber base supported by remote terminal 124 or another remote terminal (not shown) served by switch proxy 130 . If the call can be completed, controller 306 causes switching fabric 302 to connect one telephone to another. If it is not possible to route the call (e.g., the subscriber is not served by a remote terminal subtended to switch proxy 130 ) controller 306 causes switching fabric 302 to connect the calling party to an appropriate tone or recorded announcement supplied by tones and receivers unit 318 .
[0036] Controller 306 uses data stored in translation database 308 to provide such information as to determine what connections are possible as well as to provide translations between physical port addresses and telephone numbers. In addition, translation database 308 may contain information that would be useful to emergency responders such as, but not limited to: subscriber name and address, GPS coordinates, and prioritized emergency responders for each subscriber based on location. These data, or a subset thereof, in translation database 308 are synchronized to translation database 212 in local switch 102 regarding telephones connected to remote terminal 124 . Such synchronicity may be provided by a centralized switch proxy management system (which will be described herein, below, in conjunction with FIG. 7 ) or manually through a local interface to switch proxy 130 . Two exemplary approaches to management of the switch proxy 130 are illustrated in FIG. 3 : a centralized switch proxy management system 134 is interconnected to the remote switch proxy. 130 via communications means 136 ; altematively, a local terminal 140 (sometimes referred to in the art as a craft terminal) interconnects with the switch proxy 130 through communications means 138 . Communications means 136 and 138 can be, but are not limited to, dial-up modem, Ethernet, or direct serial connection as is well known in the art.
[0037] An overview of the operational modes of switch proxy 130 are illustrated in FIG. 4 in conjunction with FIG. 3 . As long as the remote terminal 124 continues to communicate normally with the host switch as determined by trunk monitoring unit 314 , bypass switch 312 remains closed and the controller 306 operates in the bypass and monitoring mode 402 in FIG. 4 . In this mode, the switch proxy 130 remains vigilant to the operational status of the trunks as shown in decision loop 406 but does not intervene in the control of remote terminal 124 . When trunk monitoring unit 314 concludes that the control signals between the host switch 102 and remote terminal 124 have failed, controller 306 changes state through process 408 to the emergency stand alone mode 404 and takes action to assume control of remote terminal 124 . While the system operates in emergency stand alone mode 404 , trunk monitoring unit 314 continues to monitor the status of trunk group 128 and as indicated by decision loop 412 will remain in emergency stand alone mode 404 as long as trunk group 128 cannot communicate with host switch 102 . While in emergency stand alone mode 404 , controller 306 causes bypass switch 312 to open and asserts control of trunk 132 to remote terminal 124 by means of trunk interface unit 304 . When trunk monitoring unit 314 ascertains that trunk group 128 has returned to operational status, controller 306 through process 410 restores the switch proxy 130 to bypass and monitor mode 402 . One skilled in the art will appreciate that momentary and/or transient behaviors in trunk group 128 should not be cause for switch proxy 130 to transition between operational modes 402 and 404 or vice versa.
[0038] FIG. 5 expands on the details of FIG. 4 and provides an exemplary embodiment of emergency stand alone operational mode 404 . Processing begins in bypass and monitoring mode 402 . When trunks 128 between the host switch 102 and the remote terminal 124 are no longer functional, decision block 406 passes processing to block 502 where bypass switch 312 is opened and simultaneously in block 504 trunks 128 are conditioned into an alarm state known in the art as “remote alarm indication” to assist in restoring service. In block 506 controller 306 by means of trunk interface unit 304 asserts control of trunks 132 towards remote terminal 124 . In preparation for call processing and using the appropriate signaling protocol (e.g., GR-303) controller 306 in block 508 establishes communications with remote terminal 124 and ascertains and initializes the status (on-hook, off-hook, ringing, etc.) of the subtended subscriber lines through an audit process. Continuing on to block 510 switch proxy 130 now begins to process calls for remote terminal 124 and remains in that mode until such time as service with the host switch 102 has been restored. The status of these trunks is ascertained by interrogating trunk monitoring unit 314 in decision block 512 . At such time as stable service in trunks 128 has been restored, processing transitions to block 514 . In this exemplary embodiment in block 514 the switch proxy does not terminate call processing services until such time as any ongoing 9-1-1 calls are completed, optionally this block may be omitted. Processing in block 516 causes trunk interface unit 304 to release trunk 132 (e.g., by entering into a disconnected or high impedance state) in preparation to restoring control to the host switch 102 through trunk 128 . Continuing with block 518 , bypass switch 312 is closed, restoring control of remote terminal 124 to host switch 102 and subsequently switch proxy 130 returns to bypass and monitoring mode 402 .
[0039] FIG. 6 expands upon the details of FIG. 5 and provides an exemplary embodiment of the call processing block 510 . For simplicity and as is common in the art, subscriber lines which originate a call are referred to as “calling” parties and those subscriber lines to which a call is placed are referred to as “called” parties. As described in the foregoing discussion of FIG. 5 , call processing block 510 is evoked after establishment of the control of remote terminal 124 in the emergency stand alone mode 404 . Beginning with block 602 wherein the controller 306 awaits a control message from remote terminal 124 through trunk interface unit 304 that a subscriber served by remote terminal 124 has gone off-hook and therefore requires service. In the case of a concentrating protocol (e.g., GR-303) switch proxy 130 then sends a control message to remote terminal 124 allocating a time slot on trunk 132 for the calling (off-hook) subscriber to use. In block 604 controller 306 connects the time slot allocated in the previous step to tones and receivers unit 318 by means of switching fabric 302 whereby calling party receives dial tone and has a digit receiver (both for rotary dialing and dual tone multi-frequency dialing, known in the art as an “originating register”) provided. After a proscribed number of dialed digits have been collected, processing moves to block 606 whereupon controller 306 interrogates translations database 308 as to the status of the called party as represented by the dialed number. For the purposes of this discussion, decision block 608 interprets the status of called party in one of three ways, to whit: that called party is on remote terminal 124 or other system (not shown) served by switch proxy 130 , called party is not on a served system, or that called party is 9-1-1. These three conditions require distinctive processing. One skilled in the art will understand that dial plans can be more complex than in the aforementioned exemplary embodiment and can be accommodated within the context of this invention.
[0040] Continuing on after decision block 608 , should the called party not be a subscriber served by switch proxy 130 (i.e., “off system”) processing passes to block 610 whereby controller 306 causes an appropriate call-progress tone (e.g., “fast busy”) or recorded announcement from tones and receiver unit 318 to be connected to the calling party through switching fabric 302 . After the calling party returns to on-hook or after a suitable time the call is cleared in block 612 . If decision block 608 confirms that the called party is served by switch proxy 130 (i.e., “on system”), processing is passed to block 614 whereupon the call is classified as a “normal call” (i.e., not a 9-1-1 call) for the duration of the call.
[0041] Finally, if the result of decision block 608 is that the called party is 9-1-1, processing is passed to block 616 whereupon the call is classified as a 9-1-1 call and afforded special treatment for the duration of the call. Connection with the public safety answering point (“PSAP”), as would be the case when functional communications exists between remote terminal 124 and host switch 102 , is not possible. In accordance with another aspect of this invention, translations database 308 contains one or more 9-1-1 designates, such as a sheriff's office or fire department, which may be advantageously associated with a specific calling party in order of preference. For example, the preferred 9-1-1 designate for a given calling party may be the one that is nearest in proximity. Initially the preferential 9-1-1 designate for this calling party is selected as the called party. If a 9-1-1 designate is busy on a call that is not a 9-1-1 call, the system will drop the existing non-9-1-1 call and will quickly connect the incoming emergency call to the 9-1-1 designate. Should processing return to block 616 as a result of a failure to complete this call, successive 9-1-1 designates are chosen and the call attempt is repeated (i.e., a “hunt group”). One skilled in the art will appreciate that many alternatives to this exemplary method of selecting alternative 9-1-1 designates to optimize the response to the calling party are possible. For example, a plurality of 9-1-1 designates could be simultaneously called and the first to answer assigned the call. This simultaneous call approach is a favored approach because it potentially finds a 9-1-1 designate faster than the hunt group approach.
[0042] It should be noted that if a 9-1-1 designate had an answering machine, the switch proxy could deliver emergency calls to the 9-1-1 designate's answering machine with potentially disastrous results. Thus, 9-1-1 designates should be instructed not to connect any answering machines to 9-1-1 designate lines.
[0043] Whether a normal or 9-1-1 call, processing will transfer to block 618 . Controller 306 communicates through trunk interface unit 304 to remote terminal 124 the port address of the called party, obtained in blocks 606 or 616 from translations database 308 , and allocates a second time slot on trunk 132 for the called party and communicates this with remote terminal 124 . Communications between controller 306 and remote terminal 124 utilize control signals embedded in trunk 132 and the applicable signaling protocol. Simultaneously remote terminal 124 is caused to initiate ringing on the called party's line. Controller 306 causes switching fabric 302 to connect the calling party time slot to an “audible ringing” tone via tones and receivers unit 318 .
[0044] Also in accordance with another aspect of this invention, special ringing patterns and caller ID messages may be sent to the called party in the event of a 9-1-1 call to advantageously alert the 9-1-1 designate as to the nature of the call. It is important that incoming emergency calls be identified to the 9-1-1 designate so that they are managed correctly. For example, if an emergency call were to come in at suppertime, and the 9-1-1 designate was unaware that the call was an emergency call, the designate may choose to ignore the call with possible disastrous results. Therefore, the system provides incoming emergency calls with “distinctive ringing”, that is, a ringing signal with an on/off pattern that is recognized as unique, so that the 9-1-1 designate recognizes that the incoming call is an emergency call. This allows the 9-1-1 designate to give the call proper (urgent) answering priority and to answer the call with an appropriate greeting.
[0045] When an emergency arises and an emergency call is made over normally operational telephone company communication systems, the emergency call is delivered to a PSAP, as is discussed above. Along with the call itself, ANI and ALI information are also delivered to the PSAP emergency operator, so that the operator knows (as a minimum) the telephone number and the address of the emergency caller and can dispatch emergency responders appropriately. This is important for a variety of reasons: because the caller may be hysterical, the caller may drop the telephone, the caller may become incapacitated, the call may be cut off, etc. In the switch proxy system described here, delivery of 9-1-1 caller information to a 9-1-1 designate is as important for the same reasons when in Emergency Stand Alone mode. In the present switch proxy system, the emergency caller's telephone number and name can be delivered using conventional telephony caller identification (Caller ID) mechanisms. In this context, as is well known in the art, these means consist of sending voiceband data signals containing the emergency caller's telephone number and name in the transmission path from the switch proxy to the 9-1-1 designate during the silent interval between ringing bursts. The 9-1-1designate needs to have a Caller ID display connected to the 9-1-1 designated line to receive and display the calling telephone number and name. In cases where the 9-1-1 designate needs only to be delivered the telephone number and name of emergency callers, conventional Caller ID equipment may be used.
[0046] In cases where it is desirable to deliver additional information, such as but not limited to, the emergency caller's address, to the 9-1-1 designate the designate line should have enhanced Caller ID equipment which contains additional data receiving and displaying capabilities. Furthermore, the switch proxy should have the ability to identify, encode and send the additional information. The switch proxy database should contain provisioning information indicating the capabilities of individual 9-1-1 designate's Caller ID equipment to optimize delivery of emergency caller's supplemental information. By means of this conventional and extended caller ID capability, the switch proxy in an advantageous and novel manner provides essential information to the 9-1-1 designate that hitherto would only have been available to personnel at the PSAP.
[0047] In block 618 , by means of an inquiry to database 308 , the capabilities of 9-1-1 designates to receive information related to the calling party may be ascertained and appropriate data signals sent as part of the “alerting” process towards the called party or parties. In the exemplary embodiment of FIG. 3 , when operating in ESA mode and a time slot has been established between the 9-1-1 designate and the trunk interface unit 304 , controller 306 may cause these data signals to be sent from tones and receivers unit 318 by means of switching fabric 302 .
[0048] The clearing of a stable call, represented by block 622 , is addressed in block 628 and requires particular attention in this exemplary embodiment in that it is advantageous to treat disconnection of normal calls and 9-1-1 calls differently. Whereas it is acceptable to clear stable calls of the “normal” type whenever either party returns to an on-hook state; control of the disconnection of a 9-1-1 call should, at least optionally, be the sole prerogative of the called party (i.e., the 9-1-1 designate). That is, should the calling party in a 9-1-1 call prematurely go on-hook it is desirable that the calling party be able to return to off-hook and continue the conversation with the 9-1-1 designate until such time as the called party goes to an on-hook state. This is known in the art as “called party control”.
[0049] Under this “called party control,” the connection between the emergency caller and the 9-1-1 designate does not get torn down when the emergency caller hangs up. It requires the 9-1-1 designate to hang up before the call is torn down. Thus, for example, if the emergency caller hangs up and tries to make another call while the 9-1-1 designate stays on the first call, the emergency caller is reconnected to the 9-1-1 designate as soon as the emergency caller goes off hook.
[0050] One last functional block in FIG. 6 needs to be addressed. All calls cleared from the system during ESA operation, regardless of cause, pass from block 612 onto block 630 which generates a record of the call for audit purposes. These records, known in the art as Call Detail Records (CDRs), contain information related to each call attempt which may include but is not limited to: calling and called party numbers, outcome of the call attempt, time and duration of the call, etc. These CDRs document the system operation while disconnected from the host switching system and afford some liability protection. The CDRs may be optionally retrieved from the switch proxy locally or archived through communications with the switch proxy management system.
[0051] In each of these cases it is necessary for the switch proxy to have access to a database containing port identifiers, names, telephone numbers, and optionally, supplemental information to support these features. The information in this database may be collected in several ways. Since the information needed is available in existing telephone company and public safety databases, it may be collected by searching for and retreiving the needed information in those databases. A similar manual mechanism can be used if the information needed is available in printed or on-line reports. In this case, a clerk periodically updates the database in the switch proxy management system (described herein, below, in conjunction with FIG. 7 and FIG. 8 ), based upon these reports. Once compiled, the information may periodically be downloaded to the switch proxy for use during Emergency Stand Alone mode. A mechanism for learning the telephone number of each port identifier in a DLC system using test calls has been described elsewhere. However, any name and address information will need to be collected from external databases and provided to the switch proxy either manually or automatically via a mechanized data delivery system. Because telephone systems are constantly changing as a result of responding to service orders, it is necessary to update these data in a timely way to insure that they are correct. Failure to update the switch proxy database in a timely way could result in sending emergency responders to incorrect locations with potentially disastrous results.
[0052] FIG. 7 is a block diagram of an exemplary embodiment of a switch proxy management system 134 in accordance with another aspect of this invention. This switch proxy management system 134 generally comprises a database 704 and a communications unit (or units) 706 , all responsive to processor 702 . At least one file is kept for each switch proxy in database 704 , wherein translations records for each line (such as lines 118 and 120 ) served by a switch proxy 130 are maintained. At a minimum, these records correlate the physical port address of the subscriber lines on the remote terminal with the telephone number. Additional information which may be associated with the subscriber line include, but are not limited to: name and address of the subscriber, emergency responders contact telephone numbers, and related information that would be useful during an emergency. This database may also be used to maintain operational information related to each switch proxy such as, but not limited to: configuration data, current software loads, aforementioned Call Detail Records, and time zone. Database 704 must be initially populated correctly and then maintained current, most importantly with respect to subscriber changes. This may be done manually (through e.g., management console 708 ) or in an automated fashion by reference to other databases that are maintained for other purposes such as, but not limited to, the service provider's operational support system or billing system through interface 710 , or third-party databases such as those maintained by 9-1-1 database providers through interface 712 . Said service provider's operational support system may be the same system that keeps translation database 212 of local switch 102 current.
[0053] The operation of switch proxy management system 134 will now be described in the context of the flow chart of FIG. 8 taken in conjunction with the block diagram of FIG. 7 . Processing starts in circle 800 . In block 802 , controller 702 causes communications unit 706 to interrogate external databases through interfaces 710 and 712 and management console 708 for changes. Processor 702 determines whether the data affects any line served by a switch proxy by comparing the data received to data in database 704 in decision block 804 . If no change affecting any switch proxy is detected, then processing loops back to block 802 and the change is ignored.
[0054] If, in decision block 804 , a change affecting one or more lines served by a switch proxy is detected, then a database lookup is performed on the affected line or lines in block 806 . Changes are recorded in database 704 in block 808 . Finally, all changes are transmitted to the affected switch proxy via communications unit 706 . The changes may be transmitted when discovered or may be transmitted as a batch job during non-peak times.
[0055] While this exemplary embodiment is described in terms of a direct connection between switch proxy management system 134 and one or more switch proxies and external databases through interfaces 710 and 712 , one skilled in the art will appreciate that there are many ways to provide this interconnection. For example, these connections may be over dial-up modems, Ethernet, or proprietary telemetry networks.
[0056] It is to be understood that the above-described embodiments of this invention are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by one skilled in the art without departing from the scope of the invention. It is therefore intended that such variations be included within the scope of the following claims and their equivalents. | A switch proxy comprising a controller, a translations database and a switching fabric are connected to a trunk group between a remote terminal and its controlling local switching system. The switch proxy monitors control and alarm signals to and from the switching system on the trunk. In the event of loss of control signals from the host switching system, the switch proxy intercepts requests for service, etc. from a calling telephone connected to the remote terminal and performs a look up in the translation database. If the call can be completed without the controlling switching system the call is looped back to the remote terminal. The translation database is maintained by a switch proxy management system that receives change orders from the local exchange carrier. The switch proxy management system forwards relevant changes to the switch proxy's translation database in the field. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a concrete finishing device for steps and more particularly pertains to smoothing poured concrete beneath formed riser on steps with a concrete finishing device for steps.
2. Description of the Prior Art
The use of concrete trowels is known in the prior art. More specifically, concrete trowels heretofore devised and utilized for the purpose of applying and smoothing various materials are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
By way of example, U.S. Pat. No. 3,947,916 to Mitchell discloses a trowel for masonry steps. U.S. Pat. No. 3,373,458 to Haivala discloses a step tool. U.S. Pat. No. 4,884,312 to Clark discloses a hand trowel. U.S. Pat. No. Des. 296,294 to Neece discloses the ornamental design for a concrete trowel. U.S. Pat. No. 4,822,209 to Dragich discloses an elongated concrete groover. U.S. Pat. No. 4,196,235 to Lindqvist discloses methods and apparatus for spreading semi-liquid compositions on a base surface.
While these devices fulfill their respective, particular objective and requirements, the aforementioned patents do not describe a concrete finishing device for steps for smoothing poured concrete beneath formed riser on steps.
In this respect, the concrete finishing device for steps according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of smoothing poured concrete beneath formed riser on steps.
Therefore, it can be appreciated that there exists a continuing need for new and improved concrete finishing device for steps which can be used for smoothing poured concrete beneath formed riser on steps. In this regard, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In the view of the foregoing disadvantages inherent in the known types of concrete trowels now present in the prior art, the present invention provides an improved concrete finishing device for steps. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved concrete finishing device for steps and method which has all the advantages of the prior art and none of the disadvantages.
To attain this, the present invention essentially comprises a trowel blade having an upper surface and a lower surface. The upper surface has a handle secured thereto. The handle is positioned closer to a back end than a front end of the trowel blade. The lower surface is dimensioned for troweling a surface of a step. The trowel blade has a countersunk screw extending upwardly therethrough inwardly of the front end. An adjustable gauge is coupled with respect to the trowel blade. The adjustable gauge comprises an L-shaped support adjustably coupled to the upper surface of the trowel blade inwardly of the front end thereof. The L-shaped support has a horizontal portion and a vertical portion. The horizontal portion has a slot extending therethrough across a width thereof. The horizontal portion is positioned on the upper surface of the trowel blade with the slot receiving the countersunk screw therethrough. A wing nut couples with the countersunk screw for tight securement of the adjustable gauge to the trowel blade.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an object of the present invention to provide a new and improved concrete finishing device for steps which has all the advantages of the prior art concrete trowels and none of the disadvantages.
It is another object of the present invention to provide a new and improved concrete finishing device for steps which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved concrete finishing device for steps which is of durable and reliable construction.
An even further object of the present invention is to provide a new and improved concrete finishing device for steps which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such a concrete finishing device for steps economically available to the buying public.
Even still another object of the present invention is to provide a new and improved concrete finishing device for steps for smoothing poured concrete beneath formed riser on steps.
Lastly, it is an object of the present invention to provide a new and improved concrete finishing device for steps including a trowel blade and an adjustable gauge coupled with respect to the trowel blade. The adjustable gauge can be adjusted to correspond with the width of a form riser on concrete steps to allow the concrete poured beneath the form riser to be properly finish the steps.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of the preferred embodiment of the concrete finishing device for steps constructed in accordance with the principles of the present invention.
FIG. 2 is a cross-sectional view as taken along line 2--2 of FIG. 1.
FIG. 3 is a side view of the present invention illustrated in use.
The same reference numerals refer to the same parts through the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular, to FIGS. 1 through 3 thereof, the preferred embodiment of the new and improved concrete finishing device for steps embodying the principles and concepts of the present invention and generally designated by the reference number 10 will be described.
Specifically, it will be noted in the various Figures that the device relates to a concrete finishing device for steps for smoothing poured concrete beneath formed riser on steps. In its broadest context, the device consists of a trowel blade and an adjustable gauge. Such components are individually configured and correlated with respect to each other so as to attain the desired objective.
The trowel blade 12 has an upper surface 14 and a lower surface 16. The upper surface 14 has a handle 16 secured thereto. The handle 16 is positioned closer to a back end 18 than a front end 20 of the trowel blade 12. Note FIG. 1. The lower surface 16 is dimensioned for troweling a surface of a step. Note FIG. 3. The trowel blade 12 has a countersunk screw 22 extending upwardly therethrough inwardly of the front end 20. Note FIG. 2.
The adjustable gauge 24 is coupled with respect to the trowel blade 12. The adjustable gauge 24 comprises an L-shaped support adjustably coupled to the upper surface 14 of the trowel blade 12 inwardly of the front end 20 thereof. The L-shaped support has a horizontal portion 26 and a vertical portion 28. The horizontal portion 26 has a slot 30 extending therethrough across a width thereof. Note FIG. 2. The horizontal portion 26 is positioned on the upper surface 14 of the trowel blade 12 with the slot 30 receiving the countersunk screw 22 therethrough. A wing nut 32 couples with the countersunk screw 22 for tight securement of the adjustable gauge 24 to the trowel blade 12. Optimally, the device 10 will be provided with a pair of wing nuts and a pair of countersunk screws so as to prevent any unwanted pivoting of the adjustable gauge 24 while in use.
In use, the adjustable gauge 24 is adjusted so that the distance between the vertical portion 24 and the front end 20 of the trowel blade is ever so slightly less than the width of the form riser 34 so that the trowel blade 12 can be slid beneath the riser 34 in order to smooth the surface thereunder without abutting the step 36 behind the riser 34. Note FIG. 3.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and the manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modification and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modification and equivalents may be resorted to, falling within the scope of the invention. | A concrete finishing device for steps including a trowel blade and an adjustable gauge coupled with respect to the trowel blade. The adjustable gauge can be adjusted to correspond with the width of a form riser on concrete steps to allow the concrete poured beneath the form riser to be properly finish the steps. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Provisional application Number 61196132, filed on Oct. 15, 2008.
[0002] Provisional application Number 61199027, filed on Nov. 12, 2008.
[0003] Provisional application Number 61271544, filed on Jul. 22, 2009.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0004] Not applicable to this application.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates generally to biomass combustion which comprises a suitably formable fuel and more specifically it relates to a continuous-fed biomass combustion system for efficiently extracting heat energy from unprocessed or processed biomass material of varying moisture content.
[0007] 2. Background
[0008] Combustion of biomass has been used by humankind to generate heat and light for thousands of years. Biomass was the world's predominant energy source until fossil fuels took over during the industrial revolution. Modern biomass can include, for example: wood, wood waste, agricultural waste, energy crops, municipal solid waste, sewage sludge and cellulostic-type industrial waste.
[0009] The burning of nondensified, loose grass has been one of the most utilized sources of biomass to generate heat and has been used for centuries. Many settlers on the Great Plains in the late 19th century stayed alive with grass heat. Hay was actually the fuel of choice in central and northern Nebraska until the corn culture supplanted it. However, feeding loose hay into a stove produced excessive smoke and required constant monitoring. These disadvantages led to various methods of processing the biomass prior to combustion.
[0010] One of the first processing methods was to densify the biomass. In the case of hay, in order to make the hay more compact, it was twisted into twig-like bundles called “cats.” This process was successful in reducing many of the disadvantages. New “stove” technology also became more advanced and produced hay-burning devices in four basic types: stove attachments, piston-driven stoves, drum stoves, and Russian furnaces. A common hay burning stove attachment was shaped like copper boilers used for washing but were twice as deep, holding about twenty pounds of hay. Lids on a cook stove were removed and the hay-filled attachment was placed with the open end down on the cook stove. A filled attachment could provide enough heat for two to four hours. Local blacksmiths made most of these stove attachments from sheet iron riveted together.
[0011] To address some of the above issues, most of the grass-burning devices currently under development are designed to use a much more densified version such as pellets or briquettes. The problem with densified biomass is that the equipment to compress biomass is very expensive to buy, requires significant maintenance, and requires significant power to operate.
[0012] A recent development is stoves that burn a single round bale of hay in a large chamber. The issues with this type of hay-burning stove include difficulties in modulating temperature as well as having a significant ash clean-out problem. The stove has to be completely shut down and allowed to cool before the ashes can be safely removed.
[0013] In the last decade, gasification has gotten a lot of attention. Gasification can be defined as a thermal process of changing a solid fuel such as coal, biomass, or municipal solid waste into combustible gas and oil vapors. Almost all kinds of biomass with moisture content of 5% to 30% can be gasified. Under controlled conditions that are characterized by low oxygen supply and high temperatures, most biomass materials can be converted into a gaseous fuel known as “producer gas”, which consists of combustible mixture of nitrogen, carbon monoxide, and hydrogen. Biomass gasification and/or combustion applications include water boiling, steam generation, drying, motive power applications such as using the producer gas as a fuel in internal combustion engines, and electricity generation.
[0014] Combustion problems with wood and other biomass fuels have been generally due to not enough heat for drying and ignition, uncontrolled cycles of drying and ignition, with either excess air or insufficient air, too much fuel burning at once or too little, and incomplete mixing of air and fuel. At the low burn rates generally required for domestic use exhaust emissions increase dramatically, because of incomplete combustion, which causes creosote and soot buildup on heat exchangers, and in turn fire hazards and even more inefficient heat transfer.
[0015] The main problems with the application of biomass gasification systems have been economic, not technical. For example, conventional biomass gasification systems are typically suitable only for large-scale operations and not small-scale operations. Also, the product from gasification is mainly a heat source and the low value of these products in today's market is insufficient to justify the capital and operating costs of conventional biomass gasification systems.
[0016] The present invention is capable of combusting a multitude of different materials including grasses without densification, wood and wood materials, waste paper and paper products, peat, refuse derived fuels (RDF), municipal solid waste, dry animal manure, or even shredded rubber tires.
[0017] The present invention also overcomes the disadvantage of combustion inefficiency. It is well documented that two-stage combustion (primary and secondary) helps minimize NOx (nitrogen oxide) formation and also has the advantage of increasing thermal efficiency by utilizing more of the fuel to product heat energy.
[0018] Also, conventional biomass fuel-burners suffer from the same symptoms of inefficient combustion. Relatively dry fuels are generally required for cleaner burning, but biomass fuels with 40% or higher moisture content (percentage of damp weight) are much more available in the form of logging residue, brush and agricultural waste. These fuels are generally available at a lower cost than seasoned cordwood and lend themselves better to automatic continuous fuel feed. The present invention overcomes these shortcomings by using an internal gasification process inside the primary combustion chamber to enable use of higher moisture content feedstock.
BRIEF SUMMARY OF THE INVENTION
[0019] In view of the foregoing disadvantages inherent in the known types of combustion and/or gasification apparatus now present in the prior art, the present invention provides a new biomass combustion system construction wherein the same can be utilized for efficiently extracting heat energy from biomass material.
[0020] The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new biomass combustion system that has many of the advantages of the combustion apparatus mentioned heretofore and many novel features that result in a new biomass combustion system which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art gasification apparatus, either alone or in any combination thereof.
[0021] To attain this, one embodiment of the present invention generally comprises a feedstock loading hopper, a hole-forming feedstock auger, an insulated feeder chamber, a fuel pre-heating magazine, a primary combustion chamber, a feedstock end stop grate at the end of the primary combustion chamber, a primary center air feed tube, a primary air modulating valve, a primary flow meter, an ash collection chamber, a stationary fan-type directing blade assembly, a secondary combustion chamber connected to the primary combustion chamber, secondary air pre-heating tubes, a secondary air mixer manifold, an airtight, insulated heat containment chamber/firebox, a secondary air modulating valve, a secondary flow meter, an insulated cyclonic filter, a residue collection bucket, a single-pass shell and tube heat exchanger, a high-temperature vacuum blower, a programmable control unit, a battery back-up system, an exhaust stack, and an air pre-heating jacket.
[0022] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and that will form the subject matter of the claims appended hereto.
[0023] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the terminology employed herein are for the purpose of the description and should not be regarded as limiting.
[0024] To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
[0025] A primary object of the present invention is to provide a biomass or formable fuel combustion system that will overcome the shortcomings of the prior art devices.
[0026] A second object is to provide a biomass combustion system for efficiently extracting heat energy from biomass material.
[0027] A further object is to provide a biomass combustion system that provides for usage of biomass combustion technologies within small-scale operations.
[0028] A further object is to provide a biomass combustion system that is capable of utilizing various types of readily available fuels.
[0029] A further object is to provide a biomass combustion system that provides a cost effective alternative fuel source compared to conventional fossil fuels.
[0030] A further object is to provide a biomass combustion system that is environmentally friendly and utilizes renewable resources.
[0031] A further object is to provide a biomass combustion system that has high combustion efficiency.
[0032] A further object is to provide a biomass combustion system that is automated and requires reduced maintenance.
[0033] A further object is to provide a biomass combustion system that may be utilized to produce heat.
[0034] A further object is to provide a biomass combustion system that forms a hollow feedstock for centrally introduced air whereby facilitating more complete combustion.
[0035] A further object is to provide a biomass combustion system that is completely surrounded with an air pre-heating jacket to better recycle, utilize, and contain the heat generated.
[0036] A further object is to provide a small biomass combustion system that may be ganged together for larger heat output demands.
[0037] A further object is to provide a biomass combustion system that completely removes products of combustion such as ashes and residues from the combustion area.
[0038] A further object is to provide automatic feeding of feedstocks and hollowing of feedstocks at the same time.
[0039] A further object is to utilize the compacted biomass to greatly reduce any uncontrolled air to enter the combustion area.
[0040] A further object is to collect any and all by-products of combustion by gravity into central collection areas for easy removal and disposal.
[0041] A further object of the invention is to provide an airtight heat containment chamber to enclose the combustion area and provide draft for complete combustion.
[0042] A further object of the invention is to use a high temperature blower in the exhaust stream to provide negative draft pressure for a heat containment chamber.
[0043] A further object of the invention is to utilize channels on the inside diameter of the combustion chamber to collect products of combustion and provide a flow path to the secondary combustion chamber.
[0044] A further object of the invention is to introduce combustion air to the hollow center of biomass and other feedstocks.
[0045] A further object of the present invention is to preheat all combustion air using an air jacket surrounding the combustion process.
[0046] A further object of the present invention is to monitor incoming combustion air with a flow meter in order to control it completely.
[0047] A further object of the present invention is to use high temperature insulating refractory materials to insulate the combustion chamber to effectively combust even with fuels containing almost half their weight in water.
[0048] A further object of the present invention is to capture most of the heat from the escaping exhaust gases by exhausting through a high efficiency heat exchanger.
[0049] A further object of the present invent is to provide combustion residue collection buckets that may easily be emptied at periodic intervals.
[0050] A further object of the present invention is to reduce the combustion mass as much as possible in order to modulate or shut down temporarily the burning (burn rate) when heat is not called for.
[0051] A further object of the present invention is to operate both primary and secondary combustion chambers at a very high temperature to ensure a substantially smokeless, clean exhaust.
[0052] A further object of the present invention is to use the screw auger and protruding rod to extrude the biomass into a hollow form that will retain shape as it is burned.
[0053] A further object of the present invention is to utilize the grate as a method to control where the combustion is taking place.
[0054] A further object of the present invention is to use a vertical grating system whereby gravity assists in removing ashes.
[0055] A further object of the present invention is to use the continuous pressure of the feedstock against the grate to remove ashes effectively.
[0056] Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages be within the scope of the present invention.
[0057] To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0059] FIG. 1 is a side cross sectional view of the present invention with heat exchanger and stack not shown for clarity.
[0060] FIG. 2 is a side view of the heat exchanger and stack of the present invention.
[0061] FIG. 3 is a view of the programmable control unit.
[0062] FIG. 4 is an end view of the present invention.
[0063] FIG. 5 is a discharge end view of the primary combustion chamber terminus with the grate and formed fuel shown.
[0064] FIG. 6 is a cross sectional side view of the primary and secondary combustion chamber.
[0065] FIG. 7 is an end view of the primary combustion chamber terminus.
[0066] FIG. 8 is a cross sectional view of the primary combustion chamber.
[0067] FIG. 9 is the fuel input and effluent stream discharge end view of the primary combustion chamber.
[0068] FIG. 10 is the inlet end view of the secondary combustion chamber.
[0069] FIG. 11 is a cross sectional side view of the secondary combustion chamber.
[0070] FIG. 12 is the exhaust discharge end view of the secondary combustion chamber.
[0071] FIG. 13 is a side view of the heat exchanger.
[0072] FIG. 14 is an exhaust input end view of the heat exchanger
[0073] FIG. 15 is an exhaust discharge view of heat exchanger.
[0074] FIG. 16 is a cross sectional view of the heat exchanger.
DETAILED DESCRIPTION OF THE INVENTION
[0075] In the following detailed description, reference is made to the accompanying drawings which form a part thereof, and in which is shown by way of illustration specific embodiments in which the invention is practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
[0076] FIGS. 1-16 illustrate a continuously-fed biomass combustion system according to one embodiment. Similar reference characters denote similar elements throughout the several figures. FIGS. 1 through 16 illustrate the biomass combustion system, which comprises a feedstock-loading hopper ( 21 ), a hole-forming feedstock auger ( 22 ) and elongated shaft ( 23 ) for delivering biomass, an insulated feeder chamber ( 26 ), a fuel pre-heating magazine ( 27 ), a primary combustion chamber ( 30 ), a feedstock end stop grate ( 35 ), primary center air feed tube ( 39 ), a primary air modulating valve ( 48 ), a primary flowmeter ( 49 ), an ash collection chamber ( 44 ), a stationary fan-type directing blade assembly ( 36 ), a secondary combustion chamber ( 37 ) fluidly connected to the primary combustion chamber, secondary air pre-heating tubes ( 52 ) connected to the secondary combustion chamber ( 37 ), a secondary air mixer manifold ( 55 ), an airtight, heat containment chamber ( 41 ) containing all combustion apparatus, a secondary air modulating valve ( 50 ), a secondary flowmeter ( 51 ), an insulated cyclonic filter ( 53 ) to remove pneumatically conveyed ash products, a residue collection bucket ( 54 ), a single-pass shell and tube heat exchanger ( 56 ) to remove heat from the exhaust gases and heat water, a high-temperature vacuum blower ( 58 ) to negatively pressurize the combustion process, a programmable control unit ( 59 ), a battery back-up system ( 60 ), an exhaust stack ( 61 ), and an air pre-heating jacket ( 43 ) to pre-heat both incoming primary and secondary air, and a propane ignition device ( 62 ).
[0077] The feedstock-loading hopper ( 21 ) is a typical V-shaped steel hopper that collects particles of feedstock ( 24 ) and gravity-delivers the material into the hole-forming feedstock auger ( 22 ). The feedstock-loading hopper ( 21 ) may optionally contain a slide gate, rotary lock, or manual cover ( 40 ).
[0078] The hole-forming feedstock auger ( 22 ) is constructed of spiral flights that are welded to a shaft in typical fashion of any screw auger. The auger is powered by auger motor ( 70 ) and gearbox ( 25 ). At the end of the hole-forming feedstock auger is an elongated shaft ( 23 ) that forms a hollow cavity ( 29 ) in the center of the feedstock. This hollow cavity ( 29 ) stays formed in the feedstock as it moves slowly into and through the primary combustion chamber until stopped by the feedstock end stop grate ( 35 ) at the terminus of the primary combustion chamber ( 30 ). The elongated shaft ( 23 ) also serves to block air leakage into the airtight heat containment chamber ( 41 ). The formed biomass material ( 28 ) further discourages any airflow into the airtight heat containment chamber ( 41 ) by substantially forming a circumferential seal.
[0079] The insulated feeder chamber ( 26 ) is located between the feedstock-loading hopper ( 21 ) and the airtight heat containment chamber ( 41 ). The insulated feeder chamber ( 26 ) is fluidly connected to the hole-forming feedstock auger assembly ( 22 ) and the pre-heating feedstock magazine ( 27 ).
[0080] The fuel pre-heating magazine ( 27 ) begins to pre-heat the feedstock because it is in contact with the hot combustion gases in the inside of the airtight heat containment chamber ( 41 ). The fuel pre-heating magazine ( 27 ) is fluidly connected to the primary combustion chamber ( 30 ) and slides smoothly inside to deliver the feedstock as illustrated in FIG. 6 .
[0081] The primary combustion chamber ( 30 ) is where primary combustion occurs thereby converting the biomass to a producer gas. The primary combustion chamber ( 30 ) in this embodiment is designed for combusting formable fuel such as, but not limited to: corn stover, switchgrass, reed canarygrass, forest slash, urban wood waste, lumber waste, wood chips, sawdust, straw, firewood, agricultural residue, dung and the like. The primary combustion chamber ( 30 ) is fluidly connected with the fuel pre-heating magazine ( 27 ) and the ash collection chamber ( 44 ). It has an internal diameter consistent with the inside diameters of both the fuel pre-heating magazine ( 27 ) and the insulated feeder chamber ( 26 ). The primary combustion chamber ( 30 ) contains a plurality of longitudinal tapered gas channels ( 32 ) of varying depth around the inside diameter of the primary combustion chamber ( 30 ). These air channels serve to fluidly connect the primary combustion chamber ( 30 ) with the secondary combustion chamber ( 37 ). The tapered gas channels ( 32 ) can get progressively larger and wider if dictated by application as they approach the secondary combustion chamber ( 37 ) in order to avoid any unburned particles of biomass from blocking the flow of hot gasses. The primary combustion chamber ( 30 ) is constructed of steel tubing welded to an angle ring ( 33 ) to act as a shell or containment structure for the refractory material ( 34 ) as shown in FIG. 7 and FIG. 8 . The insulating refractory material ( 34 ) can be cast in place and held secure after curing using special studs ( 31 ) welded to the outside tubing.
[0082] The feedstock end stop grate ( 35 ) is located at the ash end of the primary combustion chamber ( 30 ) and physically stops the formed biomass material ( 28 ) from entering the ash collection chamber ( 44 ) until it has a soft and crumbly consistency consistent with resulting carbon char and ash. In this effect, the grate acts as a filter to separate the firm and more dense combusting formed biomass material ( 28 ) from the less dense ashes ( 47 ). The feedstock end stop grate ( 35 ) in this embodiment has a rectangular structure, but can be of various shapes and dimensions based on feedstock, feed rate and other system variables.
[0083] The primary center air feed tube ( 39 ) is fluidly connected to the primary air modulating valve ( 48 ) and the hollow cavity ( 29 ) of the biomass feedstock ( 28 ). An angle is cut into the end of the primary center air feed tube ( 39 ) to avoid blockage by any formed biomass material ( 28 ) as well as ashes ( 47 ), carbon, and char. The primary center air feed tube ( 39 ) preferably includes a plurality of openings, not shown, within it for allowing air to pass unobstructed into the hollow biomass thereby feeding the primary combustion process. This has the effect of delivering primary combustion air directly to the hollow cavity ( 29 ) of the formed biomass material ( 28 ) so air can progress toward the outside diameter of the formed biomass material ( 28 ) induced by the negative pressure in the secondary combustion chamber ( 37 ) and heat containment chamber ( 41 ) by the vacuum blower ( 58 ) whereby insuring evenly distributed combustion air flowing through the fuel in the primary combustion chamber ( 30 ).
[0084] The primary air modulating valve ( 48 ) is fluidly connected to the primary center air feed tube ( 39 ) and the primary flowmeter ( 49 ). It is in communication with the programmable control unit ( 59 ) and receives a signal from the programmable control unit ( 59 ) commanding a specific airflow rate based on process parameters. In this embodiment the primary air modulating valve ( 48 ) is continuously variable between shut off (0%) and fully open (100%).
[0085] The primary flowmeter ( 49 ) is fluidly connected in series with the primary air modulating valve ( 48 ) and the air pre-heating jacket ( 43 ). In this embodiment, the primary flowmeter ( 49 ) is of the paddle wheel type and produces and sends a feedback signal proportional to flow rate to the programmable control unit ( 59 ). The programmable control unit ( 59 ) then processes this input and others to generate a new command signal for primary air modulating valve ( 48 ) and other process control elements to produce the most efficient combustion of biomass.
[0086] The ash collection chamber ( 44 ) is fluidly connected with the primary combustion chamber ( 30 ) and the ash cleanout bucket ( 45 ). The ash collection chamber ( 44 ) is airtight and has a tapered bottom to assist the ashes to fall into the ash collection bucket ( 45 ). Pre-heated primary combustion air is plumbed through the ash collection chamber ( 44 ) from the primary air modulating valve ( 48 ) to the primary center air feed tube ( 39 ) and transported into the hollow cavity ( 29 ) in the formed biomass material ( 28 ). The access hatch ( 46 ) is removable to allow inspection of the feedstock end stop grate ( 35 ) and propane ignition device ( 62 ).
[0087] The stationary fan-type directing blade assembly ( 36 ) is a hollow, round, formed steel mechanism that is fastened to the end of the fuel pre-heating magazine ( 27 ) that changes the course of the escaping combustion gases coming out of the tapered gas channels ( 32 ) in the primary combustion chamber ( 30 ). As the gas leaves the primary combustion chamber ( 30 ) it is deflected from a linear path to a helical path around the inside of the secondary combustion chamber ( 37 ). This serves as a centrifugal separator forcing any heavier, unburned particulates toward the wall on the inside of the secondary combustion chamber ( 37 ) where they can be mixed with the incoming heated air from the holes in the end of the secondary combustion chamber ( 37 ).
[0088] The secondary combustion chamber ( 37 ) is fluidly connected with the secondary air pre-heating tubes ( 52 ), the primary combustion chamber ( 30 ), and the inside of the airtight heat containment chamber ( 41 ). Two-stage combustion helps increase combustion efficiency and minimize NOx formation. The secondary combustion chamber is preferably constructed of a welded steel shell with similar construction as the primary combustion chamber ( 30 ). It has the insulated refractory material ( 34 ) cast on to the welded refractory wall support studs ( 31 ) to better contain the high heat of the secondary combustion process. The secondary combustion chamber ( 37 ) is supported at one end by the primary combustion chamber ( 30 ) and at the other end by the fuel pre-heating magazine ( 27 ). The slightly lower pressure inside the airtight heat containment chamber ( 41 ) draws hot gasses from the primary combustion chamber ( 30 ) as well as from heated air from the secondary air pre-heating tubes ( 52 ). As the two gas streams mix, the remaining fuel is self-ignited as a secondary combustion process for more complete combustion. The gas mixture continues to rotate around the inside of the secondary combustion chamber ( 37 ) until it finds the gas exit channel ( 63 ) at the end and bottom of the secondary combustion chamber ( 37 ). This gas exit channel ( 63 ) is formed into the refractory material ( 34 ) to allow the exhaust to exit the secondary combustion chamber ( 37 )
[0089] The secondary air pre-heating tubes ( 52 ) are fluidly connected with the secondary air mixer manifold ( 55 ) and the holes ( 38 ) in the end of the secondary combustion chamber ( 37 ) as shown in FIG. 6 . The secondary air pre-heating tubes ( 52 ) in this embodiment are a series of stainless steel convoluted tubing. The convolutions in the tubing aid in creating turbulence inside the tubing that increasing convective heat transfer inside the tubes. The secondary air pre-heating tubes ( 52 ) supply heated air containing oxygen into the effluent stream emitted from the biomass in the primary combustion chamber ( 30 ), thereby providing a much cleaner and reduced pollution exhaust stream.
[0090] The secondary air mixer manifold ( 55 ) is fluidly connected to the secondary air pre-heating tubes ( 52 ) and secondary air modulating valve ( 50 ) and distributes the incoming air into several secondary air pre-heating tubes ( 52 ) thus increasing the amount of surface area available for heat transfer thereby increasing the temperature of the combustion air. The secondary air mixer manifold ( 55 ) is located inside the heat containment chamber ( 41 ) to aid heat transfer as well.
[0091] The airtight heat containment chamber ( 41 ) is fluidly connected with the gas exit channel ( 63 ) in the end of the secondary combustion chamber ( 37 ), and the insulated filter ( 53 ). The airtight heat containment chamber ( 41 ) is held in negative pressure by the high temperature vacuum blower ( 58 ) located further downstream. Controlled entry for primary and secondary combustion air is maintained by negative pressure within the heat containment chamber ( 41 ). However, air movement/entry through the formed biomass material ( 28 ) is substantially prevented by the length of compacted biomass forming a circumferential seal, as well as the elongated shaft ( 23 ) that plugs the hole in the center of the formed biomass material ( 28 ). It is this predictable air intake behavior that can be adjusted/accounted for by the programmable control unit ( 59 ) when it sends signals to the primary air modulating valve ( 48 ) and secondary air modulating valve ( 50 ) to allow both primary and secondary air into the process.
[0092] The secondary air modulating valve ( 50 ) is identical to the primary air modulating valve ( 48 ) and is fluidly connected with the secondary air mixer manifold ( 55 ) and the secondary flowmeter ( 51 ). It is in communication with the programmable control unit ( 59 ) control unit and receives a signal from the programmable control unit ( 59 ) commanding a specific airflow rate based on process parameters. In this embodiment the secondary air modulating valve ( 50 ) is continuously variable between shut off (0%) and fully open (100%).
[0093] The secondary flowmeter ( 51 ) is identical to the primary flowmeter ( 49 ) and is fluidly connected between the secondary air modulating valve ( 50 ) and the air pre-heating jacket ( 43 ). In this embodiment, the secondary flowmeter ( 51 ) is of the paddle wheel type and produces and sends a feedback signal proportional to flow rate to the programmable control unit ( 59 ). The programmable control unit ( 59 ) then processes this input and others to generate a new command signal for secondary air modulating valve ( 50 ) and other process control elements to produce the most efficient combustion of biomass.
[0094] The insulated high temperature cyclonic filter ( 53 ) is fluidly connected to the airtight heat containment chamber ( 41 ), the residue collection bucket ( 54 ), and single-pass shell and tube heat exchanger ( 56 ). The heavier particles exit the bottom of the filter where they enter the residue collection bucket ( 54 ). Also, any fly ash, liquid, or solid debris that drips or falls from the end of the single-pass shell and tube heat exchanger ( 56 ) falls into the same residue collection bucket ( 54 ). The insulation around the filter reduces any heat loss in the combustion gases thereby increasing thermodynamic efficiency. The filter may also be comprised of other common configurations such as a high temperature baghouse or electrostatic precipitator.
[0095] The residue collection bucket ( 54 ) is positioned at the lower end of the insulated cyclonic filter ( 53 ) and is meant to be emptied as necessary.
[0096] The single-pass shell and tube heat exchanger ( 56 ) is constructed similar to any shell and tube heat exchanger using a plurality of stainless steel thin-wall tubes ( 69 ). At the input end an input header ( 66 ) is fluidly connected to the output of the insulated cyclonic filter ( 53 ) and accepts the hot combustion gases ready for heat removal. An alternative heat extraction method may include heating water and/or liquids, producing steam, and/or producing super-heated gases or other applications such as Stirling engines, absorption cooling, or CHP (combined heat and power) integrated into the heat containment chamber ( 41 ). The heat extraction method is not restrictive of location and may be located in the primary combustion chamber, secondary combustion chamber, heat containment chamber, filter, or any other suitable location within the device.
[0097] At the other end of the single-pass shell and tube heat exchanger ( 56 ) is the output header ( 67 ). The output header section is fluidly connected to the high temperature vacuum blower ( 58 ) for final exhaust of the cooled combustion gas to the atmosphere.
[0098] In the shell section is located water inlets and outlets typical of any heat exchanger. The shell section may also contain an expansion joint ( 65 ) if required.
[0099] A high temperature vacuum blower ( 58 ) is fluidly connected to the output header ( 67 ) of the single-pass shell and tube heat exchanger ( 56 ) and the exhaust stack ( 61 ). This blower uses suction to create a negative pressure (vacuum) inside all of the components including; output header ( 67 ) of the single-pass shell and tube heat exchanger ( 56 ), input header ( 66 ) of the single-pass shell and tube heat exchanger ( 56 ), the cyclonic filter ( 53 ), and the airtight heat containment chamber ( 41 ), the primary combustion chamber ( 30 ), the tapered primary center air feed tube ( 39 ), the primary air modulating valve ( 48 ), the primary flowmeter ( 49 ), the secondary combustion chamber ( 37 ), the secondary air pre-heating tubes ( 52 ), the secondary air mixer manifold ( 55 ), the secondary air modulating valve ( 50 ), the secondary flowmeter ( 51 ) and finally the air pre-heating jacket ( 43 ). Additionally, it also attempts to draw air from the fuel pre-heat magazine ( 27 ) through the hollow formed biomass material ( 28 ) but is restricted as the resistance to airflow of this path is much greater than the other paths.
[0100] A programmable control unit ( 59 ) as shown in FIG. 3 of the drawings is in communication with the primary air modulating valve ( 48 ), the secondary air modulating valve ( 50 ), the auger motor ( 70 ), the high temperature vacuum blower ( 58 ), and the propane ignition device ( 62 ). The programmable control unit ( 59 ) may be in communication with these devices via direct electrical connection, radio signal or other communication means. The programmable control unit ( 59 ) also is in communication with various pressure and temperature sensors within the primary combustion chamber ( 30 ), the secondary combustion chamber ( 37 ), the single-pass shell and tube heat exchanger ( 56 ), and the exhaust stack ( 61 ) to monitor the performance of the system and adjust the components accordingly. The programmable control unit ( 59 ) may be comprised of a computer or other electronic device capable of storing various types of data including input data, program data, control signals, and similar items.
[0101] The battery back-up system ( 60 ) is the power source for the entire mechanism. Because efficient components are used and power requirements can be managed utilizing the programmable control unit ( 59 ), direct current electricity can be used for the programmable control unit ( 59 ), auger motor ( 70 ), high temperature vacuum blower ( 58 ), vacuum sensors (not shown), temperature sensors (not shown), and warning lights (not shown).
[0102] An exhaust stack ( 61 ) is fluidly connected to the high-speed vacuum blower ( 58 ) and exits the structure. The exhaust stack ( 61 ) may have a rain cap (not shown) to keep out moisture and pests.
[0103] The air pre-heating jacket ( 43 ) completely surrounds the heat containment chamber ( 41 ) using light steel such as sheet metal. Outside fresh air enters the air pre-heating jacket via in air inlet ( 42 ) and starts to warm up from the intense heat on the outside surface of the heat containment chamber ( 41 ). Air from the inside of the jacket is delivered either to the primary flowmeter ( 49 ) or secondary flowmeter ( 51 ).
[0104] The propane ignition device ( 62 ) is used to automatically start the combustion process. Typically, a soft copper propane tube (not shown), thermocouple (not shown), and spark ignition wires (not shown) are placed inside the ash collection chamber ( 44 ) near the end of the primary center air feed tube ( 39 ). Since there is a negative pressure inside the primary combustion chamber ( 30 ) when the biomass is ready to ignite, the flame will begin to travel down the hollow cavity ( 29 ) of the formed biomass material ( 28 ) and start the combustion process.
[0105] In use, unprocessed or processed feedstock is loaded within the feedstock-loading hopper ( 21 ). The feedstock is gravity fed to hole-forming feedstock hopper ( 22 ) and then automatically augered into the insulated feeder chamber ( 26 ), which then feeds the biomass into the fuel pre-heating magazine ( 27 ), and finally into the primary combustion chamber ( 30 ). The entire process is controlled automatically by the programmable control unit ( 59 ). The high temperature vacuum blower ( 58 ) then starts to develop a vacuum in the components it is fluidly connected to. This negative pressure then draws air into both the primary combustion chamber ( 30 ) and secondary combustion chamber ( 37 ). Ignition is started using the propane ignition device ( 62 ) and water starts to flow through the shell and tube heat exchanger ( 56 ).
[0106] After the start up sequence has been completed and the temperature of the components has substantially reached a steady state temperature the biomass feed rate is controlled by the programmable control unit ( 59 ). As the biomass is consumed in the primary combustion chamber, the system temperature begins to fall slightly which is sensed by installed sensors and signal sent to the programmable control unit ( 59 ). The programmable control unit ( 59 ) then starts the auger motor ( 70 ). After waiting a few seconds to see the temperature start to rise again, the programmable control unit ( 59 ) waits for another temperature drop before commanding the auger motor ( 70 ) to add more fuel into the primary combustion chamber ( 30 ).
[0107] The formed biomass material ( 28 ) burns towards the feeding auger as primary air progresses from the inside out (hollow cylindrical form with air introduced at the center). At the outside of the primary combustion chamber ( 30 ) the air channels collect the products of combustion and transfer the products to the directing blade assembly ( 36 ). The products of combustion are then spun in the secondary combustion chamber ( 37 ) to depart a cyclonic movement to them that uses centrifugal force to mix any unburned particles and unburned gasses with secondary air while directing heavier particles towards the outside of the secondary combustion chamber ( 37 ).
[0108] The pre-heated secondary air is introduced to mix with the primary combustion effluent stream. This creates conditions for a second, higher temperature oxidation process that burns even more of the volatiles and particles.
[0109] The hot combustion gases then exit the secondary combustion chamber ( 37 ) into the heat containment chamber ( 41 ), then into the cyclonic filter ( 53 ), then into the single-pass shell and tube heat exchanger ( 56 ) to transfer the heat to water or other heat transfer fluid, then into the high temperature vacuum blower ( 58 ), then into the exhaust stack ( 61 ), with final discharge to the atmosphere.
[0110] As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed to be within the expertise of those skilled in the art, and all equivalent structural variations and relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A combustion system for extracting thermal energy from biomass or other formable fuels that does not require densification or other processing of the biomass prior to combustion. This system continuously feeds the biomass fuel from an auger or other conveyance system while simultaneously causing the biomass fuel to be formed with a hollow core. The biomass fuel is ignited from within the hollow core and burns primarily radially outward due to negative pressure surrounding combustion chamber thus facilitating and containing the combustion process. This system also utilizes pre-heating the fuel, primary and secondary air pre-heating, insulated combustion chambers, and carefully control combustion air to ensure substantial combustion is achieved even with fuels having high moisture content. In the preferred embodiment, a heat exchanger is utilized to capture thermal energy of combustion products for use as an energy source for additional processes. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/247,109, filed Apr. 7, 2014, now U.S. Pat. No. 9,084,488, issued Jul. 21, 2015, which is a continuation of U.S. patent application Ser. No. 13/942,347, filed Jul. 15, 2013, now U.S. Pat. No. 8,690,247, issued Apr. 8, 2014, which is a continuation of U.S. patent application Ser. No. 12/881,012, filed Sep. 13, 2010, now U.S. Pat. No. 8,534,758, issued Sep. 17, 2013, the entire contents of each of which are incorporated herein by reference.
BACKGROUND
1. Field
The present disclosure relates to reclinable seating, and more particularly to self-adjusting reclinable seating.
2. Description of the Related Art
Reclinable seating has been known for many years. Early solutions to devising seating with a reclining backrest used manual recline controls with prefixed reclining positions, for example, employing notches in the hinged connection between the backrest and the seat or by using notches in the armrests of the seating. These early solutions, although still widely used, are deficient because of their very limited range of recline positions and because many do not permit the seat to move in relation to the backrest.
The related art has attempted to solve the deficiencies of manual recline controls with self-adjusting reclinable seating. Self-adjusting reclinable seating does not rely upon prefixed reclining positions. This allows the seating to be positioned anywhere along a range of movement. However, a user may find the positioning of the seat and backrest in the reclining positions in the seating solutions offered by the prior art to be uncomfortable and, consequently, shift his or her position on the seat to accommodate for the backrest's angle of recline. Accordingly, a need remains for seating that improves user comfort and decreases or eliminates the user's need to shift position on the seat when reclined.
SUMMARY
In various embodiments, reclinable seating is disclosed that continuously moves the seat and backrest portions relative to the ground as the user moves. When the user applies a force to the seating by shifting his or her center of gravity, the backrest and seat portions of the seating move in response to the force to recline the seating. The seating is preferably configured to compensate for the tendency of the seat portion to tilt downwards as the backrest portion reclines. Preferably, the front portion of the seat inclines upwards as the backrest reclines. In some embodiments, the position of the seat relative to the ground forms an acute angle, and the angle of the seat relative to the ground is substantially maintained as the seat moves forward and the backrest reclines. Alternatively, the angle of the seat relative to the ground can decrease as the backrest reclines. In certain preferred embodiments, however, the vertical distance of the front of the seat relative to the ground increases. The user can return the seating to an upright position by again shifting his or her center of gravity. Such a configuration eliminates the need for manual recline controls. This seating may improve a user's seating comfort, for example, by decreasing or eliminating the user's need to shift position on the seat when reclined.
The seating can comprise a frame structure to which the backrest portion is pivotably coupled, but the seat portion is not itself pivotally coupled to the frame structure.
The seating can comprise a seat portion that rides on a fixed track that does not move with the seat.
In seating that comprises side or lateral frame structures generally on either side of the seat portion those structures can be formed from at least front and rear upright members, typically joined at their upper portions by a member at least some of which forms an arm rest. Such seating can also comprise at least one cross member joining either or both of the front and rear upright members. Preferably, the track upon which the seat portion rides is not on or part of the upright members or armrest, but is an additional member.
The track can extend generally from the front to the rear portions of the seating between either the front and rear upright members and/or the front and rear cross members. The track can extend generally alongside the seat portion and/or underneath it or in a plane lower than that of the seat portion. Typically, there will be two tracks associated with each seating portion.
The rear portion of the seat in some embodiments is not lifted during the reclining of the seating. Some preferred embodiments of the invention seek to enhance comfort of and convenience of use for the user by configuring the seating such that, in use, the front of the seat portion will rise. The plane or angle of the seat portion, with respect to its front, may decrease with respect to the floor or ground as the seating is reclined, or the plane or angle may remain relatively constant.
In at least one embodiment, seating comprises a backrest configured to recline from an upright position and a seat hingeably connected to the backrest at the rear portion of the seat. The seat is configured to move in relation to the backrest. The seating also includes a track that extends substantially parallel to the sides of the seat. A guide assembly is fixedly attached to the seat and slideably engaged with the track, such that the guide assembly supports the seat on the track. The guide assembly can extend laterally from a side of the seat or extend downwardly from the bottom of the seat. The guide assembly is configured to slide along the track upon application of a force to the backrest and/or seat. Such seating can be incorporated into furniture, such as a chair, couch, or chaise lounge.
Preferably, the guide assembly and track are configured to lift the front portion of the seat as the backrest reclines. For instance, the track can be configured such that at least a portion of the track slopes downward from the direction of the front portion of the seat to the direction of the rear portion of the seat. The guide assembly can be engaged with the track such that the guide assembly is higher on the slope of the track when the backrest is reclined than when the backrest is upright. The guide assembly can include a frictional control, such as a friction member or a knob, for adjusting the amount of friction between the guide assembly and the lower portion of the track. Such frictional control can be used as a tightening mechanism to prevent the guide assembly from sliding on the track, thereby maintaining the seat and backrest in a fixed position.
In certain embodiments, the seating includes a frame. The frame can comprise a front member disposed near the front portion of the seat and/or a rear member disposed near the rear of the seat. The track can extend between the front member and the rear member of the frame. In some embodiments, the track adjoins the front member and the rear member of the frame. Alternatively, the track can be connected to either the front member or the back member. The track need not be connected to either the front or back member.
When present, the front member can be upwardly extending or it can be laterally extending. Like the front member, the rear member can be upwardly or laterally extending. In some embodiments, a second rear member extends perpendicularly from the rear member and provides support for the backrest. The second rear member can be pivotally connected to the backrest. In some embodiments, the second rear member can comprise a pivot, and the backrest is attached to the pivot. The second rear member could also comprise a generally horizontally-extending bar, and the backrest contacts the bar.
The track can optionally comprise at least one stop configured to limit the range of motion of the guide relative to the track. In certain embodiments, the track includes an upper portion and a lower portion separated by one or more generally upward-extending member, such as a bend in the track. The guide assembly can be engaged with the lower portion of the track, which slopes downward from the direction of the front portion of the seat to the direction of the first portion of the seat. The extent of slide of the guide assembly can be limited by the upward-extending member(s) on the track.
In some embodiments the seating comprises a backrest configured to recline from an upright position; a seat comprising a front portion and a rear portion and hingeably connected to the backrest at the rear portion of the seat, the seat being configured to move in relation to the backrest; a frame comprising: an upwardly-extending front member disposed near the front portion of the seat, an upwardly-extending rear member disposed near the rear portion of the seat, a pivot member extending generally horizontally from the rear member and connected to the backrest so that the backrest can pivot about the pivot member, and a track extending between the front member and the rear member. The track has an upper portion, a lower portion, and two generally upward-extending bends connecting the upper portion to the lower portion, at least the lower portion of the track sloping downward from the direction of the front member to the direction of the rear member; and a guide configured to support the seat on the track. The guide is fixedly attached to the seat and slideably engaged with the downward-sloping lower portion of the track, such that the guide is configured to slide along the track upon application of a force to the backrest and/or seat, and the guide being configured to be higher on the slope of the track when the backrest is reclined than when the backrest is upright, the extent of slide being limited by the two generally upward-extending bends on the track.
In some embodiments there is provided reclinable seating comprising: a backrest configured to recline from an upright position; a seat comprising a front portion and a rear portion and hingeably connected to the backrest at the rear portion of the seat, the seat being configured to move in relation to the backrest and a frame. The frame comprises a front member being disposed near the front portion of the seat, a rear member being generally upright and disposed near the rear portion of the seat, a pivot member extending generally horizontally from the rear member and contacting the backrest so that the backrest can pivot about the pivot member. The seating further comprises track extending from the front member toward the rear member, at least a portion of the track sloping downward from the direction of the front member to the direction of the rear member; and a guide configured to support the seat on the track, the guide being fixedly attached to the seat and slideably engaged with the downward-sloping portion of the track, such that the guide is configured to slide along the track upon application of a force to the backrest and/or seat, and the guide being configured to be higher on the slope of the track when the backrest is reclined than when the backrest is upright.
In some embodiments, there is provided reclinable seating comprising: a backrest configured to recline from an upright position; and a seat comprising a front portion and a rear portion and hingeably connected to the backrest at the rear portion of the seat; and a guide fixedly engaged with the seat and slidingly engaged with a track disposed proximate the seat, the guide and track being configured to incline the front portion of the seat as the backrest reclines.
BRIEF DESCRIPTION OF THE DRAWINGS
A general structure that implements the various features of the disclosed apparatuses and methods will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments and not to limit the scope of the disclosure.
FIG. 1A is a side view of reclinable seating in an upright position.
FIG. 1B is a side view of the reclinable seating in a fully reclined position.
FIG. 2 is a front-perspective view of the reclinable seating comprising supportive straps on the seat and backrest.
FIG. 3A and 3B are front-perspective views of the inner and outer surfaces of the pivot connection between the backrest and seat in the reclinable seating.
FIG. 4 is a front-perspective view of the reclinable seating in an upright position.
FIG. 5 is a side view of the reclinable seating showing an alternative position for the guide assembly.
FIG. 6 is a bottom-perspective view of a track and guide assembly used in the reclinable seating.
FIG. 7 is a side-perspective view of a track and guide assembly used in the reclinable seating.
FIG. 8 shows a front-perspective view of an example frame for a love seat comprising the reclinable seating.
FIG. 9 shows a rear-perspective view of the connection between the inner tracks and the front member of the frame in the example frame of FIG. 8 .
Throughout the drawings, reference numbers are reused to indicate correspondence between referenced elements. In addition, the first digit of each reference number indicates the figure it which the element first appears.
DETAILED DESCRIPTION
An example embodiment of reclinable seating 100 is shown in FIG. 1A and FIG. 1B . In this example, the seating 100 is a chair. However, the seating 100 can be integrated into a variety of formal and casual, indoor and outdoor seating options, such stationary or swivel rockers or chairs, lounge chairs, action loungers or swivel action loungers, chaise loungers, settees, love seats, couches, and the like.
The seating 100 comprises a backrest 112 portion that is configured to recline from an “upright” position, as shown in FIG. 1A , to a “fully reclined” position, as shown in FIG. 1B . For more formal dining-type seating, the backrest 112 can be in the range of about 102° to 122° (e.g., around 110°) relative to the ground in the upright position and in the range of about 123° to 143° (e.g., around 133°) relative to the ground in the fully reclined position. For lounge-type seating, the backrest 112 can in the range of about 104° to 124° (e.g., around 113°) relative to the ground in the upright position and in the range of 135° to 155° (e.g., around 145°) relative to the ground in the fully reclined position. The seat 114 is generally in the range of 9° to 16° relative to the ground in the upright position for dining-and deep-type seating. The seat angle for the fully reclined position will be discussed in more detail below.
The seating 100 is continuously adjustable, in that a user can position the backrest 112 at any point between upright and fully reclined. The seating 100 also comprises a seat 114 portion. Cushioning can be provided on the seat 114 and/or backrest 112 . However, such cushioning is optional. As shown in FIG. 2 , for instance, the seat 114 and backrest 112 can comprise transverse straps 210 engaged around supportive tubing. As additional examples, the seat and backrest can comprise a fabric or mesh sling, woven straps, or a solid cast material. Sling, strap, and cast seating are known in the art, and the seating disclosed herein can be integrated with each.
With reference to FIG. 1A , the seat 114 can be connected to the backrest 112 at the rear of the seat 114 , for example, using a hinge, pin, rod, or other suitable pivot 116 , so that the seat 114 can move relative to the backrest 112 .
An example pivot 116 is shown in greater detail in FIG. 3A , which shows the pivot 116 from the inside-out, and FIG. 3B , which shows the pivot 116 from the outside-in.
With reference to FIG. 1A , a frame 118 is disposed around the backrest 112 and seat 114 . The example frame 118 includes a front member 120 , rear members 122 , and a track 124 .
The front member 120 is located near the front of the seat 114 . Conventional framing components known in the art can be used for the front member 120 . For instance, a front arm post or other suitable generally upright framing component can be used, as shown in FIG. 1A . As shown in FIG. 4 , two front members 120 can extend upward at a 90° angle relative to the ground. However, any generally upright angle is suitable for use herein. For instance, two front members can be generally trapezoidal relative to each other. Alternatively, a generally horizontal front rail or other non-upright framing component can be used. A front rail 120 ′ is shown in FIG. 8 , which is discussed in more detail below. Materials commonly used for framing are woods, such as teak, cedar, oak, or the like, metals, such as aluminum, steel, iron, or the like, or synthetic polymers, such as heavy-duty plastics and composites. These materials are suitable for use in the embodiments disclosed herein.
Referring again to FIG. 1A , the rear members 122 are located near the rear of the seat 114 . In this example, the rear members 122 include a first rear member 126 and a second rear member 412 , which is omitted from FIG. 1A , but shown in the perspective view of FIG. 4 . Again, conventional framing components can be used for the rear members 122 , and the first rear member can be positioned at any suitable angle. For example, the first rear member 126 can comprise a generally upright member, such as a back upright slat, or a back arm post, as shown in FIG. 1A . A back rail, crest rail, or other generally horizontal framing component, such as the back rail 414 in FIG. 4 , is also suitable. Other irregular angles, such as trapezoidal angles, are also suitable for use.
In the example embodiment of FIG. 4 , a second rear member 412 extends substantially horizontally, e.g., generally perpendicularly, from the first rear member 126 . The second rear member 412 is configured to provide support for the backrest 112 , and to provide a pivot connection to the frame 118 that allows the backrest 112 to move in relation to the seat 114 . The second rear member 412 can comprise a hinge, pin, rod, ball and socket, or other suitable pivot connection adjoined to or passing through the backrest 112 .
As explained above, the second rear member 412 provides a pivotal connection to the backrest 112 . However, the second rear member 412 could be removed, and the back rail 414 or crest rail extending perpendicularly from the first rear member 126 could serve a similar function. In such an embodiment, the backrest 112 does not pivot about a connection to the frame 118 . Rather, the backrest 112 would abut the frame 118 at the back rail 414 , and pivot about the abutment.
Returning again to FIG. 1A , a track 124 extends from the front member 120 toward (that is, in the direction of) the rear members 122 . Preferably, the track 124 adjoins both the front member 120 and the first rear member 126 , but it need not do so. For instance, the track could contact the front member 120 and the ground.
A guide assembly 132 is configured to support the seat 114 on the track 124 . In FIG. 1A , the guide assembly 132 extends laterally from the side of the seat 114 and engages a portion of the track to the side of the seat 114 . An alternative configuration for the guide assembly 132 ′ is shown in FIG. 5 . In that example, the guide assembly 132 ′ extends downwardly from the seat 114 and engages a portion of track 124 ′ underneath the seat 114 . Such a track-and-guide assembly configuration can be advantageously incorporated into seating lacking one or more armrests, as explained in detail below.
An example guide assembly 132 is shown in greater detail in FIG. 6 and FIG. 7 . In this example, the guide assembly 132 comprises a connector portion 610 that is fixedly attached to the seat (not shown). Suitable methods for attaching the connector portion 410 and the seat are known in the art and include screwing, bolting, and so on. The guide assembly 132 also includes a slide portion 612 , comprising a device such as a slide shoe or cylinder, which is slideably engaged with the track 124 . In this example, the slide portion 612 includes a first half slide shoe 614 and a second half slide shoe 614 ′ engaged around the track 124 . At least the inner surfaces of the first half slide shoe 614 and the second half slide shoe 614 ′ are made of a durable material having a low coefficient of friction with the track 124 . The coefficient of friction should be sufficiently low to permit the slide portion 612 to easily slide on the track 124 when the user changes his or her center of gravity on the seating 100 . Furthermore, the material should be sufficiently durable to withstand repeated use under heavy loads. DELRIN®, a polyoxymethylene plastic originally manufactured by DuPont, which is hard, yet has a dynamic coefficient of friction against steel in the range of about 0.19 to 0.41, has been used successfully. However, a variety of durable, low-friction materials, such as compositions of rubbers, resins and plastics (e.g., PTFE, HDPE, TEFLON®), ceramics (e.g., BN), metals (bronze, Mb), and/or graphite are also contemplated for use in the slide portion 612 .
In certain embodiments, the guide assembly 132 also includes a frictional control 616 , such as a knob, that permits a user to increase the amount of friction between the slide portion 412 and the track 124 . In this example, the frictional control 616 is in the form of a wheel. However, alternative knobs, such as a bar, cubical or spherical member, and the like are also suitable for use. In the embodiment of FIG. 6 and FIG. 7 the frictional control 616 increases the tightness of the first half slide shoe 614 and a second half slide shoe 614 ′ around the track 124 . Preferably, the frictional control 616 is adjusted so that the amount of friction between the slide portion 612 and the track 124 is large enough such that a user, sitting relatively still in an equilibrium position, will not cause the slide portion 612 to slide along the track 124 . However, the adjustment will preferably keep the coefficient sufficiently low, such that when the user shifts his or her center of gravity, the slide portion 612 will slide along the track 124 in response to the shift.
As the slide portion 612 slides along the track 124 in response to changes in the user's center of gravity, the seat (not shown) and backrest (not shown) will move accordingly to accommodate the user's position. Thus, once the user adjusts the frictional control 616 to the user's specific body weight, the seating (not shown) will adjust itself to various positions simply by the user shifting his or her weight.
After the initial adjustment, the frictional control 616 no longer needs to be adjusted. However, the frictional control 616 can be adjusted at any time to “lock” the seating 100 into a particular position by increasing the coefficient of friction between the track 124 and the slide portion 612 , such that the slide portion 612 will not move if the user changes his or her center of gravity.
Although the frictional control 616 advantageously permits a high degree of customization to a user's particular weight and center of gravity, it is optional. For example, the materials and configuration of the slide portion 612 can be selected to provide a coefficient of friction that is sufficiently high to permit the slide portion 612 to hold its position when the user stops changing his or her center of gravity for a majority of users, for example, assuming a normal distribution around an average user weight of about 180 lbs (81.6 kg). This configuration would advantageously allow the seating (not shown) to hold an equilibrium position until application of force, as described above, for most users. Materials such as DELRIN® have been found to function without such a frictional control 616 . Such a configuration could be advantageously employed in, for example, the middle section(s) of a couch in which a frictional control is not easily reachable by the occupant; however, it can be employed in any furniture configuration embodying the disclosed seating.
With reference again to FIG. 1A and FIG. 1B , as the seating 100 moves from the upright position ( FIG. 1A ) to the fully reclined position ( FIG. 1B ), the rear portion of the seat 114 begins to lift upward, because the rear portion of the seat 114 is pivotally connected to the backrest 112 , which itself is rotatably connected to the frame 118 . It was discovered, however, that a user's comfort can be improved if the angle of the seat 114 relative to the ground is maintained in the range of 8° to 22° when the backrest 112 is fully reclined. Maintaining such an angle decreases a user's desire to elevate his or her knees when seated in a reclined position if the angle is too steep or, conversely, obviates the user's feeling of sliding off the seat if the angle is too shallow. Thus, certain embodiments include the realization that reclinable seating 100 should increase vertical distance between the front of the seat 114 and the ground as the backrest 112 reclines, to improve user comfort. Accordingly, some preferred embodiments of the invention seek to enhance comfort of and convenience of use for the user by configuring the seating such that, in use, the front of the seat portion will rise. The plane or angle of the seat portion, with respect to its front, may decrease with respect to the floor or ground as the seating is reclined, or the plane or angle may remain relatively constant.
An example method for increasing the vertical distance between the front portion of the seat 114 and the ground as the backrest 112 reclines is explained below. As shown in FIG. 1A , at least a portion of the track 124 slopes downward, with the higher portion of the slope toward the front member 120 and the lower portion of the slope toward the rear members 122 . The guide assembly 132 is engaged with the track 124 within this downward-sloping portion of the track 124 . When the backrest 112 is in the upright position, as in FIG. 1A , the guide assembly 132 is engaged with the track 124 near the bottommost portion of the slope. As the backrest 112 reclines, the guide assembly 132 slides up the slope. When the backrest 112 is fully reclined, as in FIG. 1B , the guide assembly 132 is engaged with the track 124 near the topmost portion of the slope. Such a configuration increases the vertical distance between the front of the seat 114 and the ground as the backrest 112 reclines, permitting the seat 114 to have an angle of 9° to 16° relative to the ground when the backrest 112 is upright, and an angle relative to the ground in the range of 8° to 22° when the backrest 112 is fully reclined. This configuration advantageously improves a user's comfort throughout the range of movement of the seating 100 .
For a user's safety and/or comfort, it can be desirable to limit the seating 100 movement. As explained above, the rear portion of the seat 114 lifts as the backrest 112 reclines. This motion causes the front portion of the seat 114 to move laterally outward (that is, in a direction away from the backrest). It can be desirable to limit this forward lateral travel to between about 3 in. (7.62 cm) and 8 in. (20.32 cm), for example, to about 4¾ in. (12.07 cm) of forward lateral travel for dining-type seating or about 6.375 in. (16.19 cm) of forward lateral travel for deep-type seating. As another example, it can also be desirable to limit the backward lateral travel of the seat 114 (that is, travel toward the direction of the backrest 112 ). As the seat 114 moves backward, toward the backrest 112 , the backrest 112 will move forward toward the seat 114 . If this motion were not limited, the backrest 112 and seat 114 could fold together, which raises a potential safety concern.
Thus, the track 124 can include stops that limit the range of movement of the backrest 112 and/or seat 114 . An example of a stop is an upward-projecting member in the track 124 , such as an upward-projecting bend The example of FIG. 1A includes two upward-projecting bends, a front bend 134 and a back bend 136 . The guide assembly 132 cannot travel up the steep angle between the upward-projecting bends and the lower portion of the track 124 . Thus, the front bend 134 limits the forward lateral travel of the seat 114 . The limitation upon lateral travel of the seat 114 also results in a limitation upon the amount that the backrest 112 reclines. Consequently, the front bend also defines the fully reclined backrest 112 position. The back bend 136 , limits the backward lateral travel of the seat 114 (and, consequently, defines the upright backrest 112 position). One or more of these bends can be eliminated if no limitation on the forward and/or backward lateral movement of the seat 114 is desired, other than the limitations created by the pivot connections described herein. Moreover, alternative stops can be employed, such as solid stoppers placed along the track 124 . The guide assembly 132 and track 124 , including the front bend 134 and back bend 136 is shown in greater detail in FIG. 7 .
Frame components for a couch or loveseat are shown in FIG. 8 . The example loveseat has outer armrests, but lacks inner armrests. The sides of the frame include outer tracks 124 extending between upright front members 120 and upright first rear members 126 . The side tracks 124 include a front bend 134 and a back bend 136 . The center of the frame includes inner tracks 124 ′ extending between a laterally-extending front member 120 ′ and an upright first rear member 126 ′. FIG. 9 shows a detailed rear-perspective view of the connection between the inner tracks and the front member 120 ′ of the frame. A seat and backrest can be engaged with the frame, as described above, between each set of inner and outer tracks. The assembled loveseat would thus comprise a pair of reclining seats and backrests. In the example of FIG. 8 , downwardly-extending guide assemblies (not shown) can be installed on the bottom of the seats (not shown) to engage the inner tracks 124 ′, while laterally-extending guide assemblies (not shown) can be installed on the sides of the seats to engage the outer tracks 124 . When so installed, the front bends 134 of the outer tracks 124 would limit the forward travel of the seats. A three-person couch can be constructed by adding one or more additional seats and backrests between two outer seats and backrests. The additional seats and backrests can be reclinable or stationary.
For purposes of summarizing the inventions and the advantages achieved over the prior art, certain items and advantages of the inventions have been described herein. Of course, it is to be understood that not necessarily all such items or advantages may be achieved in accordance with any particular embodiment of the inventions. Thus, for example, those skilled in the art will recognize that the inventions may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught or suggested herein without necessarily achieving other advantages as may be taught or suggested herein. Moreover, various embodiments and features are described herein and it will be understood that the disclosure is intended to include all combinations and selections of those embodiments and features, rather than to be limited to the disclosure to a specific combination or feature that may be disclosed in a particular paragraph hereof. | In various embodiments, self-adjusting reclinable seating is disclosed. When the user applies a force to the seating by shifting his or her center of gravity, the backrest and seat portions of the seating move in response to the force to recline the seating. The user can return the seating to an upright position by again shifting his or her center of gravity. Such a configuration eliminates the need for manual recline controls. The seating is further configured to continuously vary the angle of the seat and backrest portions relative to the ground as the user moves. In particular, vertical distance between the front of the seat and the ground increases as the backrest reclines. Continuously varying the angle of both the seat and the backrest portions of the seating relative to the ground may improve a user's seating comfort, for example, by decreasing or eliminating the user's need to shift position on the seat when reclined. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a cushion, and method for producing the same, with at least one soft elastic region. More specifically, the invention relates to a felt cushion with a silicone pad, for use with orthopedic devices.
2. The Prior Art
It is known that such cushions may be used in orthopedic devices, e.g., in epicondylitis braces. Therefore, a felt cushion is adapted to the shape of the epicondylitis brace. Silicone spots are applied to the skin of the user of the orthopedic devices to prevent the cushion from slipping. Recesses are usually cut into the felt cushion and soft elastic regions or silicone castings are glued into these recesses.
Such orthopedic devices are known for example from WO 97/24085 and WO 99/09917.
SUMMARY OF THE INVENTION
An object of the present invention is to create a cushion which can be used for an especially long period of time. In addition, the object of this invention is also to provide a method of producing such a cushion.
According to the invention, the soft elastic region is detachably attached to the cushion. This permits a reduction of material because the component of the cushion, namely either the cushion itself or the soft elastic region which is subject to less wear, can be reused. Therefore, if the soft elastic region, in particular a silicone pad, has become worn due to frequent use it can be removed from the cushion and replaced by a new one. Furthermore, the cushion area can be replaced if it is subject to greater wear. Numerous fastening options are available for arranging the cushion on the soft elastic region. The soft elastic region preferably has a retaining element with which the soft elastic region is attached to the cushion. It is also possible for the soft elastic region to be designed such that it is inserted into a recess in the cushion and remains there merely by friction. In this case, the soft elastic region would have to be designed to be exactly the same size or slightly larger than the corresponding recess.
However, it is preferable to design the soft elastic region in the form of a silicone casting, so that the retaining element projects beyond the dimensions of the other soft elastic region. The retaining element is designed as a retaining flange which is provided in at least two locations on the soft elastic region and is disposed on the upper edge of the soft elastic region. This allows the soft elastic region to be inserted into a corresponding recess in the cushion and the retaining flanges provided on the upper edge are in contact with the cushion. Therefore, the soft elastic region is designed thicker than the cushion by the thickness of the retaining flange. In a preferred embodiment, the retaining flange is designed peripherally and with a through-passage, so that a retaining effect is achieved in the entire soft elastic region. The retaining flange is arranged on the side facing away from the user's body, so that a flush seal is on the side facing away from the user's body.
In another preferred embodiment, a VELCRO®-type hook and loop element is provided as the retaining element. If VELCRO® hook and loop tape is provided on the soft elastic region, then a fleece is preferably arranged on the cushion. The VELCRO®-type hook and loop clement is preferably designed to project above the soft elastic region so that the VELCRO®-type hook and loop element can be engaged with a corresponding strip on the back side of the cushion. The soft elastic region can be inserted into a recess in the cushion and detachably attached to the cushion with the VELCRO®-type hook and loop element. The soft elastic region can then be detached as needed and replaced by a new soft elastic region. As an alternative, it is also possible to provide the VELCRO®-type hook and loop element on the back of the soft elastic region. The VELCRO®-type hook and loop closure is then established with the orthopedic device used with the cushion.
The VELCRO®-type hook and loop element can be attached to the soft elastic region in various ways. The VELCRO®-type hook and loop element is preferably bonded to the soft elastic region. This means that the VELCRO®-type hook and loop element forms with the soft elastic region a bordering layer or a boundary layer approximately 1 mm thick in which the soft elastic region is drawn into the VELCRO®-type hook and loop element.
To produce such a cushion, the, soft elastic region is designed from a cast. To form the casting, a free flowing material is poured into a mold, the VELCRO®-type hook and loop element is brought in contact with the material while it is still free-flowing, and the free-flowing material is then vulcanizec and bonder to the VELCRO®-type element. Therefore, the VELCRO®-type hook and loop clement is brought in contact with the material while still liquid before it undergoes vulcanization. The viscosity of the material and the vulcanization time must be selected so that the free-flowing material fuses with the VELCRO®-type hook and loop element, but does hot completely permeate it. As an alternative, the VELCRO®-type hook and loop element can be glued to the soft elastic region. Suitable adhesives include mixed adhesives, reactive adhesives, solvent adhesives or hot-melt adhesive, e.g., hot-melt adhesive films.
The VELCRO®-type element can be attached to the soft elastic region in various ways. The VELCRO®-type element is preferably bonded to the soft elastic region. This means that the VELCRO®-type element forms with the soft elastic region a bordering layer or a boundary layer approximately 1 mm thick in which the soft elastic region is drawn into the VELCRO®-type element.
To produce such a cushion, the soft elastic region is designed from a cast. To form the casting, a free-flowing material is poured into a mold, the VELCRO®-type element is brought in contact with the material while it is still free-flowing, and the free-flowing material is then vulcanized and bonded to the VELCRO®-type element. Therefore, the VELCRO®-type element is brought in contact with the material while still liquid before it undergoes vulcanization. The viscosity of the material and the vulcanization time must be selected so that the free-flowing material fuses with the VELCRO®-type element, but does not completely permeate it. As an alternative, the VELCRO®-type element can be glued to the soft elastic region. Suitable adhesives include mixed adhesives, reactive adhesives, solvent adhesives or hot-melt adhesives, e.g., hot-melt adhesive films.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 shows a top view of a cushion with a soft elastic region;
FIG. 2 shows a side view of a cushion with a soft elastic region according to FIG. 1;
FIG. 3 shows a cross-sectional view of the soft elastic region during the production process;
FIG. 4 shows a cross section through a cushion with a soft elastic region produced according to FIG. 3;
FIG. 5 shows a cross section through,an alternative embodiment of a soft elastic region according to the invention during the production process;
FIG. 6 shows a diagram according to FIG. 5 in an advanced stage of the process; and
FIG. 7 shows a cross section through a cushion with another embodiment of the soft elastic region.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now in detail to the drawings and, in particular, in FIG. 1 there is shown a cushion 1 intended for use in a epicondylitis brace. The shape of the cushion is adapted to the shape of the epicondylitis brace, and soft elastic regions 2 are arranged on the enlarged end areas so that they come in contact with the skin and prevent cushion 1 from slipping.
FIG. 2 shows a side view of cushion 1 . In its lower area, cushion 1 contains a felt cushion 3 on which fleece 4 is arranged. Fleece 4 is designed to engage with a hook strip to form a VELCRO®-type closure. Soft elastic regions 2 may be designed so that they have a retaining element 5 which projects above cushion 1 . Retaining element 5 is arranged on the side of cushion 1 facing away from the user's body.
FIG. 3 shows a cross sectional view through soft elastic region 2 during the production process. A mold 6 rests on a heating plate 7 . A liquid material, in particular liquid silicone, is introduced into this mold 6 and then vulcanizes in the mold to assume the shape indicated. The vulcanization time depends on the temperature, which is controlled by heating plate 7 , the catalyst content, and the original consistency or viscosity of the material cast in the mold. The soft elastic region is produced as one piece with peripheral retaining flange 8 formed in a corresponding recess in mold. Retaining flange 8 runs along the upper edge area of soft elastic region 2 .
FIG. 4 shows a cross section through soft elastic region 2 detachably arranged in felt cushion 3 . Thus, soft elastic region 2 can be inserted and removed through retaining flange 8 on felt cushion 3 . Secure handling is ensured when the side of felt cushion 3 on which retaining flange 8 is located is facing the user. This prevents unintentional detachment of soft elastic region 2 . If a continuous closure of felt cushion 3 and soft elastic region 2 is desired, the bottom side should face the user. This almost completely rules out unintentional slippage of soft elastic region 2 from felt cushion 3 because the cushion is usually used together with an orthopedic device, such as an epicondylitis brace with the back of soft elastic region 2 in contact with in. The back of soft elastic region 2 may be attached to the epicondylitis brace, e.g., by a VELCRO®-type hook and loop closure.
FIGS. 5 and 6 show cross sections through a cushion with a soft elastic region during two different steps of the method for production of the cushion. FIG. 5 shows a mold 6 which is resting on a heating plate 7 and in which a soft elastic region 2 is produced by filling it with liquid silicone. A plurality of molds 6 are preferably arranged on heating plate 7 so that a plurality of soft elastic regions 2 can be produced at the same time. This is also true of the embodiment of the method according to FIG. 3 .
FIG. 6 shows a retaining element 5 , formed by a VELCRO®-type element 9 , applied to the casting according to FIG. 5 while still molten. VELCRO®-type hook and loop element 9 is either a fleece or a VELCRO® hook and loop tape, so that it can be brought into VELCRO®-type hook and loop closure with a corresponding VELCRO® hook and loop strip or fleece. VELCRO®-type hook and loop element 9 is applied to the casting while still hot so that the liquid material is absorbed into the VELCRO®-type hook and loop element 9 about 1 mm, and is fused thereto. Soft elastic region 2 is then vulcanized by heating plate 7 , and then soft elastic region 2 can be removed from mold 6 and used in a cushion. VELCRO®-type hook and loop element 9 is attached to the orthopedic device according to the embodiment shown. Soft elastic region 2 can also be used with cushions which do not have any recesses but instead have a section corresponding to VELCRO®-type hook and loop element 9 . The soft elastic region is then applied directly to the cushion by a VELCRO®-type connection and projects slightly above it. As an alternative, it is also possible to use a VELCRO®-type hook and loop element 9 which projects beyond the edges of soft elastic region 2 in its outside dimensions.
A cross section through soft elastic region 2 is felt cushion 3 is shown in FIG. 7, VELCRO®-type hook and loop element 9 projects above soft elastic region 2 with a projection 10 . By using a VELCRO®-type hook and loop closure, this projection 10 can be attached with its VELCRO®-type hook and loop element facing downward to the felt cushion 3 or a corresponding fleece or VELCRO® strip hook and loop which is arranged on felt element 3 . Therefore, soft elastic region 2 can be detachable from the cushion.
Accordingly, while only a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made there unto without departing from the spirit and scope of the invention. | A cushion having at least one soft elastic region for use with orthopedic devices. The soft elastic region is detachably arranged on the cushion so that the cushion or the soft elastic region can be replaced when it is worn out while still using the other part. | 0 |
1. FIELD OF THE INVENTION
[0001] The invention relates to systems and applications on a network such as the Internet that send and are recipients of performance measurement queries. Such systems and applications include and are not exclusive to routers, firewalls, proxy servers, stateful filtering or other filtering devices, clients, servers, hosts, load distribution/balancing systems, caching servers, and similar devices. Often these systems determine the best server to use to connect a client to a server for a network application. More specifically, a method and apparatus are provided for intercepting and responding to performance metric packets (which are also known as performance measurement packets) sent from a sender to a recipient or recipient network at a point outside of a recipient personal computer or network.
2. DESCRIPTION OF THE RELATED ART
[0002] As the Internet began to develop, the measurement of the time it takes to send and receive a packet through the use of ping packets became a widely used tool. This measurement is commonly called the round trip time (“RTT”) and can be gathered through the use of other protocols as well by measuring the amount of time taken to send and receive the packet. The design of Internet packets included a field in the packet header by design to provide information as to the number of servers or routers a packet traversed in its path between the source and destination of the packet. The field that identifies the hop count is known as the time to live (“TTL”) field.
[0003] Internet Control Message Protocol (“ICMP”), Transmission Control Protocol (“TCP”), and User Datagram Protocol (“UDP”) are all transport layer protocols that are then encapsulated in internet protocol (“IP”) packets to be sent across an IP network such as the Internet. All of these protocols can be used to gather the measurements like the RTT and the TTL of a packet between hosts. The TTL can be used to determine the path a packet takes from one computer system to another computer system mapping out all of the nodes between the two hosts by sending out packets starting with a TTL of 1 to get the IP address or name of the first hop from the sender to the recipient of the packet. The second packet sent out has the TTL field set to 2 in order to obtain the name or IP address of the host at the second hop in the path between the source or sending client and the destination or recipient client. The TTL field continues to be incremented until the final destination is reached. The round trip time of each step in the iterative process is also returned to help gather the path information and the performance metrics for each hop, server, or router along the path between the two hosts.
[0004] These metrics are useful tools for testing the performance between two or more hosts on the Internet as well. An example of this would be a load balancing system that is used to determine the closest server to a client in term of network metrics. In this case, a client initiates a connection to a server or recipient and the packet is received by a ‘load distribution’ system on behalf of the server. The load distribution system communicates with other load distribution systems that are connected to servers that can also handle the client's request. The load distribution servers then use performance metrics to determine which server would provide the best connection to the client. The load distribution servers and application servers, such as a web server, file transfer protocol (“FTP”) server or other Internet application server, may be at various physical locations and may be networked to the Internet via different Internet Service Providers (“ISPs”) thus providing various connection speeds to any one client on the Internet. The servers or load distribution servers may send multiple performance metric queries to the client system to determine which application (web, etc.) server to establish the application connection to.
[0005] As mentioned, various transport level protocols can be used to gather these statistics, some of which include ICMP, UDP, and TCP packets. Currently, commonly used ICMP echo and echo-reply packets (“ping packets”), UDP packets (ex: traceroute packets), and other protocols such as TCP, use an application request and response procedure like a Domain Name Service (DNS) query. The above mentioned protocols provide the necessary information for the performance, distance, or path information between two hosts or networks, but all can be or appear to be malicious to a recipient of the packet.
[0006] In other words, the sending system can gather information for malicious purposes as to the existence of a recipient if a response is received. The sending system can also gather information as to the path taken between the two sending systems. As a result of various implementations of these transport level protocols and other protocols, it is possible to determine information about the recipient computer or destination host that could be useful to someone with malicious intent. Computer systems are often broken into after such an information gathering process or reconnaissance phase of an attack has been completed. The information gathered might be used to determine the active systems on the network and the operating systems of each as well as any protocols that respond to queries by an outside server. Thus, performance metric queries that were initially designed to be useful tools for network and system administrators have also become useful tools in the reconnaissance phase of a network attack.
[0007] For example, a ping packet can be used to map a network, to flood a host or network, identify an operating system, or for other malicious intent. Many networks block ping packets from entering their network as a precautionary measure. The result of this is that an initiator of a the valid request for information can not receive the performance information required to know if a network is reachable or to determine the best path or server for a connection to the network. If ping packets are permitted, security administrators have the difficult task of attempting to distinguish non-malicious from potentially malicious packets.
[0008] A traceroute packet can be used to determine the path taken from the source host to the destination host and to gather performance metrics (measurments) at each hop along the path. If enough traceroute commands are initiated, it would be possible to determine all of the paths possible to enter a specific network. There may be one or more entry points to a network and a traceroute packet can be used to show all of the hops prior to the entry points of a network. This information would be enough for a malicious entity gathering the data to launch a successful denial of service attack against the network by targeting each entry point. Since there are many useful applications of traceroute packets, it cannot always be assumed that the intent is malicious. Therefore, in some cases traceroute packets should not be blocked on a network. The security administration of the network would have to distinguish non-malicious packets from potentially malicious packets causing additional unnecessary work especially in light of the increased use of performance metric gathering servers used on the Internet.
[0009] Alternatively, it is often desirable to query a server such as the DNS (Domain Name Service) server of the client who initiated the request. This query would gather statistics on the performance metrics for the RTT of a packet between the server and the client DNS server. This might be useful since the query is typically allowed by the DNS server hence, the server initiating the query is more likely to receive a response. Also, the request might be via the TCP protocol and the measurement may better reflect the performance of the application to be used once the best path is selected. DNS and other services are often outsourced or located on different networks from client systems, thus providing an inaccurate measurement to the requesting application or server. Another concern is that DNS servers and other application servers frequently have exploitable bugs, which raise the concerns of the administrators when there are unnecessary queries that could potentially be malicious queries to the application servers wasting unnecessary time.
[0010] As mentioned above, some networks have multiple paths that can be used to reach a destination that resides on the network. The existence of multiple paths may be a result of having multiple connections to the Internet or network/routing decisions made at steps between the initiating host and the recipient host system or client (destination host). If the information were gathered from multiple servers to a network where the client resides, it would be possible to record the path information and map out the network and the various connections to the Internet over a period of time. The map of the network and the entry points could be used to launch a denial of service attack against the client's network and leave them with no available network resources since all of the various connections to the Internet were identified and flooded leaving little if any access to the Internet for the duration of the attack. Another possibility of malicious behavior would be targeted attacks against the identified host systems that respond to the performance metric queries. These hosts are now known to be active systems and thus subject to attack.
[0011] Performance measurements can be used as described for a ‘load distribution’ system or other performance metric system for analyzing the connection speed between to systems. As a result, there is often a large number of queries used to obtain the information needed in order to decide upon the best system in which the client should be connected to in order to provide the best connection for the end users satisfaction. There are some systems that try to mitigate the number of queries used and how often they are used, but there are further improvements that could be made to mitigate this problem. Currently, there are systems that cache responses for a period of time to be used for subsequent connection requests from clients in the same network. Other means of minimizing the number of queries used is through the use of routing protocols that can determine the best path from the client to one of the servers with which the connection will ultimately be established. Even with these options in place, the sheer number of queries received by clients' network can still be quite large. This causes a problem where the administrators have to determine the intent of the queries and also generates unnecessary traffic to the client's network. Subsequent connection requests from the client can initiate this process all over again where the servers or load distribution type systems query the client's network to determine the server to connect the client based on the fastest connection speed between the client and one of the servers.
[0012] Thus, the otherwise useful performance measurement packets result in several problems. The first problem is that destination networks or recipients see a potentially large number of performance queries that may appear to be malicious in nature hitting their network. Security administrators carefully watch their network to determine if there is any malicious intent in the packets reaching their network. As mentioned above, there is quite a bit of information that can be gathered from the types of requests that are sent as performance metric measurement packets. Both individual requests from applications like ping and traceroute packets as well as measurement requests from systems like a load distribution system or web caching server appear to be harmful packets to the recipient's network. Often, the performance measurement packets like ping and traceroute packets are blocked at the border of the client's network if possible. This presents a problem for both the sender of the packet who cannot determine the existence, RTT, or hop count of the destination host as well as the network at the client's end of the connection. Resources at the client's end, or recipient's end, of the network are used to drop the packets if it is possible and if not, the traffic can set off alarms and cause needless extra work for the security administrators of the site. The security administrators have to attempt to determine the intent of the sender to know if an attacker is at the reconnaissance phase of a network attack or if it is a load distribution or other performance metric system gathering statistics that are not harmful in intent. Recently, this type of probe on a network has become quite common. It also provides a cover for an attacker to gather information and mask it as that of valid network traffic.
SUMMARY OF THE INVENTION
[0013] An object of the present invention is to provide a method of gathering information about a connection between a sender and a recipient in a network which avoids the problems identified above.
[0014] A second object is to provide a new distance measuring protocol, DMP to provide information about a connection between a sender and a recipient in a network that avoids the problems identified above.
[0015] A third object of the present invention is to provide a border device positioned between a sender and a recipient for use in gathering information regarding a connection between the sender and the recipient in a network that avoids the problems identified above.
[0016] A method of gathering information about a connection between a sender and a recipient in a network having the steps of: a) generating an information query by the sender; b) sending the information query to the recipient; c) receiving the information query at a border device of the recipient; and d) processing the information query at the border device to provide selected information requested by the information query to the sender. The selected information provided to the sender may include identification information that is different than that of the border device. The method may further include the steps of: e) storing at least a portion of the selected information sent from the border device to the sender at the sender when a destination address of the information query corresponds to a predetermined group of addresses stored at the sender; and f) utilizing the stored selected information from the response whenever an information query is generated including any of the predetermined group of addresses stored at the sender. In addition, the method may include a step of deleting the stored selected information after a predetermined period of time.
[0017] A method of gathering information about a connection between a sender and a recipient in a network having the steps of: a) generating an information query by the sender; b) sending the information query to the recipient; c) receiving the information query at a border device of the recipient; and d) processing the information query at the border device according to a plurality of predetermined rules, wherein said predetermined rules provide for one of: providing selected information requested by the information query in a response to the information query to be sent to the sender; discarding the information query; and passing the information query through the border device to the recipient for response. One of said plurality of predetermined rules provides for discarding the information query when the information query is of a size larger than a predetermined range of allowable sizes. Another rule of said plurality of predetermined rules provides for passing the information query through the border unit to the recipient for response when the information query includes predetermined identification information. The method may further include the steps of: e) storing at least the selected information of the response provided from the border device when a destination address of the information query to which the response was generated corresponds to any of a plurality of predetermined addresses stored at the sender; and using the stored selected information of the response whenever an information query including any of the plurality of predetermined addresses stored at the sender is generated rather than sending the information query to the recipient. The stored selected information may be deleted after a predetermined period of time passes.
[0018] A border device positioned between a sender and a recipient for use in gathering information regarding a connection between the sender and the recipient in a network, the border device having: a) a receiver for receiving an information query from the sender addressed to the recipient; b) a processor for processing the information query on behalf of the recipient to generate a response to the information query including selected information; and c) a transmitter for sending the response including the selected information to the sender. The response to the information query includes identification information that differs from identification information of the border device. The border device may respond to information queries for a plurality of recipients.
[0019] A method of gathering performance measurement information regarding a connection between a sender and a recipient in a network having the steps of: a)generating an a performance measurement packet by the sender; b) sending the performance measurement packet to the recipient; c) receiving the performance measurement packet at a border device of the recipient; d) and processing the performance measurement packet at the border device according to a plurality of predetermined rules, wherein said predetermined rules provide for one of: generating a response packet to the performance measurement packet providing performance metric information to be sent to the sender; discarding the performance measurement packet and passing the performance measurement packet to the recipient. When the predetermined rules provide for generating the response packet to the performance measurement packet including performance metric information, the response includes identification information that is different than identification information of the border device. One of the predetermined rules provides for discarding the performance measurement packet when a size of the performance measurement packet exceeds a range of allowable sizes. Another rule of the plurality of predetermined rules provides for passing the performance measurement packet through the border unit to the recipient when the performance measurement packet includes predetermined identification information. The method may further include the steps of: e) storing at least the performance metric information of the response packet generated by the border device in response to the performance measurement packet when a destination address of the performance measurement packet corresponds to one of a plurality of predetermined addresses stored at the sender; and e) using the stored performance metric information of the response packet whenever a performance measurement packet including any of the plurality of predetermined addresses stored at the sender is generated by the sender rather than sending the performance measurement packet to the recipient. The method may further include the step of deleting the stored performance metric information after a predetermined period of time.
[0020] A method of gathering information about a connection between a sender and a recipient in a network having the steps of: a) generating an information query by the sender; b) sending the information query to the recipient; c) receiving a response to the information query including selected information from the recipient by the sender; d) storing at least the selected information of the response for a predetermined period of time when the destination address of the information query is one of a plurality of predetermined addresses stored at the sender, such that when a subsequent information query includes a destination address corresponding to any of the plurality of predetermined addresses, the stored selected information of the response is used without sending the subsequent information query to the recipient and e) the predetermined period of time may be different from a period of time for which the selected information of the response is stored when the destination address of the information query is an address other than one of the plurality of predetermined addresses. The plurality of predetermined addresses may be a group of Classless Inter-Domain Routing addresses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a block diagram illustrating communication between a sender and a recipient in a network.
[0022] [0022]FIG. 2 is an illustration of a performance measurement packet and a response packet sent to respond to the performance measurement packet.
[0023] [0023]FIG. 3 is a flow chart illustrating operation of a method of gathering information according to an embodiment of the present application.
[0024] [0024]FIG. 4 is a flowchart illustrating a method of gathering information according to a second embodiment of the present application.
[0025] [0025]FIG. 5 is a block diagram illustrating a border device according to an embodiment of the present application.
DETAILED DESCRIPTION OF THE INVENTION
[0026] [0026]FIG. 1 represents a connection between the sender 1 and a recipient 2 . The sender 1 may be, for example, an individual establishing connection to the recipient 2 via a personal computer or a server of a local area network. In addition, the sender 1 may be a device or entity which requests performance measurement information for use with its applications such as a load balancer server. The recipient 3 may similarly be an individual or part of a network of potential recipients. At a border of the recipient personal computer or network a border device 3 is positioned. The border device 3 provides information regarding the connection between the sender 1 and recipient 2 on behalf of the recipient 2 and at the same time conceals its own identity. More specifically, the border device 3 provides a response to the sender 1 including performance metrics such as the TTL and RTT regarding the connection between the border device 3 and the sender 1 .
[0027] [0027]FIG. 3 illustrates a procedure for gathering information about a connection between the sender 1 and recipient 2 illustrated in FIG. 1. At step 10 , the sender 1 generates an information query, such as a performance measurement packet 20 as shown in FIG. 2, for example, to request information about connection between the sender 1 and recipient 2 . At step 12 the performance measurement packet 20 is sent to the recipient 2 . The performance measurement packet 20 includes a destination address or network number 22 that corresponds to the recipient 2 . At step 14 the border device 3 receives the performance measurement packet 20 . If the destination address or network number 22 of the performance measurement packet 22 matches that of a range of addresses corresponding to a group of at least one recipient for which the border device 3 is to respond, at step 16 , the border unit 3 generates a response, or response packet 24 as illustrated in FIG. 2, to the performance measurement packet 20 and includes the information about the connection requested by the sender 1 . Such information generally includes the RTT (not shown) and TTL 23 between sender 1 and recipient 2 . However, the performance metric packet 20 never reaches the recipient 2 , instead the border device 3 responds with information regarding the path to the border device 3 . The border device 3 also includes the original destination address or network number 22 of the recipient as the source address of the response packet 24 . At step 18 the response is returned to the sender 1 and the information is used to determine the best path between recipient and sender or otherwise utilized by the application requiring the metric information.
[0028] The sender 1 is provided with the required information regarding the connection between the sender 1 and recipient 2 , however, that information represents only information regarding connection between the sender 1 and the border unit 3 , which is located outside, or at a border of the recipient's personal computer or network. Since the connection between the border device 3 and recipient 2 within the recipient network remains constant, the information concerning connection between the sender 1 and the border unit 3 is sufficiently accurately to allow the sender 1 to properly execute its applications.
[0029] The procedure of FIG. 3 can be adapted to existing performance measuring protocols such as the Internet Protocol to mitigate security concerns of a recipient 2 . In such a situation, however, the destination address, and not the network number, of the recipient would be included in the response packet as the source address of the response packet because the conventional internet protocols would discard a response packet having a network number as a source address. Most simply, this procedure is used in devices or hosts to effectively intercept performance measurement packets on behalf of the recipient 2 and to provide adequate information to the sender 1 or source of the performance measurement packet as to the performance of the packet via the RTT, TTL, or other performance metrics requested of the destination host, or recipient 2 .
[0030] The procedure of FIG. 3 can also be applied to a specific application as a new type of protocol which this specification will refer to as a distance metric protocol (“DMP”). The DMP protocol identifies its requests as a DMP request. The use of a specific protocol designated for this purpose would identify it uniquely to devices and filter lists, etc. Such a DMP protocol can then be distinguished from other protocols that gather performance metrics and can be trusted since path information, host existence, network mapping, protocol existence (port probe), operating system mapping, and other malicious intent would not be possible. The DMP protocol would be used to replace current applications, which gather information as to the amount of time taken for a packet to travel from a sender to a destination and back to the sender as well as gathering the hop count or TTL of a packet.
[0031] One embodiment of the DMP protocol can be an Internet protocol for sending a performance measurement packet 20 from a source host or sender 1 to a destination host or recipient 2 to gather performance metrics such as the round trip time (RTT) and time to live (TTL) where the packet 20 is intercepted outside the destination network by a border device 3 such as a perimeter router or firewall for example. The border device 3 can be programmed to respond for any host or recipient 2 within a network block or range or to a specific host address to allow for ambiguity as to the existence of network IP addresses on the protected network by the intercepting host (border device). The response to the request has the source address of the destination host or network number of the destination host or a different address instead of the address of the border device 3 intercepting the packet and sending the response. This prevents the requestor (sender) of the query from gathering information as to the design of the network and the perimeter IP addresses of the network or the intercepting device.
[0032] For example, load balancer servers commonly use performance metric packets to gather data in order to determine the most efficient path between the load balancing servers to a client or the client's network which can provide a desirable connection to an individual who wants to connect to the server. As mentioned, the ICMP protocol is a common protocol for determining the round trip time between two hosts, like the load balancing server and a server to which connection is desired. In a traditional embodiment, an echo packet is sent from the load balancer on behalf of the servers serviced by the load balancing server to the client which responds with an echo-reply ICMP packet type. The echo reply includes metrics such a the TTL and the RTT, from which the load balancing server determines the best server to use to provide the best connection. However, as mentioned above ICMP packets can be used to gather information about a network such as mapping information (identifying all valid addresses on the network) which can be used against the network.
[0033] The DMP protocol of this invention is provided for performing performance measurements. The DMP protocol has an assigned port and protocol number to distinguish the request type of the DMP protocol from those of other protocols. If the border device 3 receives the DMP packet or other measurement packet at the perimeter of a network, meaningful results can be returned to the initiator of the request. Through the DMP protocol, existence of a network can be identified and the RTT and TTL determined to the border or perimeter where the recipient may reside. This information is enough for applications that seek to determine the best path from multiple points in the Internet since the remaining time interval into the client network typically remains a constant from the perimeter of the client network depending upon the placement and use of the DMP protocol or border device. The recipient is free to essentially define the border at which the border device is placed in accordance with there needs. In fact, the border device may even be placed within a local area network (LAN) to provide security between different internal groups, for example.
[0034] The main concept here is that the identity and existence of the host, or recipient 2 remains unknown to the sender 1 of the metric query since the response is from an intermediate device, the border device 3 , answering for any number of programmed hosts, network blocks, or address ranges. The other protected information is the path to the recipient 2 since the only information returned is the limited performance metrics that might include the RTT and the TTL of the packet and potentially other limited information from the border device 3 . As noted above, the round trip time is the time it takes for the packet to be sent from the source, received by the client or intermediate device and processed, then the return packet is received by the sender of the DMP query. Information like the TTL is contained in the packet header of any IP packet. The distance metric protocol described here can be implemented with any protocol to query the IP address of the client/recipient in which the distance information is required rather than obtaining the distance information from another host such as a DNS server which, may or may not be located on the same network.
[0035] As discussed above, the procedure of FIG. 3 can be applied to currently existing performance measurement protocols. In this embodiment, the border device 3 , such as a router or firewall outside of a destination network or server implements the method by which metric performance packets are intercepted at the border of the destination network or recipient 2 . The border device 3 intercepts performance metric packets whose destination includes a predetermined range of destination addresses or network numbers. The border device 3 generates a response including performance metrics expected by the sender 1 of the performance metric packet 20 . The source address of the response is that of the recipient while the metric information such as the round trip time from the sender 1 to the border device 3 is returned. The sender 1 would then be provided with sufficient information to determine which server provides the best connection for a requested connection, if the sender were a load balancer server for example, however, the identity and address of the border device 3 are concealed. Thus, since the address and existence of the border device 3 are hidden, it is not possible to determine how many entries into a network or server exist or the addresses of these entries if used in this way. Furthermore, since the border device 3 responds to a programmed list of addresses or network numbers and responds with the provided destination address whether or not that address is active, mapping of the network is also prevented.
[0036] In an alternative embodiment, the procedure of FIG. 3 is modified to allow recipients to control the response of the border device 3 based on a plurality of predetermined riles provided by the recipient or a network administrator of the recipient network. This procedure is explained with reference to FIG. 4. At step 40 the sender 1 generates an information query or performance metric packet 20 requesting information regarding connection between sender 1 and recipient 2 and including a destination address corresponding the recipient 2 . In step 42 the performance metric packet 20 is sent to the recipient 2 . In step 44 , the border device 3 receives the performance measurement packet 20 . When the destination address of the performance measurement packet corresponds to a recipient for which the border device 3 is to respond, the border device 3 responds according to a plurality of predetermined rules. At step 46 , the rules determine whether the border unit 3 responds to the packet as in the procedure of FIG. 3 SS6, discards the packet SS7, or passes the packet to the recipient 2 , SS5 or other point in the network.
[0037] The procedure of FIG. 4 can be adapted to compliment current security procedures. Intrusion Detection has led security experts to identify a signature of the packets sent from certain vendors which enable them to distinguish these packets from others and identify the vendor of the load balancer. Therefore, one of the predetermined rules may instruct the border device 3 to recognize such distinguishing information and allows such performance measurement packets to enter the recipient personal computer or network or to allow the border device 3 to respond. Another rule may instruct the border device 3 to analyze the size of a performance measurement packet 20 . Where a size of the packet is larger than a predetermined size, the packet is determined to be malicious and is discarded. Using these predetermined rules allows the recipient more flexibility in protecting their personal computer or network from attack. Of course, other rules can be implemented according to the needs of the recipient.
[0038] Either procedure illustrated in FIG. 3 and/or FIG. 4 can also be adapted to optimize the query process in the case where there are multiple devices that may be in different locations or connected to various ISP's. In such a case, performance metrics determine the fastest connection from one of the devices, or senders, to the client/recipient or network that is being polled. Systems such as Internet application load balancers, as discussed above, or web caching devices perform these measurements to provide an end user with the fastest possible connection to an end user.
[0039] An extension to this process to enhance the time needed for the setup phase of the application connection would be to include tables of Classless Inter-Domain Routing (CIDR), addresses to be referenced when performing the metric measurements. The performance measurement protocol could be used to determine if a network is accessible through a simple distance metric protocol request, however when used from a group of sender systems to determine which of the group has the best possible connection back to an Internet host or network number, the response to the request may be cached for later use for a specified amount of time. Caching the results of a query for later use is a common practice. Specifically using a CIDR table of addresses in the process enhances the benefits of such caching.
[0040] CIDR blocks are network numbers that have been assigned to specific Internet Service Providers and can only be routed to that ISP. Since the devices polling the destination networks or recipients may be located on separate networks in separate physical locations, one may have a better performance metric to the client address than the others. The primary difference between a CIDR block of numbers and non-CIDR network numbers, is that the block can only be routed to recipients by the ISP that owns the CIDR and the CIDR blocks cannot be multi-homed. As a result, the best path information is less likely to change unless there is a problem with the server or the server's network connection that has the best connection statistics from previous queries, or a network problem at a crucial point, like the Network Access Point (NAP), between providers if the server and client are not already connected to the same ISP.
[0041] When a CIDR address is the destination address of the performance measurement packet 20 , a cached response is used to provide the required information. The procedure operates to generate a response including current performance metrics according to the method described with reference to FIG. 3 or 4 above. Once this response is generated and sent to the sender 1 , the response can be cached for a predetermined period of time by the sender 1 . Since CIDR performance metrics for CIDR addresses are unlikely to change often, providing the information in the cached response to the requesting application is sufficient and there is no need to generate and send performance measurement packets each time. The cache time can be higher for CIDR network blocks than non-CIDR network blocks since CIDR blocks can only be routed by one ISP and the best path information is less likely to change. Non-CIDR addresses might be routed via a dynamic routing protocol such as the Border Gateway Protocol (BGP). However, the BGP protocol allows for more potential change of the best path information.
[0042] It is a common practice to cache results to queries, however the use of the CIDR addresses can allow for the cached results to be more useful for that subset of Internet addresses for a greater period of time. The time or other means to determine when the cache should be purged is a programmed rule in the sender. CIDR addresses would limit the time needed for the initial connection setup phase for instance where the best possible path to take was cached. This practice would help to limit network traffic and the number of requests a client may receive for performance metric information.
[0043] The border device 3 of the present application is further described with reference to FIG. 5. The border device 3 may be a firewall, periphery router or network server for example, and is provided at a boundary of a recipient personal computer, network, or otherwise between the sender and recipient. The border device 3 includes a receiver 50 for receiving performance measurement packets from a sender 1 , and storage 52 for storing at least one destination address corresponding to a recipient for which the boundary device 3 will intercept performance measurement packets and generate a response. The border device 3 may respond to a plurality of destination addresses or network numbers in the destination address slot in the performance measurement packet 20 . A processor 54 is provided to generate the response to the performance measurement packet 20 with the response including the information regarding connection between sender and recipient and substituting the destination address or network number of the recipient 2 provided in the performance measurement packet 20 for the address or network number of the border device 3 in the source address of the response. A transmitter 56 is provided to transmit the response back to the sender 1 .
[0044] Where the border device is used in conjunction with the method described with reference to FIG. 4, the border device 3 comprises substantially the same elements. However, the processor 56 will not automatically respond to the performance measurement packet 20 , but will respond based on the predetermined rules which can be stored in the storage 52 .
[0045] In either case, the border device 3 provides metric information to the sender 1 such that the sender 1 can use the information to establish a favorable connection or satisfactorily engage applications requiring the metric information about the connection to the recipient 2 . However, the IP address and network number of the border device 3 are concealed in the response. Therefore, the sender 1 of the performance measurement packet 20 , will be unable to accurately identify the border device 3 and therefore cannot identify different entries into the recipient network or destinations inside the recipient network.
[0046] The problems identified above are solved in a communications system and method in which Internet protocol packets used for gathering performance statistics are intercepted at a programmed point in the network to enhance security of the network. The Internet Protocol (IP) packet is received by a router or firewall device and intercepted based on a configurable parameter on behalf of the ultimate destination host. The router or firewall device determines, based on the programmed rules, whether or not to respond the request on behalf of the client. If there is a rule to permit a response, router or firewall creates a packet response to return the metric count to the source host on behalf of the client. The source address of the return packet can either be the actual destination IP address of the initial packet or the network number to provide ambiguity as to the existence of active hosts on the network. Ideally, the use of this protocol would be at the edge of the recipient network of the packet to provide a meaningful statistic to the device or program eliciting the response. A few benefits result from the use of this protocol, the protocol returns a minimal amount of information to the requesting host, which may or may not be malicious, and path information for the connection is not returned to the requesting host. Current applications of the protocol would be devices on the Internet that gather performance measurements to determine the best route or path a connection can take to provide the best possible connection for an application.
[0047] In addition, the system and method would be useful in load balancers for Internet protocols and web caching devices which perform metric measurement functions to gather statistics on the best path from several points in the network back to an end user or client. A client may initiate a web connection to a particular server and the server attempts to determine which of several alternative servers to connect the client to based upon the performance metrics from the server back to the client. The above mentioned protocol would be used at the client network end of the connection to protect the network from mapping attempts that are possible through the use of any ICMP, TCP, or UDP packet that is passed through the perimeter of the network. This protocol could be adapted at the router or firewall level to intercept an existing packet type, such as a ping or a traceroute packet for compatibility to existing protocols and immediate usefulness on the network. This could also be formulated into a new IP protocol to replace the traceroute and ping packet types to distinguish the request as a request for distance metrics as opposed to network mapping, path gathering, or other possibly malicious packet types.
[0048] An extension of this protocol for security needs at the router or firewall of the client end, the recipient end of metric protocol, can also be used to determine if there was a valid request to a server from a client/recipient in the protected network which might cause the server to initiate the request for the performance metric. The firewall or router, possibly a stateful inspection filter or application proxy firewall, would then decide to either respond to the request or discard the packet based upon the rules programmed into the device. This would be a logical extension used at a firewall level since many firewalls maintain tables of the state of active sessions that are permitted through the device.
[0049] As discussed above, at the server/sender end, additional improvements could be done to include tables of Classless Inter-Domain Routing (CIDR), addresses to be used when performing the metric measurements. The protocol could be used to determine if a network is accessible through a simple distance metric protocol request, however when used from a group of systems to determine which of the group has the best possible connection back to an Internet host or network number, the response to the request may be cached for later use for a specified amount of time. It is a common practice to cache results to queries, however the use of the CIDR addresses can allow for the cached results to be more useful for that subset of Internet addresses for a greater period of time, which can be programmed into the device. CIDR addresses are addresses that have been assigned to specific Internet Service Providers and each block can only be used within the ISP that owns the network block. Since the devices polling the clients may be located on separate networks in separate physical locations, one may have a better performance metric to the client address than the others. The unique characteristic of a CIDR address is that it can only be routed by the ISP that owns the CIDR address and may assign these to their clients. As a result, the best path information is not likely to change unless there is a problem with the server or the server's network or at a crucial point, like the Network Access Point (NAP), between providers if the server and client are not already connected to the same ISP. The cache time can be higher for CIDR addresses than non-CIDR addresses since the CIDR addresses can only be routed by one ISP and the best path information is less likely to change. Non-CIDR addresses might be routed via a dynamic r outing protocol such as the Border Gateway Protocol (BGP) that is more dynamic and has more potential for the best path information to change. A method and apparatus for gathering information about a connection between a sender and a recipient while avoiding transfer of information that can be used to attack the recipient or recipient server is provided.
[0050] While specific embodiments of this invention have been described herein it should be noted that many variations are possible. This invention is intended to include all variations permissible under the claims attached hereto. | A method in which a border device of a destination network located outside of a recipient personal computer or network intercepts a performance measurement packet for a specified recipient in order to relieve problems that arise when performance metric packets are interpreted as harmful to a recipient network or server. A border device intercepts the performance metric packet and returns requested information to the sender while masking the source address of the response as the original destination address of the original recipient or the network number of that recipient. The sender of the packet receives ample information on the performance metrics to the perimeter of the recipient for use in its application and the recipient network is protected as well by masking the IP addresses in use on the its network. The method is applicable in both existing performance metric protocols and is adaptable to a new protocol which would also additionally assist in identifying the purpose of the performance metric packets and protecting the destination network from outside interference. The number of performance metrics queried by some applications could also be reduced through the use of CIDR network block tables. These tables would be referenced to determine if a previous response was cached from this network block or to allow for a longer cache time-out due to the static nature of CIDR blocks. | 7 |
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates generally to refrigeration. In a more particular sense, the invention has reference to refrigerated display cases of the type used in food markets. In yet a more specific sense, the invention is a refrigerated display case of the so-called "wide island" category, in which side-by-side product display wells are separated by an upstanding partition that extends longitudinally and centrally of the case, with both wells being uncovered and opening upwardly to provide ready access to the displayed products.
2. Description Of The Prior Art
Refrigerated display cases of the type referred to above require frequent defrosting. To this end, many defrosting arrangements have been utilized in the art. One of these is air defrost. A case utilizing this defrost means draws ambient air into the conduits or air passages through which refrigerated air is circulated during refrigeration cycles. The relatively warm ambient air, when circulated through the conduits, melts the frost that has accumulated on the conduit walls and even more importantly on the evaporator coils, until ultimately the conduits and coils are completely clear of frost and are ready for resumption of the refrigeration cycle.
While air defrost can advantageously be employed in many types of cases, it has certain disadvantages as compared to other defrost arrangements. For example, hot gas defrost is widely used, and is highly efficient in that it accomplishes complete defrost in a relatively short time. Hot gas defrost, however, involves additional piping and valving, and requires special attention to the pressures developed in different areas of the system. Electrical defrost is also well known, utilizing electrical heating elements to melt the frost from the evaporators. The electrical energy requirements of this type of defrost, however, are high.
Considerable efforts, accordingly, have been made to develop efficient air defrost systems for refrigerated display cases, which require no additional piping or valving, and which add only minimally to the normal electrical energy requirements of the case.
Air defrost systems, however, have their own peculiar set of problems, and these problems can vary from one type of case to another. In a wide island case, for example, it is common to design the case for merchandising frozen food along one side of the case, in one product well, and ice cream in the product well at the other side. In such instances, the temperature requirements at the opposite sides of the case differ. Accordingly, during a refrigeration cycle it is important to keep the air circulating around one product well at a given temperature, while maintaining the circulating air of the other product well at a different temperature. Intermixing of the air circulated about one well with the air circulating about the other well, during a refrigeration cycle, should understandably be held to a minimum.
Yet, despite the obvious desirability of preventing commingling of the air flow patterns during refrigeration in wide island cases of the type described, there are strong reasons for defrosting both wells simultaneously and, of course, in the shortest possible amount of time. For example, one reason for simultaneously defrosting both sides of the case is that if one side is maintained in refrigeration while the other side is in defrost, heat exchange between the two sides would adversely affect both the refrigeration of the first side and the defrost of the second side. In any event, the prior art as exemplified by such patents as U.S. Pat. No. 4,314,457 and 4,337,626 both to Ibrahim; 4,304,098 to Rydahl; and 4,182,130 to Ljung, all disclose one or another of two types of wide island cases: (a) "unitized" cases in which there is a center flue that is common to both sides so that both sides must carry the same products to be refrigerated to the same temperature, with the air being intermixed both during refrigeration and defrost; or (b) cases in which the air flows at opposite sides are kept separate both during refrigeration and defrost.
Accordingly, it is desirable that if possible, in a wide island case having a partition down the center rather than a common center flue, and adapted for maintaining different refrigerating temperatures at the respective, opposite sides of the partition, there should be an air defrost system which will, during defrost and only during defrost, draw defrost air from the ambient atmosphere and circulate it through the conduit of one side, and then transfer it to the other side of the case, for circulation through the conduit and evaporator thereof, and then exhaust it back to atmosphere from the conduit of said other side of the case. The present invention has as its main purpose the provision of such a system.
SUMMARY OF THE INVENTION
Summarized briefly, the refrigerated display case of the present invention is of the type in which side-by-side product wells are separated by a vertical, solid partition extending longitudinally and centrally of the case structure. The partition, at the bottom of the case, has an opening which provides communication between the air conduit of the product well at one side of the partition, and the air conduit of the product well at the other side thereof. In the opening a defrost fan is mounted, with its axis perpendicular to the vertical plane of the partition, and with its blades lying in and rotating in said plane. Each product well has a primary conduit extending continuously around the bottom and both sides of the upwardly opening product well. An inlet and outlet are provided at the upper ends of the respective sides of the conduit of each well, so that during refrigeration air circulated through the conduit flows directly across the open top of the product well. In the conduit of each product well there is provided the usual evaporator and circulating fan.
In accordance with the invention, during refrigeration the defrost fan is idle. The primary circulating fans of the respective wells are on and operate in a normal forward direction at this time, so as to circulate refrigerated air through the respective evaporators and across the open tops of the product wells. When the air is circulated in this way, it does not flow through the communicating opening provided at the bottom of the partition, so that the refrigerating systems are in effect separately maintained, thus permitting the refrigerated air of one product well to be maintained at a temperature different from that of the other well, if desired.
During defrost, the defrost fan is operated, the primary fan of one product well continues to operate in a normal forward direction, and the primary fan of the other well is reversed. As a result, at the side having the reversely operating primary fan, ambient air is drawn into both the inlet and outlet of the primary conduit, flowing through both sides and the bottom thereof. This air is transferred by the defrost fan to the second side of the case, where the primary fan has continued to operate in a normal forward direction. In the conduit of the second side of the case, the air is circulated through both sides and across the bottom, and is exhausted from both the inlet and outlet of said second conduit.
If desired, to equalize the defrost time of both sides, after the defrost cycle has continued for a selected period of time, all the fans can be simultaneously reversed. Thus, for the duration of the defrost cycle, the conduit at one side of the partition that was the air intake conduit during the first stage of the defrost becomes the exhaust conduit, while the conduit at the other side is changed over from being an air exhaust to an air intake conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
While the invention is particularly pointed out and distinctly claimed in the concluding portions herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawings, in which:
FIG. 1 is a transverse sectional view of a wide island case during a normal refrigeration cycle;
FIG. 2 is a similar view of the case, during defrost;
FIG. 3 is a similar view during an optional second stage of the defrost in which all the fans have been reversed;
FIG. 4 is a simplified schematic view of the electrical circuitry utilized for controlling the fan operation, during the single-stage defrost cycle illustrated in FIG. 2; anc
FIG. 5 is a schematic view of the circuitry used for the two-stage defrost cycle illustrated in FIGS. 2 and 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Designated generally at 10 is a wide island case, including an insulated bottom wall 12 common to both sides of the case and extending across the full width of the case. Extending upwardly from the bottom wall are insulated first and second side walls 14, 16 respectively, cooperating with a vertical, insulated center partition or divider 18 in defining, at opposite sides of the partition, first and second, side-by-side product display wells 20, 22 respectively that open upwardly to provide ready access to the products displayed therein.
Display well 20 includes a bottom air conduit wall 24, and outer and inner air conduit walls 26, 28 respectively. Walls 24, 26, 28 are spaced inwardly of the case from the walls 12, 14, 18 respectively to define a continuous air conduit 30 extending around the bottom and both sides of the product display area of well 20. In cross section, the air conduit 30 is generally U-shaped, having an outer side duct portion 30a, a bottom duct portion 30b, and an inner side duct portion 30c. Generally vertical duct portions 30a, 30c extend upwardly from and are in continuous communication with the generally horizontal bottom duct portion 30b.
Product well 22 is similarly constructed at the other side of partition 18. Thus, it includes a bottom conduit wall 32, and upstanding outer and inner conduit side walls 34, 36 respectively. Walls 32, 34 and 36 are spaced inwardly from walls 12, 16, 18 respectively, to form a conduit 38 about the display area of well 22, said conduit extending continuously across the bottom and up both sides of said display area and having an outer side duct portion 38a, a bottom duct portion 38b, and an inner duct portion 38c. At the upper ends of duct portions 30a and 30c there are provided an air outlet 40 and an air inlet 42, respectively. Similarly, an outlet 44 and an inlet 46 are provided at the upper ends of the duct portions 38a, 38c, with the several outlets 40, 42, 44, 46 all being disposed in approximately a common horizontal plane perpendicular to a vertical plane P (see FIG. 1) of partition 18.
Within the conduits 30, 38 there are provided evaporator coils 48, 50 respectively and primary circulating fans 52, 54 respectively.
At the bottom of the case, partition 18 is formed with an opening 55. Mounted in this opening is a defrost fan 56, the axis A of which (FIG. 1) lies perpendicular to the plane P of partition 18, with the blades 57 of the fan rotating in the plane of the partition.
At the upper end of the partition there is provided a sill 58 which extends the length of the display case, and which is symmetrically formed and arranged in respect to the plane P. The sill projects laterally outwardly in opposite directions from the partition, overlying the air inlets 42, 46 of the respective primary conduits 30, 38. Above the sill, an air splitter panel 60, which may have a base 62 to facilitate mounting of the panel on the sill, extends upwardly above the open tops of the display wells.
It is understood that the sill 58, panel 60, and base 62 of the panel, can be utilized for photographic displays and pricing information, and for lighting purposes, in addition to performing certain functions, to be explained hereinafter, during the defrost cycle.
The air flow patterns developed during a refrigeration cycle are shown in FIG. 1. In the case illustrated by way of example, in each well the circulating fan, during refrigeration, causes flow along the bottom conduit portion through the evaporator in a direction from the center of the case to the outer side, with the flow then being directed upwardly within the outer conduit portions 30a, 38a, respectively. The refrigerated air is discharged through the outlets 40, 44, in a direction from the outer side of each access opening, across the access opening toward the center of the case, and then into the inlets 42, 46 respectively. The return air passes through the inner side portions 30c, 38c of the respective conduits, back to the bottom portions 30b, 38b.
The flow around each product well is maintained separately from the flow of the other product well. Although there is an opening 55 at the bottom of partition 18, air does not flow through said opening during the refrigeration cycle, since the defrost fan 57 is idle, and each of the fans 52, 54 turn outwardly all air that exits from the inner side portions 30c, 38c of the conduits 30, 38 respectively.
Although the air, during the refrigeration cycle, travels from the outer side to the inner side of the case across the top of each display well, the normal flow during a refrigeration cycle could be in the opposite direction, that is, in some wide island cases the openings 42, 46 are the outlets and the openings 40, 44 are the inlets.
At this point, it may be noted that the wells 20, 22 could, as previously indicated herein, contain products to be refrigerated at different temperatures. For example, well 20 could be a frozen food area, and well 22 could be a display area for ice cream. These would be maintained at different temperatures, and no problem is presented in accomplishing this since the opposite display wells are separated by a solid, insulated partition 18. In a typical installation, these two different types of foods are often marketed at opposite sides of a wide island case, and since the temperatures at which these products are maintained are not too far apart, no problem is presented by heat transfer through the defrost fan 57 and its mounting plate 64, during refrigeration of both sides.
When a defrost cycle is initiated, refrigeration of the coils 48, 50 is terminated, fan 52 is reversed, defrost fan 56 is turned on and operates to force air from left to right viewing the same as in FIG. 2, while the other primary fan 54 remains on in its normal direction.
In these circumstances, ambient air is drawn into conduit 30 of display well 20, from the area above the well 20. Fan 52, which is now forcing air to the right in FIG. 2, pulls ambient air downwardly, through outlet 40, said air passing downwardly through outer conduit portion 30a, and thereafter flowing within conduit portion 30b through coil 48 to defrost the same.
At the same time, defrost fan 57, which is selected to move a greater volume of air in a given amount of time than fan 52, pulls air downwardly from the ambient atmosphere above well 20 through the inlet 42. This air passes downwardly through conduit portion 30c and along with the air pulled into the conduit by fan 52, is forced by fan 57 through the communicating opening 55 between the opposite sides of the case, into the conduit 38. Fan moves a greater volume of air in a given amount of time than fan 54, so that some of the air transferred by fan 57 is forced upwardly within conduit portion 38c, exiting through the inlet 46. The remaining air transferred by fan 57 to conduit 38 is forced by fan 54 through the coil 50, and upwardly through conduit portion 38a, exiting through outlet 44. The air forced through outlet 44 and inlet 46 meets above the well 22, and is directed upwardly and outwardly over the outer side wall thereof.
The panel 60 and sill 58 cooperate in preventing commingling of the ambient air drawn into the conduit 30, with the cooler air exhausted from the conduit 38. Sill 58, as will be noted, deflects the incoming air laterally outwardly, to assure that fresh ambient air is drawn into the conduit 30, and in particular to the inner side portion 30c thereof. Sill 58, being symmetrically formed and arranged in respect to the plane of the partition 18, also deflects laterally outwardly the air exhausted from the conduit 38, in particular the inner side portion 38c thereof. Thus, the fresh incoming air and the used defrost air are widely separated by the sill 58. Splitter panel 60, meanwhile, assures still further, in cooperation with the sill, that there will be no commingling of the fresh, incoming ambient air and the cooler, exhausted air, so that the incoming and outgoing air currents are completely separated and do not interfere with each other's flow patterns.
FIGS. 4 and 5 show the electrical circuitry used as a means for controlling the fan operation. In FIG. 4 there is shown a circuit that would be used in installations in which the single stage defrost cycle (FIG. 2 only) is sufficient, considering the temperatures at which the opposite sides of the case are to be maintained, and such other factors as the humidity and temperature of the store environment in which the equipment is installed.
FIG. 5 illustrates the circuitry that would be employed in those installations in which it is found desirable to utilize the two-stage defrost cycle of FIGS. 2 and 3, in which, in the first stage, the fans are operated in the direction shown in FIG. 2; and in the second stage, are operated in the directions shown in FIG. 3 until defrost is completed.
Whether the single-stage or the two-stage defrost cycle is used, it may be desirable to incorporate a supplemental heating element 66 for operation during defrost in, for example, the side of the case that is normally maintained at a lower temperature during normal refrigeration. This element is shown in close proximity to coil 50 in the illustrated example. It could be located elsewhere, or if desired there could be another heating element in proximity to coil 48. Or, the use of supplemental heating elements can be omitted entirely in some installations. Should, however, the element be used, it could be electrically connected in the circuitry shown in FIGS. 4 and 5 without difficulty.
Referring to FIG. 4, the movable contacts of a relay 67 are shown in full lines in their normal position as they would be during refrigeration, and in dotted lines in the positions to which they shift during the defrost cycle shown in FIG. 2. Electrical current flows from a suitable power source as follows: leads 68, 70, contact 72 of de-energized relay 67, lead 74, capacitor 76, leads 78, 80 extending from the capacitor to the parallel windings of primary fan 52 which is of the permanent split capacitor motor type, and return to the power source through lead 82.
Current also flows through lead 68, lead 84, capacitor 86, capacitor motor leads 88, 90, primary fan 54 (which is of the same type as fan 52), and return through leads 92, 82.
Defrost would be initiated either by a timer 93, or if the system utilizes demand rather than timed defrost by a frost sensing device, not shown. In any event, when defrost is initiated, power is supplied to the winding 94 of relay 67 through leads 96 extending from the timer or other defrost-initiating device. This operates relay contacts 72, 98 to their dotted line positions. Power will flow through lead 100 to capacitor 76, and leads 78, 80 to the motor of fan 52. When fan 52 was in normal operation, current flowed directly through leads 74, 78 to one winding of the motor, while being forced through the capacitor and lead 80 to the other winding. For reversing the motor, current from the power source flows directly through lead 100 and lead 80 to the second winding of the motor, while flowing through the capacitor and lead 78 to the first winding, causing reversal of the fan.
Meanwhile, fan 54 operates in its normal forward direction, since the current flow to the windings thereof remains as it was during refrigeration.
During the defrost cycle of FIG. 2, current also flows through leads 68, 70, relay contact 98, lead 102, motor lead 106, capacitor 104, and motor lead 108, to operate the motor of defrost fan 56 with the power returning to the source through leads 110, 82. The shifting of switch contact 98 to the dotted line position responsive to energizing of relay winding 94 also energizes heating element 66 through the provision of leads 112, 114.
If it is desired to utilize a two-stage defrost cycle with the FIG. 2 arrangement being the first stage and the FIG. 3 arrangement being the second, the circuitry shown in FIG. 5 is employed. In this circuitry, again the movable contacts are shown in full lines as they appear during refrigeration, and in dotted lines during the defrost stages. During refrigeration, current flows as follows: lead 116, movable contact 118 of relay 120, lead 122, and lead 124 to a first winding of primary fan 52. Current also flows through capacitor 126, and lead 128 to the second winding of fan 52. Return to the source of power is through leads 130, 132.
Primary fan 54 is similarly energized, by current flowing through lead 134, movable contact 136 of relay 138, and lead 140 to one winding of motor 54. Current also flows through capacitor 142 to lead 144 extending to the other winding of fan 54 and back to the source of power through leads 146, 132.
At the initiation of defrost, the closing of contacts on a timer 147, or on a frost sensing defrost initiating means (not shown) close, causing power to flow through lead 148, contact 150, lead 152, the winding 154 of relay 156, and back through lead 158 to the source of power to which the winding 154 is connected by the now closed contacts of the timer. As a result, movable contact 118 is shifted to the dotted line position thereof shown in FIG. 5, so that current flows through lead 116, contact 118, and lead 128 to the second winding of motor 52, and also through capacitor 126 and lead 124 to the first winding of the motor, causing the primary fan 52 to be reversed as shown in FIG. 2. Return to the source of power is through leads 130, 132.
Current also flows through the motor 54, which operates in its normal forward direction during the first stage of defrost shown in FIG. 2, with current flowing through leads 116, 134, contact 136, capacitor 142, and leads 140 and 144, motor 54, lead 146, and lead 132 back to the source of power.
Closing of the contacts on the timer also energize, through leads 158, 160 connected to leads 148, 158 respectively, the winding 162 of a relay 164. As a result, current will flow through leads 116, 134, contact 166 which will have been moved to its dotted line position by energizing of winding 162, heating element 66, and back to the source of power through lead 132.
Current will also flow through leads 116, 134, contact 166, lead 168, contact 170, lead 172, lead 174 to the first winding of defrost fan 56, and also through capacitor 176 and lead 178 to the second winding of fan 57, with return through leads 180, 132.
When the defrost is to go into its second stage, the timer remains on. A second timer 149 can at this time operate contact 150 to the dotted line position in FIG. 5. Timer 149 could if desired be combined with the primary or main timer 147, as a second contact means 150 thereof. The means 150 would in this event be closed by the main timer after a predetermined period of time following initiation of the first defrost stage. Or, instead, the device 150 could be a thermostatic device used to initiate the second stage of defrost. A predetermined rise in temperature at a selected location in the case would then be utilized to operate the contact 150 to the dotted line position. Whether a timer or a thermostat is used, in these circumstances the circuit through winding 154 is opened by movement of contact 150 to the dotted line position, so that switch contact 118 reverts to the full line position thereof, causing primary fan 52 to revert to its normal forward operating direction, with current flowing therethrough as described above in the discussion of the refrigerating cycle. At this time, however, a coil 182 of relay 184 is energized, by current flowing through lead 148, contact 150, lead 186, coil 182, lead 188, and lead 158. This operates contacts 136, 170 to the dotted line positions thereof. As a result, the direction of the other primary fan 54 is reversed, by current flowing through leads 116, 134, 136, 190, and lead 144, and by current flowing from lead 190 through capacitor 142 and lead 140.
Current also flows through the heater element in the second stage, and in addition the direction of the defrost fan 56 is reversed, by current flowing through leads 116, 134, contact 166, lead 168, contact 170, lead 192, and lead 178 to one winding of the defrost fan, with current also flowing through lead 192, capacitor 176, and lead 174 to the other winding of the fan 56. Return to the power source is through leads 180, 132.
As a result, in the second stage the direction of all the fans is reversed, with primary fan 52 reverting to the normal forward direction, primary fan 54 being reversed, and defrost fan 56 also being reversed.
While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent, that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention. | A refrigerated display case of the wide island type having side-by-side, upwardly opening product display wells, uses its primary air circulating fans and a defrost fan to draw ambient air into the inlet and outlet of the air conduit of one product well, circulate it through the conduit of that well, transfer it to the air conduit of the second well, circulate it through the second conduit, and discharge it to atmosphere through the inlet and outlet of the second conduit. The case incorporates a solid center partition having an opening near the bottom of the case in which the defrost fan is mounted to transfer the air from one product well to the other. A splitter panel and sill at the upper end of the partition prevent the intake air from becoming mixed with the exhausted air. During a defrost cycle the air can be drawn into the first well and exhausted from the second well for the full duration of the cycle. Or, part way through the cycle a complete reversal of air flow can be effected so as to now draw the air into the second well and exhaust it from the first well for the remainder of the defrost cycle. | 0 |
BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] A drum dryer equipped with a heat exchanging unit, for holding the air flow intake flowpath and the flowpath of the hot air discharged from the drum, has the features of energy saving through preheating the air flow from the intake flowpath by the thermal energy of the hot air.
[0003] (b) Description of the Prior Art
[0004] For the conventional rolling drying device, such as the drum dryer, the intake air flow is heated by the electric heating device, and then enters the drum room to dry the clothes, and the hot air is directly discharged during the operational period, causing the thermal energy waste.
SUMMARY OF THE INVENTION
[0005] The present invention aims at the drum dryer drying the rolling clothes by the electric heating thermal energy, and a heat exchanging unit with heat recovery function is further installed between the room temperature air flow and the discharged hot air, for preheating the intake air flow by the thermal energy of the discharged hot air through the heat exchanging unit, to reduce the thermal energy loss.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic view showing the main structure of the embodiment, according to the present invention.
DESCRIPTION OF MAIN COMPONENT SYMBOLS
[0007] ( 101 ): Air inlet port
[0008] ( 102 ): Heat exchanging unit
[0009] ( 103 ): Electric heating device
[0010] ( 104 ): Drum
[0011] ( 105 ): Drum drive motor set
[0012] ( 106 ): Electric fluid pump set
[0013] ( 1061 ): Fan motor
[0014] ( 1062 ): Fan
[0015] ( 107 ): Electronic control unit
[0016] ( 108 ): External operation interface
[0017] ( 109 ): Air exhaust port
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] A drum dryer equipped with a heat exchanging unit, for commonly passing the air flow intake flowpath and the flowpath of the hot air discharged from the drum, has the features of preheating the air flow from the intake flowpath by the thermal energy of the hot air; FIG. 1 is a schematic view showing the main structure of the embodiment, according to the present invention; as shown in FIG. 1 , except for the case, the power line, and the drum unit driven by the electric motor, the main components including:
[0019] air inlet port ( 101 ): by way of pumping by an electric fluid pump set ( 106 ), the external room temperature air flow attracted to inflow from the air inlet port ( 101 ), through a heat exchanging unit ( 102 ) and an electric heating device ( 103 ), and then into a drum ( 104 );
[0020] heat exchanging unit ( 102 ): equipped with the intake flowpath for passing through the external room temperature air flow, and the hot current flowpath for passing through the discharged hot air, in which a good thermal conductive structure is installed between the intake flowpath and the hot current flowpath for separating the both, thus the thermal energy of the hot air preheats the air flow in the intake flowpath;
[0021] electric heating device ( 103 ): related to an electric heating device heated by the electric energy, which is controlled by an electronic control unit ( 107 ) over the heating temperature and the ON/OFF operation, to heat the intake air flow into the hot air;
[0022] drum ( 104 ): driven by a drum drive motor set ( 105 ) constituted by the drum drive motor and the transmission, to operate at determined rotary speed and direction, in which the drum ( 104 ) has hot air inlet and exhaust port, and the clothes or articles to be dried are put within the drum, and rolled through the driving by the drum drive motor set ( 105 ) to be dried by the hot air;
[0023] drum drive motor set ( 105 ): controlled by the electronic control unit ( 107 ) through the electric motor thereof, and driving the drum ( 104 ) through the transmission for revolution at preset rotary speed and direction;
[0024] electric fluid pump set ( 106 ): driving a fan ( 1062 ) through an electrified fan motor ( 1061 ) to produce flow kinetic energy of air flow, to make the external room temperature air flow enter the heat exchanging unit ( 102 ), pass through the room temperature fluid outlet of the heat exchanging unit ( 102 ) to further pass through and be heated by the electric heating device ( 103 ), and then reenter the drum, and to make the hot air at the outlet enter the hot air inlet of the heat exchanging unit ( 102 ), and then be discharged from an air exhaust port ( 109 ) at the hot current flowpath of the heat exchanging unit ( 102 );
[0025] electronic control unit ( 107 ): constituted by the electromechanical component, or the solid state electronic component, and/or the microprocessor and operation software, for receiving the electric energy from the power supply and being set and controlled by an external operation interface ( 108 ), to control the operations of the electric heating device ( 103 ), the drum drive motor set ( 105 ), and the electric fluid pump set ( 106 ); and
[0026] external operation interface ( 108 ): constituted by the electromechanical component, or the solid state electronic component, and/or the microprocessor and operation software, for receiving manual input to control the operation of the electronic control unit ( 107 ).
[0027] By way of the above devices, when the operator turns on the external operation interface ( 108 ) for operation, the electronic control unit ( 107 ) starts the electric fluid pump set ( 106 ), the electric heating device ( 103 ), and the drum drive motor set ( 105 ), at this time, the room temperature air flow enters the intake flowpath of the heat exchanging unit ( 102 ) through the air inlet port ( 101 ), the room temperature air flow passes through the heat exchanging unit ( 102 ) for heat exchanging with the discharged hot air, and then is discharged by the outlet at the intake flowpath of the heat exchanging unit ( 102 ) for further being heated into hot air by the electric heating device ( 103 ), and then reenters the drum ( 104 ) driven by the drum drive motor set ( 105 ) to dry the clothes, and then flows into the inlet at the hot current flowpath of the heat exchanging unit ( 102 ) from the air exhaust port of the drum ( 104 ) to release the heat to the follow-up intake air flow entering the intake flowpath of the exchanging device from the air inlet port through the heat exchanging unit ( 102 ) before being discharged from the air exhaust port ( 109 ). | The present invention aims at the drum dryer drying the rolling clothes by the electric heating thermal energy, and a heat exchanging unit with heat recovery function is further installed between the room temperature air flow and the discharged hot air, for preheating the intake air flow by the thermal energy of the discharged hot air through the heat exchanging unit, to reduce the thermal energy loss. | 3 |
FIELD
[0001] This disclosure relates to knitted wire mesh filters and methods of making such filters where the filters are completely free of “tinkles.”
BACKGROUND
[0002] U.S. Pat. No. 5,217,515, which issued to Geno Guglielmi on Jun. 8, 1993 and is entitled “Abatement of Tinkles in Wire Mesh” (hereinafter the Guglielmi patent, the contents of which are incorporated herein in their entirety by reference), sets forth a long-standing problem in the field of filters made from knitted wire mesh, namely, the presence of “tinkles” (also known as “gotchas”) in knitted wire mesh and thus in filters made from such mesh. The Guglielmi patent at column 1, lines 48-56, describes the source of tinkles as follows:
When knitted wire mesh is cut, it results in the production of loose pieces of scrap commonly known in the wire knitting industry as tinkles. The material making up the tinkles had formally been a portion of the knit. In other words, a tinkle is a knitted loop, or a portion of a knitted loop, which has been cut. Tinkles are of irregular shape and distribution and have no predetermined location, size or shape. However, they do tend to remain near the cut line where they were formed.
[0004] FIGS. 1 and 2 hereto are copies of the corresponding figures of the Guglielmi patent which show a knitted wire mesh sock 10 and its associated tinkles 20 formed when the sock was cut from a continuous length of wire mesh (a continuous tube of wire mesh) produced by a circular knitting machine. As described in the Guglielmi patent at column 3, lines 36-39: “Tinkles are portions of cut knit loops. They do not have a characteristic size or shape. Indeed, the act of cutting the mesh can distort the wire to produce shapes not found in the original knit.” Having come from the knitted wire mesh, tinkles are composed of metal and are thus undesirable for most filter applications and impermissible for applications where the introduction of small pieces of metal into the gas or liquid stream being filtered cannot be tolerated, e.g., the filtering of the gases produced by an airbag inflator or the filtering of a fuel stream being provided to an internal combustion engine.
[0005] As described in the Guglielmi patent, efforts have been made to solve the tinkle problem by shaking the knitted wire mesh sock or picking the tinkles off by hand (Guglielmi patent at column 1, lines 59-61). These are highly labor-intensive processes and do not guarantee that filters made from the socks will be free of tinkles. As an alternative to trying to remove the tinkles, efforts have also been made to try to immobilize the tinkles. The Guglielmi patent represents one such effort in which electric resistance welding is used to bond tinkles to the wire mesh.
[0006] U.S. Pat. No. 5,849,054, which issued on Dec. 15, 1998 to Katsuhide Fujisawa and is entitled “Filter for an Inflator” (hereinafter the Fujisawa patent, the contents of which are incorporated herein in their entirety by reference), shows another immobilization approach in which, in making a filter, the sock is folded upon itself so that the cut ends of the sock end up buried inside the filter. FIG. 3 hereto is a copy of Fujisawa's FIG. 6( b ′) which shows a folded sock in which knitted wire mesh 15 covers cut ends 14 of the mesh.
[0007] As the Guglielmi and Fujisawa patents illustrate, the mindset of inventors working on knitted wire mesh filters has been to accept tinkles as a fact of life and then look for ways of dealing with the tinkles. Unfortunately, no matter how sophisticated a tinkle control technique may be, at the end of the day, there can be no guarantee that every last tinkle has been dealt with. As indicated above, for a variety of applications, e.g., in-line fuel filters, airbag inflators, and the like, such uncertainty can be unacceptable. As discussed fully below, in accordance with the present disclosure, a completely new approach has been taken to the tinkle problem, namely, to make knitted wire mesh filters without generating a single tinkle. In this way, for the first time, knitted wire mesh filters that are guaranteed to be tinkle-free can be made.
SUMMARY
[0008] In accordance with a first aspect, a method is disclosed for making a plurality of knitted wire mesh filters ( 19 ) each of which is free of tinkles ( 20 ) which comprises:
(I) producing a knitted tube ( 11 ) that comprises (i) a plurality of segments ( 13 ) of knitted rows of wire and (ii) a plurality of segments ( 12 ) of knitted rows of yarn, the segments ( 13 ) of wire alternating with segments ( 12 ) of yarn; (II) producing a plurality of separated segments ( 13 ) of knitted rows of wire without cutting any loops of knitted wire and thus without producing any tinkles ( 20 ); and (III) producing the plurality of knitted wire mesh filters ( 19 ) from the plurality of separated segments ( 13 ) of wire; wherein step (II) comprises treating the knitted tube ( 11 ) or a separated portion thereof (i.e., a portion comprising at least one and, typically, multiple wire segments ( 13 )) to remove yarn.
[0012] In accordance with a second aspect, a method is disclosed of making a plurality of knitted wire mesh filters ( 19 ) each of which is free of tinkles ( 20 ) comprising:
(I) producing a knitted tube ( 11 ) that comprises (i) a plurality of segments ( 13 ) comprising knitted rows of wire and (ii) a plurality of segments ( 12 ) comprising knitted rows of yarn, the segments ( 13 ) comprising knitted rows of wire alternating with segments ( 12 ) comprising knitted rows of yarn; (II) producing a plurality of separated segments ( 13 ) comprising knitted rows of wire without cutting any loops of knitted wire and thus without producing any tinkles ( 20 ); and (III) producing the plurality of knitted wire mesh filters ( 19 ) from the plurality of separated segments ( 13 ) comprising knitted rows of wire;
wherein the segments ( 13 ) comprising knitted rows of wire are connected to one another by non-knitted sections of wire ( 16 ) that span the intervening segments ( 12 ) comprising knitted rows of yarn and step (II) comprises:
(A) cutting segments ( 12 ) comprising knitted rows of yarn and non-knitted sections of wire ( 16 ) to free segments ( 13 ) comprising knitted rows of wire from the knitted tube ( 11 ); and (B) treating the freed segments ( 13 ) comprising knitted rows of wire to remove the yarn.
[0018] In accordance with a third aspect, a method is disclosed of making a plurality of knitted wire mesh filters ( 19 ) each of which is free of tinkles ( 20 ) comprising:
(I) producing a knitted tube ( 11 ) that comprises (i) a plurality of segments ( 13 ) comprising knitted rows of wire and (ii) a plurality of segments ( 12 ) comprising knitted rows of yarn, the segments ( 13 ) comprising knitted rows of wire alternating with segments ( 12 ) comprising knitted rows of yarn; (II) producing a plurality of separated segments ( 13 ) comprising knitted rows of wire without cutting any loops of knitted wire and thus without producing any tinkles ( 20 ); and (III) producing the plurality of knitted wire mesh filters ( 19 ) from the plurality of separated segments ( 13 ) comprising knitted rows of wire;
wherein step (II) comprises unweaving ( 18 ) of knitted yarn.
[0022] Tinkle-free wire mesh socks and tinkle-free wire mesh filters made from such socks are further aspects of the present disclosure.
[0023] The reference numbers used in the above summaries of the various aspects of the invention are only for the convenience of the reader and are not intended to and should not be interpreted as limiting the scope of the invention. More generally, it is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention and are intended to provide an overview or framework for understanding the nature and character of the invention.
[0024] Additional features and advantages of the invention are set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as exemplified by the description herein. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. It is to be understood that the various features of the invention disclosed in this specification and in the drawings can be used in any and all combinations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a schematic drawing illustrating a prior art knitted wire mesh sock and its associated tinkles.
[0026] FIG. 2 is a schematic drawing illustrating some of the shapes exhibited by tinkles.
[0027] FIG. 3 is a schematic drawing illustrating a prior art attempt to deal with tinkles by locating them internally within a folded knitted wire mesh sock.
[0028] FIG. 4 is a photograph of a knitted tube prepared in accordance with an exemplary embodiment of the present disclosure.
[0029] FIG. 5 is a close-up photograph showing a wire segment/yarn segment/wire segment portion of FIG. 4 .
[0030] FIG. 6 is a photograph showing the structure of FIG. 5 with the yarn segment unwoven.
[0031] FIG. 7 is a photograph of a knitted tube prepared in accordance with another exemplary embodiment of the present disclosure. For purposes of illustration, the rightmost yarn segment in FIG. 7 has been unwoven.
[0032] FIG. 8 is a photograph of an exemplary knitted wire mesh filter having a configuration suitable for use as a filter for an airbag inflator.
[0033] FIG. 9 is a schematic diagram illustrating an exemplary configuration for a circular knitting machine for use in preparing the knitted tubes of the present disclosure.
[0034] The reference numbers used in the figures refer to the following:
[0035] 10 knitted wire mesh sock with associated metal tinkles—prior art
[0036] 11 knitted tube
[0037] 12 segment of knitted tube comprising knitted rows of yarn
[0038] 13 segment of knitted tube comprising knitted rows of wire (when separated from its knitted tube, such a segment is referred to herein as a “sock”)
[0039] 14 cut end of knitted wire mesh—prior art
[0040] 15 knitted wire mesh—prior art
[0041] 16 non-knitted section of wire
[0042] 17 non-knitted section of yarn
[0043] 18 unwoven yarn
[0044] 19 filter
[0045] 20 metal tinkles—prior art
[0046] 21 circular knitting machine
[0047] 22 wire
[0048] 23 spool for wire
[0049] 24 knitting needles of circular knitting machine
[0050] 25 yarn
[0051] 26 spool for yarn
[0052] 27 plate
[0053] 28 apex for wire
[0054] 29 apex for yarn
[0055] 30 eyelet in plate for wire
[0056] 31 eyelet in plate for yarn
[0057] 32 feed eyelet for feeding wire to needles
[0058] 33 feed eyelet for feeding yarn to needles
[0059] 34 positioning cylinder for wire
[0060] 35 positioning cylinder for yarn
[0061] 36 plate
[0062] 37 cam hub
[0063] 38 timing stub
DETAILED DESCRIPTION
[0064] As discussed above, the present disclosure relates to the production of knitted wire mesh filters that are free of tinkles. In overview, the filters are made by: ( 1 ) producing a knitted tube having segments composed of wire and segments composed of yarn, ( 2 ) using the segments composed of yarn as the means for separating the segments composed of wire into individual (i.e., separated) wire mesh socks without the generation of tinkles, and ( 3 ) then using the tinkle-free wire mesh socks to make the filters.
[0065] FIG. 4 shows a representative knitted tube 11 composed of alternating wire segments 13 and yarn segments 12 , while FIG. 5 shows a close-up of the transition from one of the wire segments 13 to a yarn segment 12 and then to a another wire segment 13 . As can be seen in this figure, as well as in FIG. 7 discussed below, yarn segments 12 are considerably shorter than wire segments 13 . This will typically be the case in order to minimize the amount of yarn needed to make knitted tube 11 , although longer yarn segments, including yarn segments longer than their abutting wire segments, can be used if desired. Typically, on the order of 3-5 rows of yarn per yarn segment has been found to work successfully.
[0066] FIG. 6 shows the structure that results when yarn segment 12 of FIG. 5 is removed. As can be seen in this figure, wire segments 13 are connected to one another by a section of wire 16 that is not knitted. As discussed below in connection with FIG. 9 , this non-knitted section of wire is produced as the circular knitting machine is knitting yarn. Similarly, when the circular knitting machine is knitting wire, a non-knitted section of yarn is created which can be seen at 17 in FIGS. 6 and 7 .
[0067] As discussed more fully below, yarn segment 12 can be removed in various ways, in some of which the non-knitted section of wire 16 is cut before (or simultaneously with) the removal of the yarn segment. As shown in FIG. 6 , the yarn segment has been removed by being unwoven leaving the non-knitted section of wire intact. In this figure, the unwoven yarn is shown at 18 .
[0068] FIG. 7 shows another representative knitted tube 11 having a different aspect ratio for the knitted wire mesh segments 13 , i.e., in FIG. 4 , the wire segments 13 are longer than they are wide, while in FIG. 7 , they are wider than they are long. For example, the wire mesh segments in FIG. 4 can be on the order of 8 inches long by 2½ inches wide when flattened, while in FIG. 7 , the segments can be on the order of 2 inches long by 3½ inches wide when flattened. In general terms, subject to the capabilities of the available circular knitting machines and the availability of yarn having the requisite breaking strength (see below), tinkle-free wire mesh socks of essentially any desired size, aspect ratio, density, and wire composition, configuration, and dimensions can be produced using the techniques disclosed herein. The ability to make wire mesh socks having a wide variety of properties, in turn, means that knitted wire mesh filters having a wide variety of properties can be made using the technology disclosed herein.
[0069] In particular, knitted wire mesh filters of the types now known or which may be developed in the future can be made using tinkle-free, knitted wire mesh socks produced in accordance with the present disclosure. As just one non-limiting example, FIG. 8 shows a knitted wire mesh filter 19 having a configuration suitable for use as the filter of, for example, an airbag inflator, which could be made from a tinkle-free, knitted wire mesh sock of the type disclosed herein. Commonly-assigned U.S. Pat. Nos. 7,025,797 and 7,559,146, the contents of which are incorporated herein by reference in their entireties, illustrate other filter configurations that can benefit from the technology disclosed herein. It should be noted that the tinkle-free, knitted wire mesh socks disclosed herein will primarily be used in making filters for applications where freedom from tinkles is important, but can also be used in other situations, if desired.
[0070] As noted above, there are a number of ways to remove yarn segments 12 from knitted tube 11 . A preferred approach is to treat the knitted tube to remove the yarn. For example, the knitted tube can be treated with a solvent in which (i) the wire is insoluble and (ii) the yarn is soluble. The entire composition of the yarn need not be soluble in the solvent. For example, the yarn can comprise fibers that are bonded to one another by an adhesive (binder), with the adhesive, but not the fibers, being soluble in the solvent. By restricting the length of the fibers, the yarn will fall apart when the adhesive (binder) is removed.
[0071] A particularly preferred yarn comprises fibers, e.g., polyester fibers, which are bonded to one another by polyvinyl alcohol, the polyvinyl alcohol (but not the fibers) being soluble in water, which is a preferred solvent. Yarns composed of fibers, e.g., polyester fibers, bonded to one another by polyvinyl alcohol are commercially available for use in the manufacture of various consumer products, e.g., high loft towels, and thus in addition to the physical and chemical properties that make such yarns well-suited for use in the present technology, these yarns have the additional advantage that they are already being produced in large quantities and thus are relatively inexpensive.
[0072] When water is the solvent used in the treatment, it typically will be employed at an elevated temperature and indeed, the water may be entirely or partially in the form of steam at the time of use. The water (steam) can be applied to the yarn at various points in the process, e.g., it can be applied to an intact knitted tube produced by a run of a knitting machine, or it can be applied to a portion of a knitted tube which contains multiple yarn segments and has been separated from the main body of the tube by cutting at least one non-knitted section of wire, or it can be applied to an individual wire segment or a group of segments each having yarn on either or both of its ends, the wire segment(s) having been freed from the knitted tube by cutting at least one non-knitted section of wire. Other variations will be evident to those skilled in the art from the present disclosure.
[0073] The cutting of non-knitted sections of wire can be performed, for example, using a guillotine cutter located below a circular knitting machine or it can be performed offline. The cutting of the non-knitted sections of wire prior to the removal of the yarn produces cut knitted loops and cut portions of knitted loops, but these loops and portions of loops are not the troublesome tinkles of the prior art because rather being composed of metal, which cannot be removed, they are composed of yarn, which can be removed.
[0074] The yarn removal treatment can be performed online as the knitted tube is being formed or, more typically, will be performed offline in a separate processing operation. For a water (steam) treatment, equipment of the general type used to wash/sanitize kitchen utensils can be used to perform the yarn removal, with the water/steam being renewed at a sufficient rate so as not to compromise the rate of dissolution of the adhesive and to avoid the creation of a water/adhesive solution of high viscosity.
[0075] Although water (steam) is a preferred solvent for removing the yarn, other solvents which will not adversely affect the knitted wire, e.g., organic solvents, can be employed in the treatment step if desired. For example, alcohol can be used to dissolve nylon yarn. As a further, non-limiting, alternative, caustic solutions can be employed as the solvent. As with a water treatment, these solvents can dissolve all of the yarn or just a portion thereof, e.g., just an adhesive portion of the yarn. As another alternative in the treatment category, the yarn can be burnt off of the knitted wire, which can be advantageous in cases where the wire is going to be heat treated for other reasons, e.g., to anneal the wire of the wire mesh. However, burning off the yarn can lead to hard-to-remove chemical residues on the wire that are unacceptable for some applications.
[0076] In addition to the treatment approach for removing the yarn, unweaving of the knitted yarn can also be used if desired. The unweaving can be performed on a knitted tube or a portion thereof prior to cutting the non-knitted sections of wire to produce the separated wire mesh segments or can be performed on the separated wire mesh segments, the former approach being preferred. FIGS. 6 and 7 illustrate the unweaving approach applied to a portion of a knitted tube, where reference number 18 in these figures shows the unwoven yarn. The unweaving can be performed online as the knitted tube is being formed or offline, as desired. In should be noted that unlike trying to remove tinkles, unweaving can, in many cases, be performed by simply pulling a single thread to remove the entire knitted yarn. The treatment and unweaving approaches can be used in combination, if desired.
[0077] Knitted tube 11 can be produced by a variety of commercial or custom knitting machines, now known or subsequently developed. FIG. 9 is a schematic diagram of a representative commercial circular knitting machine 21 sold by Karl Mtiller GmbH Maschinenfabrik, Weissenburg, Germany, adapted for use in making knitted tube 11 . So as not to obscure the discussion of the primary components of the machine, various conventional components, e.g., pulleys, tension monitors, drive mechanisms, electronic control equipment, etc., have been omitted from FIG. 9 . Also, the rows of knitted yarn that make up yarn segment 12 of knitted tube 11 have not been explicitly shown in FIG. 9 , again to facilitate the presentation.
[0078] In overview, circular knitting machine 21 feeds wire 22 from wire spool 23 to circular knitting needles 24 or feeds yarn 25 from yarn spool 26 to those needles. As is conventional, the wire or yarn travels upward to pulleys (not shown) located above plate 27 before turning downward at apices 28 and 29 and passing through eyelets 30 and 31 (e.g., ceramic eyelets) mounted in plate 27 . The wire and yarn then pass through feed eyelets 32 and 33 (e.g., tungsten carbide eyelets) whose positions relative to circular knitting needles 24 are controlled by positioning cylinders 34 and 35 (e.g., non-rotating positioning cylinders of the type sold by Festo Corporation, Hauppauge, N.Y.). Positioning cylinders 34 and 35 are, in turn, controlled by pneumatic and programmed electronic control equipment.
[0079] In operation, the positioning cylinders determine whether wire or yarn is being knitted by knitting needles 24 . Thus, when wire is to be knitted, positioning cylinder 34 moves feed eyelet 32 into position so that wire 22 is captured under the hooks of the knitting needles. Conversely, when yarn is to be knitted, positioning cylinder 35 moves feed eyelet 33 into position so that the needle's hook captures yarn 25 . The positioning cylinders also move the wire/yarn feed eyelets away from the needles when the other material is being knitted. During such non-knitting periods, the material that is not being knitted continues to be fed from its spool and forms the non-knitted sections 16 and 17 of wire and yarn discussed above and illustrated in FIGS. 6 and 7 .
[0080] In practice, a distance on the order of, for example, 25 millimeters between the knitting and non-knitting positions of the feed eyelets has been found to work successfully. To avoid the problem of double stitches, a stripper (not shown in FIG. 9 ) can be employed to hold the loops in position, i.e., to hold the loops down, as the needles move upwardly.
[0081] To produce a tube, either the circular array of knitting needles 24 needs to rotate past the positioning cylinders 34 , 35 or the positioning cylinders need to rotate around the array of knitting needles. In the former case, i.e., the rotating needles case, the knitted tube will rotate with the needles, which may be undesirable for some applications. FIG. 9 illustrates the latter case, i.e., the case where the positioning cylinders rotate around the array of knitting needles. Specifically, positioning cylinders 34 , 35 are mounted on cam hub 37 which surrounds the circular array of knitting needles 24 and rotates with plate 36 . For this embodiment, plate 27 , which carries spools 23 and 26 , and is supported with standoffs (not shown) from plate 36 , also rotates. To count the rotations or partial rotations of the plate and the hub, plate 27 can, for example, include a series of timing stubs 38 spaced along its perimeter to trigger a fixed sensor (not shown) to control sock length.
[0082] Once the tinkle-free wire mesh socks have been produced, they can be formed into tinkle-free wire mesh filters using a variety of techniques now known or subsequently developed. The filter can have a variety of configurations, including, without limitation, circular (disc-shaped), annular, elliptical (oval), triangular, square, octagonal, etc. Typically, the sock will be pressed into its desired shape using a compression mold, which in the case of an annular filter may include a mandrel and a plunger to produce a filter having an annulus with the desired physical dimensions, weight, and density.
[0083] The wire employed in producing the tinkle-free socks will be chosen based on the filtering requirements, the fluid (gas, liquid, or mixed phases) that is to be filtered, and the environment in which the filter will operate. Suitable materials for the wire include, without limitation, stainless steels, including austenitic and nickel alloys, such as, 304 , 309 , and 310 grades of stainless steel, or combinations thereof. The diameter of the wire will depend on the particular application of the filter. For example, the wire used for fabricating airbag filters can range from about 0.011 inches in diameter to about 0.03 inches in diameter (from about 0.35 mm to about 0.75 mm in diameter), although larger or smaller wires can be used, if desired. In the case of filters designed to filter fuel for an internal combustion engine, the wire diameters can range from about 0.001 inches to about 0.006 inches, although again larger or smaller wires can be used if desired. The cross-sectional shape of the wire will also depend on the particular application, with round and flat cross-sections being most common. As a further alternative, the filters of the present disclosure can employ wire that has been subjected to various types of processing to alter its properties. For example, additional strength can be obtained by heat treating.
[0084] Although typically a single type of wire will be used throughout the tinkle-free sock, a combination of two or more wires of different types, e.g., wires having different diameters, compositions, and/or geometries, can be knit into a single mesh if desired. Rather than using different types of wires in a single sock, a composite filter can be produced by compressing tinkle-free socks made of different types of wires into a single filter.
[0085] Yarns having a variety of compositions and structures can be used to produce the knitted tubes of the present disclosure. In general terms, the yarns will be metal free, but otherwise essentially any yarn that can be removed by the treatment and/or unweaving approaches discussed above can be used. Importantly, however, because yarn segments 12 need to interface with wire segments 13 , the yarn needs to have sufficient strength properties to withstand the forces (takedown forces) applied to the yarn as the wire is being knitted. These forces increase as the diameter and strength of the wire increases and/or as the mesh becomes finer (tighter).
[0086] As a rule of thumb, to avoid damage to the wire while it is being knit, the maximum force applied to the wire is kept substantially below the yield strength of the wire, e.g., the knitting is performed at or below approximately 50-60% of the yield strength of the wire. Accordingly, the breaking strength of the yarn should be at least 50% of the product of the wire's yield strength times the wire's cross-sectional area. Quantitatively, for wire having a diameter in the range of 1 to 30 thousandths, the yield strength runs in the range of 20,000-150,000 psi, so that the yield strength times area product runs in the range from under 10 grams to over 100 pounds. Taking 50% of these values gives a representative range of breaking strengths for the yarn of from ˜5 grams to ˜50 pounds. A variety of yarns having breaking strengths in this range and above are commercially available. Also, individual strands of yarn can be wound together to achieve a net breaking strength value sufficiently high to withstand the forces associated with knitting the wire chosen for the filter. In particular, a variety of yarns composed of polyester fibers bonded to one another by a polyvinyl alcohol adhesive (PVA binder) and having a breaking strength for a single strand on the order of 20 pounds are commercially available at reasonable costs. By winding together ten or so strands of this yarn, breaking strengths in the above range or higher are easily achieved.
[0087] A variety of modifications that do not depart from the scope and spirit of the invention will be evident to persons of ordinary skill in the art from the foregoing disclosure. The following claims are intended to cover the specific embodiments set forth herein as well as modifications, variations, and equivalents of those embodiments. | “Tinkles” (also known as “gotchas”) (see reference number 20 in FIGS. 1 and 2 ) are portions of knitted metal loops produced when a tube of knitted wire mesh is cut into individual pieces. In the prior art, tinkles have been considered a fact of life and the approach has been to try to shake them out of the mesh or immobilize them on or in the mesh. By producing a knitted tube ( 11 ) having alternating segments ( 12,13 ) of knitted rows of yarn and knitted rows of wire, completely tinkle-free knitted socks are produced which are used to produce completely tinkle-free knitted wire mesh filters. Knitted wire mesh filters that cannot release tinkles because they do not have any tinkles can be used in such applications as fuel filters and airbag filters. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Applicants' invention relates generally to an aiming and shooting support apparatus, designed to assist disabled users of devices needing to be aimed, such as projectile weapons or video recording devices, but with application for all users of such devices. More specifically, it relates to a lightweight, portable, aiming and shooting device that provides hunters, photographers, and others with an easily guidable, stable, fatigue-reducing support apparatus.
2. Background Information
It is well known that holding a weight at arm's length for an extended period is fatiguing. When a person is attempting to aim a weapon, a telephoto camera, or other device requiring high degrees of stability, such fatigue can cause aim-spoiling muscle spasms or trembling. Also, persons with a disability in one arm, such as loss of use of levitator muscles in the shoulder, are unable to properly hold and aim two-handed weapons such as rifles and bows.
Accordingly, inventors have devised a number of braces that assist the user in supporting their arm as discussed below; however, these devices have a number of flaws making them inferior to the present invention.
U.S. Pat. No. 2,474,050 issued to Herbert H. Harris on Jun. 21, 1949 discloses an armrest, which must be attached to the user's arm via an encircling strap and buckle arrangement. The arm-encircling strap and bracket are attached to a brace via a hinge, but the device does not rotate about its axis. The bottom of the brace is a friction pad designed to rest against the body or a flat work surface; however, it does not provide sufficient stability for firing a rifle or shotgun.
U.S. Pat. No. 4,575,964 issued to Donnie R. Griffin on Mar. 18, 1986 discloses a portable gun rest. The rest has two U-shaped saddle members, one of which fits over the thigh with the other fitting under the weapon. The two saddle members are held in coaxial alignment by the same pin that adjusts the height of the rest. Only when the pin is removed and the rest retracted to its shortest height can the saddle members freely rotate about the longitudinal axis of the brace. The upper end of the device is designed to directly hold a rifle or shotgun.
U.S. Pat. No. 5,351,867 issued to Clyde L. Vest on Oct. 4, 1994 discloses an arm steady brace (The “Vest brace”). The brace is strapped or clipped to the user's belt and then extends upward to support the user's forearm. When not supporting the user's arm, it is carried in a locked downward position, which can hinder mobility and elevates the risk of an impalement injury in the event of a fall.
U.S. Pat. No. 5,930,931 issued to Jerry Wade Watson on Sep. 15, 1997 discloses an adjustable gun rest. Like the Griffin device, this device directly supports the weapon; however, this device improves upon the Griffin device by allowing the user to position the weapon at an angle other than parallel with the user's thigh. A set-screw allows variable adjustment of the gun rest's height, as opposed to the discrete adjustment settings of the Griffin device.
U.S. Pat. No. 5,685,104 issued to Robert P. Breazeale, Jr. on Nov. 11, 1997 discloses a gun rest that mounts to a tree stand. The device directly supports the weapon, but is unusable except in a tree stand.
U.S. Pat. No. 6,637,708 B1 issued to Thomas K. M. Peterson on Oct. 23, 2003 discloses an articulated aiming support. This support directly supports the weapon and is mounted to a shooting platform or tree stand. Like the Breazeale device, the support is unusable away from a platform or stand.
Thus, there is a need for a method and device for supporting the support arm of the user, both in a resting position and in a shooting position. Further, it is advantageous for the device to provide sufficient stability for firing a weapon, be freely rotatable about the longitudinal axis of the device in any configuration, is not attached to the user, and is not attached to an inanimate object.
The present invention addresses the requirement for a lightweight, portable aiming device that provides a wide range of motion without manual adjustment, reduces fatigue, and adapts to a range of shooting positions.
SUMMARY OF THE INVENTION
By the present invention, a unique aiming aid is disclosed.
Accordingly, one of the objects of the present invention is to provide an improved arm brace that will enable a person unable to lift the user's arm to effectively hold and aim a weapon or other device.
Another of the objects of the invention is to provide an improved arm rest that is easier and less expensive to manufacture than those available in the past.
Another of the objects of the invention is to provide an improved arm rest that is comfortable for extended use and reduces the fatigue of holding a weapon or other device in a ready position.
Another of the objects of the invention is to provide an improved arm rest providing freedom of movement and aim, while maintaining a stable firing platform and without requiring the user to remove the user's hands from the weapon to make adjustments.
Another of the objects of the invention is to provide an improved arm rest that reduces the risk of injury during a fall by not being attached to the user and thus more easily rid of by the user in the event of a fall or other accident. Because it is not attached, if the user falls, the natural movement of the user's arms and legs will tend to allow the invention to fall away from the user and thus reduce the risk of injury due to the user falling on an end of the device.
Still another object of the invention is to provide an improved arm rest that is lightweight, easily portable, usable from the sitting or kneeling positions, and silent in use.
The most obvious difference between the present invention and the prior art, other than the Vest brace, is that the present invention, rather than directly supporting a rifleman's weapon, supports the rifleman's extended support arm. This fundamental difference provides several main benefits. First, by allowing the user to hold the weapon with the user's hand rather than separating the two by placing the weapon on an inanimate object, the user has a better “feel” of the weapon and thus obtains more control over its acute manipulation providing for more accurate aim than with a device that attaches to the weapon and separates the weapon from the user. Second, the device enables a wide range of motion without requiring the user to remove the user's hands from the weapon to make an adjustment. Third, users of the aiming aid are not limited to the use of weapons or cameras that fit in, or are attachable to, the aiming aid itself. Virtually anything that is intended to be held and aimed by hand is usable, including without limitation, firearms, bows and cameras. Fourth, the aiming aid is ideal for use by any individual who has limited strength in their support arm, such as the elderly, youths, and handicapped individuals who cannot raise their support arm but can still flex their elbow and maintain a grip on a weapon, providing the user with a natural aiming and shooting experience, without the requirement for rigidly-mounted braces or safety-endangering straps and clips.
The present invention differs from the Vest brace by providing an arm-bracing system that is more comfortable for prolonged periods of arm extension and more stable than a hip-mounted, belt-clip base.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention in an extended position.
FIG. 2 is a side view of the present invention.
FIG. 3 is a front view of the present invention in a retracted position.
FIG. 4 a shows the present invention in use in an extended position at rest.
FIG. 4 b shows the present invention in use in an extended position aiming forward.
FIG. 4 c shows the present invention in use in an extended position aiming to the side.
FIG. 5 a shows the present invention in use in a retracted position at rest.
FIG. 5 b shows the present invention in use in a retracted position aiming forward.
FIG. 5 c shows the present invention in use in a retracted position aiming to the side.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, FIG. 1 shows a perspective view of the aiming aid ( 10 ) in an extended position. The aiming aid ( 10 ) is comprised of a leg support member ( 18 ) and an arm support member ( 16 ) with a support shaft ( 11 ) having a axis (L—L) disposed between them. The support shaft first end ( 11 a ) attached to the arm support member ( 16 ) and the support shaft second end ( 11 b ) attached to the leg support member ( 18 ). The length of the support shaft ( 11 ) is adjustable. The support shaft ( 11 ) is comprised of a first extension member ( 12 ) and a second extension member ( 14 ). The leg support member ( 18 ) is attached via a second connector ( 22 ) to the second extension member ( 14 ). The first extension member ( 12 ) fits inside of and is coaxial with the outer brace tube. The first extension member ( 12 ) is connected to the arm support member ( 16 ) via a first connector ( 20 ).
The overall length of the support shaft ( 11 ) and consequently the aiming aid ( 10 ) is adjustable due to the first extension member ( 12 ) being slidably engageable with the second extension member ( 14 ) so as to change the length of said support shaft ( 11 ). Generally, it is anticipated that first extension member ( 12 ) and the second extension member ( 14 ) will be hollow or tubular shaped, and that the first extension member ( 12 ) will be shaped and sized so as to fit within the second extension member ( 14 ) (or vice versa). The length of the support shaft ( 11 ) is adjusted by means of the first extension member's ( 12 ) telescoping into, or outwardly from, the second extension member ( 14 ) (or vice versa). In the preferred embodiment, a set pin ( 24 ) fits into one of a plurality of apertures ( 26 ) in the second extension member ( 14 ) and thus can be used to adjust and fix the length of the support shaft ( 11 ). However, it is anticipated that other set means of altering and fixing the length of the aiming aid ( 10 ) may be used, including but not limited to: pneumatics, hydraulics, friction devices, threaded devices, removable locking pins, clamps, or other devices familiar to those with ordinary skill in the art. The adjustable nature of the first extension member ( 12 ) and the second extension member ( 14 ) allows for use of the aiming aid ( 10 ) by operators of different physical proportion and also provides the user with the ability change, during the course of aiming and shooting, the user's support arm and weapon positioning with minimized limitations.
Opposite ends of an optional sling ( 32 ) are attached to, and the sling ( 32 ) runs between, an arm support connection piece ( 28 ) and a leg support connection piece ( 30 ). The sling ( 32 ) allows for hands-free carrying of the aiming aid ( 10 ). The arm support connection piece ( 28 ) is attached to the arm support member second end ( 16 b ) and the leg support connection piece ( 30 ) is attached to the leg support member second end ( 18 b ). The support connection pieces ( 28 & 30 ) may be designed to break away from the ends of the sling ( 32 ), or from the arm support member ( 16 ) and the leg support member ( 18 ), when placed under stress, prior to the remainder of the aiming aid ( 10 ). This “break away” design helps to reduce the likelihood of injury to the user in the event of the aiming aid ( 10 ) hanging on a snag or other accident. It is anticipated that the support connection pieces ( 28 & 30 ) could include buttons, snaps, clips, or other devices designed for closure but allowing release as are familiar to those with ordinary skill in the art. Alternatively, the sling ( 32 ) can be designed with a limited tensile strength, or limited tensile strength at desired “break points,” to provide the same sort of safety mechanism. The arm support member ( 16 ) and the leg support member ( 18 ) curl outward at the carrying-strap support connection pieces ( 28 & 30 ), preventing the aiming aid ( 10 ) from snagging on the operator's clothing or body, and ensuring smooth movement during operation.
In the preferred embodiment of the aiming aid ( 10 ), the arm support member ( 16 ) and the leg support member ( 18 ) are arcuate in order to engage the user's arm and leg respectively. It is further intended that the arm support member ( 16 ) and the leg support member ( 18 ) be able to adaptively fit a variety of users' body dimensions. For this reason; the arm support member ( 16 ) and the leg support member ( 18 ) are sized and shaped to fit a relatively large number of various sized users' arms and legs. Additionally, the arm support member ( 16 ) and the leg support member ( 18 ) may be constructed of a material that is pliable enough so as to allow the user to repetitively shape and reshape the arm support member ( 16 ) and/or the leg support member ( 18 ) in order to provide a custom fit for different users (or for the same user if a different fit becomes desirable), but that does not deform during normal use or transport.
It is anticipated that the arm support member ( 16 ) and the leg support member ( 18 ) will be constructed so as to provide an appropriate trade-off between weight distribution (which favors a wider surface area) and maneuverability (which favors a narrower surface area). To best accomplish this goal, it is anticipated that arm brace contact surface ( 16 c ) and the thigh brace contact surface ( 18 c ) will be in the range between 0.5 inches and 2.5 inches wide. Other widths are contemplated for different uses of the aiming aid ( 10 ), depending upon the maneuverability required by the application and the weight that the user's arm must support in such application.
In the preferred embodiment, the arm support member ( 16 ) is shaped in a symmetrical or asymmetrical “u-shape.” Often, the lateral or outside half of the arm support member ( 16 ), running from the point at which the first connector ( 20 ) is connected to the arm support member ( 16 ) to the arm support member second end ( 16 b ), has a gradual convex curve to accommodate the shape of the user's outer arm and arm muscle typically existing on the outside of the arm. The medial or inside half of the arm support member ( 16 ), running from the point at which the first connector ( 20 ) is connected to the arm support member ( 16 ) to the arm support member first end ( 16 a ), generally has a more acute and immediate curve, designed to fit the flatter, inside part of the user's arm. Additionally, the arm support member ( 16 ) of the aiming aid ( 10 ) fits to the user's arm, rather than to the specific weapon or device being supported, thus giving the aiming aid ( 10 ) universal application. The user therefore may employ the aiming aid ( 10 ) to support a camera, rifle, pistol, bow, nail guns, drills, or any other device or weapon supported by one arm. Even if only the user's arm is to be supported in order to help the user employ the supported hand, the aiming aid ( 10 ) can be effective.
In an alternative embodiment, the medial portion or side of the leg support member ( 18 ) may be longer than the lateral portion or side. The medial portion of the leg support member ( 18 ), running from the point at which the second connector ( 22 ) is connected to the leg support member ( 18 ) to the leg support member first end ( 16 a ), rests over the medial aspect of the thigh, while the lateral portion of the leg support member ( 18 ), running from the point at which the second connector ( 22 ) is connected to the leg support member ( 18 ) to the leg support member second end ( 16 b ), rests over the lateral aspect of the thigh. The arcuate shape of the leg support member ( 18 ) allows for comfortable rotation of the leg support member ( 18 ) about the thigh while maintaining overall stability of the braced arm. Thus, the extra length of the leg support member ( 18 ) on the medial aspect of the thigh maintains stability of the aiming aid ( 10 ) as the user rotates the user's upper body away from center, such as in aiming to the side (as shown in FIGS. 4 c and 5 c ). The rotation ability of the invention allows the user to easily rotate the user's upper body from side to side without needing to remove the user's hands from the weapon, camera or other device.
The aiming aid ( 10 ) may be made using a variety of materials, such as metals, alloys, carbon fibers, plastics, ceramics, fiberglass, and a variety of coatings, such as paint, Teflon or non-stick coatings, fabric, sealed foam or other padding, gels, powder coating, bluing, or anodization. Other materials and coatings that conform to the manufacturing and use requirements of the aiming aid ( 10 ) are also contemplated by the invention. The advantages of the various materials and coatings is apparent when contemplated with respect to the use of the aiming aid ( 10 ). For example, stainless steel used in the manufacture of the aiming aid ( 10 ) would provide great strength as well as not rusting in the field. Aluminum and carbon fiber would provide strength and would not rust, but would also be generally lighter weight. Coatings, such as non-stick and padding on the arm support member contact surface ( 16 c ) and leg support member contact surface ( 18 c ) would provide increased ease of maneuverability and comfort for the user.
FIG. 2 shows a side view of the aiming aid ( 10 ). As shown from this angle, the aiming aid ( 10 ) incorporates a first extension member ( 12 ) and a second extension member ( 14 ) which telescope within each other along an axis (L—L) (as shown in FIG. 1 ) and such that the aiming aids ( 10 ) overall length is adjustable. As shown in this embodiment of the aiming aid ( 10 ), the orientation of the first extension member ( 12 ) to the second extension member ( 14 ) is set via a spring loaded set pin ( 24 ) which, when oriented with one of the apertures ( 26 ), springs outwardly to affix the position of the first extension member ( 12 ) relative to the second extension member ( 14 ). In order to affect the telescoping action of the extension members ( 12 ) and ( 14 ), the outer diameter of the first extension member ( 12 ) is sized slightly less than the inner diameter of the second extension member ( 14 ). In this embodiment, the first extension member second end ( 12 b ) slides into the interior of the second extension member ( 14 ) through the second extension member second end ( 14 b ). At the first extension member first end ( 12 a ), the arm support member ( 16 ) is connected via a first connector ( 20 ). The first connector ( 20 ) is rotatable about the axis (L—L) likewise allowing the arm support member ( 16 ) to rotate about the axis (L—L).
At the second extension member second end ( 14 b ) the leg support member ( 18 ) is connected via a second connector ( 22 ) which is rotatable about the axis (L—L). Like the arm support member ( 16 ), the leg support member ( 18 ) is rotatable about the axis (L—L). A sling ( 32 ) is connected at each end, one to the arm support connection piece ( 28 ) which may be found near the arm support member second end ( 16 b ), and to the leg support connection piece ( 30 ) which is found at or near the leg support member second end ( 18 b ). The sling ( 32 ) may be used by the user to strap the aiming aid ( 10 ) to the user's body while the aiming aid ( 10 ) is not use and the user is changing position.
FIG. 3 shows a front perspective view of the aiming aid ( 10 ) in a retracted position. In contrast, FIG. 1 showed the same view of the aiming aid ( 10 ), but in an extended position. A comparison of FIGS. 1 and 3 illustrates how the aiming aid ( 10 ) can be adjusted to fit both different sized users and various aiming positions. As shown in FIG. 3 , a more retracted position of the first extension member ( 12 ) and the second extension member ( 14 ), would be appropriate for a smaller user. Similarly, it would also be appropriate for those situations in which the user was aiming downward such as from a tree stand or high position. In contrast, the extended position as shown in FIG. 1 would be more useful for a taller user or for a user who is aiming upwards such as when shooting fowl. Or, a central position might be most appropriate for aiming along a generally horizontal plane. As will be noted, it is anticipated that there will be multiple positions that allow for a range of combined length of the first extension member ( 12 ) and the second extension member ( 14 ). Thus, it is anticipated that the illustrated set pin ( 24 ) and aperture ( 26 ) means for setting the overall length of the first extension member ( 12 ) and second extension member ( 14 ) is only one of a number of means of doing so. Other anticipated means include, but are not limited to, rotational means using pressure on the first extension member ( 12 ) and/or second extension member ( 14 ), hydraulic means, set screw means, springed means, set pin means, as well as other like means. FIG. 3 also illustrates that while the relative length of the first extension member ( 12 ) and second extension member ( 14 ) can be modified, the remaining components of the aiming aid ( 10 ) do not change. The arm support member ( 16 ) still accepts the user's arm and is rotatable about the (L—L) axis of the aiming aid ( 10 ) by means of the first connector ( 20 ). Like wise, the leg support member ( 18 ) still engages the user's leg and is also rotatable about the axis (L—L) of the aiming aid ( 10 ) by means of the second connector ( 22 ). While it is anticipated that most embodiments of the aiming aid ( 10 ) will incorporate tubular first extension members ( 12 ) and second extension members ( 14 ), there is no intended limitation regarding the shape of the first extension member ( 12 ) and second extension member ( 14 ). For example, the extension members ( 12 ) and ( 14 ) could be rectangular or triangular in shape so long as the prospective shapes of the first extension member ( 12 ) and second extension member ( 14 ) allowed for adjustment of the overall length of the aiming aid ( 10 ). Likewise, it is irrelevant whether the first extension member ( 12 ) fits within the second extension member ( 14 ), or the second extension member ( 14 ) fits within the first extension member ( 12 ), again so long as the overall embodiment of the aiming aid ( 10 ) allows for modification of the overall length.
FIG. 4 a illustrates the use of the aiming aid ( 10 ) with a rifle as shown in a resting position. The user, in a kneeling or sitting position, places the leg support member ( 18 ) atop the user's thigh, close to the crotch, with the long part of the brace on the inner thigh. The user then places the arm support member ( 16 ) either superior or inferior to the user's elbow depending upon the desired trajectory of the shot. The first extension member ( 12 ) and the second extension member ( 14 ) can be adjusted to provide the desired support height. The user holds the device in place by maintaining slight pressure between the user's arm and the user's thigh. Rotation of first connector ( 20 ) and second connector ( 22 ) allow the user to flex the user's elbow while maintaining the invention and weapon in a ready position, greatly decreasing or eliminating the fatigue caused by other devices that tend to lock the arm in an extended position.
FIGS. 4 b and 4 c illustrate the use of the aiming aid ( 10 ) with a rifle as shown aiming forward and rotated aiming to the side. The first connector ( 20 ) and second connector ( 22 ) allow the arm support member ( 16 ) and the leg support member ( 18 ) to rotate a full 360 degrees about the common axis (L—L) (as shown in FIG. 1 ) of the first extension member ( 12 ) and the second extension member ( 14 ). This rotation provides the user with a wide range of motion without sacrificing stability. Further, this free rotation allows the aiming aid ( 10 ) to be used on either side of the body, regardless of which thigh is used as a support point. No straps or other means are required to secure the aiming aid ( 10 ) to the user's body during use. Not being secured to the user's body is an advantage of the aiming aid ( 10 ) because it may be more rapidly deployed in preparation for a quick shot. Additionally, the lack of straps or other securing means attaching the aiming aid ( 10 ) to the user, allow the aiming aid ( 10 ) to be quickly and easily discarded in the event of a fall by the user, thereby reducing the risk of injury due to contact with the aiming aid ( 10 ). The absence of straps securing the aiming aid ( 10 ) to the user's body also facilitates the smooth movement and guidance of the camera or weapon as the operator rotates the user's torso, allowing the hunter or photographer to freely track or lead an animal.
Providing a multitude of possible positions, with a minimum of adjustment, is the most import feature of the aiming aid ( 10 ). Once the user has established a position relative to the anticipated target, for example in a tree stand looking down on a game trail, the user sets the length of the support shaft ( 11 ) and will generally not need to reset the length. After setting this length, the user can move the user's arm, leg, and torso in order to acquire the target. Thus, the degrees of freedom of movement inherent in the aiming aid ( 10 ) allow the user to swing, for example, from the position shown in FIG. 4 b to the position shown in FIG. 4 c as a user might do in tracking the movement of a target without changing the basic length of the support shaft ( 11 ). After such gross movement positions the aim of the user in the general vicinity of the target, the support the aiming aid ( 10 ) provides to the user helps the user make fine adjustment movements to zero in the user's aim on the target. This ability to make fine adjustments, while not having to readjust the length of the support shaft ( 11 ), during the use of the aiming aid ( 10 ) is essential for accuracy.
FIGS. 5 a , 5 b and 5 c illustrate the use of the aiming aid ( 10 ) with a bow as shown in a resting position, aiming forward, and rotated aiming to the side. The portable design of the invention allows for its use in a variety of situations and positions, including, but not limited to: use in blinds, tripods, or tree stands; while the user is kneeling; or while the user is sitting in a chair or on the ground.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. | The present invention provides stable support for the extended arm of the operator of a projectile weapon or camera. The invention contains two support members oriented opposed from one another and connected by telescoping support extension members. One support member accepts the user's arm, while the other accepts the user's thigh. Since the invention supports the user's arm rather than the object being used, the invention may accommodate—without alteration—any device the user wishes to operate. Between each support member and the extension member is a connector which provides for 360 degree rotation of each support member. This innovation allows the user to extend or contract the user's arm while still supported by the invention, thereby alleviating the fatigue which may develop from keeping the arm fixed in an extended position. The invention requires no straps or other means to affix it to the operator's body and instead is held in place by tension between the user's arm and the user's thigh. This design helps minimize injury from a fall by enabling the user to quickly discard the invention. The noiseless operation of the invention ensures it will not frighten away game or other wildlife. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Divisional application of U.S. patent application Ser. No. 14/146,677, filed Jan. 2, 2014, for Visual Prosthesis with User Interface, which is a divisional application of U.S. patent application Ser. No. 13/708,551, filed Dec. 7, 2012, for Package for an Implantable Device, which is a Divisional application of U.S. patent application Ser. No. 11/926,012, filed Oct. 28, 2007, for Coating Package for an Implantable Device, which is a Divisional application of U.S. patent application Ser. No. 11/206,484, filed Aug. 17, 2005, which is a Divisional application of U.S. patent application Ser. No. 09/515,373, filed Feb. 29, 2000, which claims the benefit of U.S. Provisional Application No. 60/125,873, filed Mar. 24, 1999.
TECHNICAL FIELD OF INVENTION
The present invention relates to electrical stimulation of the retina to produce artificial images for the brain. It relates to an improve system for providing user controls to an implanted visual prosthesis.
BACKGROUND
Color perception is part of the fabric of human experience. Homer (c. 1100 b. c.) writes of “the rosy-fingered dawn”. Lady Murasaki no Shikibu (c. 1000 a.d.) uses word colors (“purple, yellow shimmer of dresses, blue paper”) in the world's first novel. In the early nineteenth century Thomas Young, an English physician, proposed a trichromatic theory of color vision, based on the action of three different retinal receptors. Fifty years later James Clerk Maxwell, the British physicist and Hermann von Helmholtz, the German physiologist, independently showed that all of the colors we see can be made up from three suitable spectral color lights. In 1964 Edward MacNichol and colleagues at Johns Hopkins and George Wald at Harvard measured the absorption by the visual pigments in cones, which are the color receptor cells. Rods are another type of photoreceptor cell in the primate retina. These cells are more sensitive to dimmer light but are not directly involved in color perception. The individual cones have one of three types of visual pigment. The first is most sensitive to short waves, like blue. The second pigment is most sensitive to middle wavelengths, like green. The third pigment is most sensitive to longer wavelengths, like red.
The retina can be thought of a big flower on a stalk where the top of that stalk is bent over so that the back of the flower faces the sun. In place of the sun, think of the external light focused by the lens of the eye onto the back of the flower. The cones and rods cells are on the front of the flower; they get the light which has passed through from the back of the somewhat transparent flower. The photoreceptor nerve cells are connected by synapses to bipolar nerve cells, which are then connected to the ganglion nerve cells. The ganglion nerve cells connect to the optic nerve fibers, which is the “stalk” that carries the information generated in the retina to the brain. Another type of retinal nerve cell, the horizontal cell, facilitates the transfer of information horizontally across bipolar cells. Similarly, another type of cell, the amacrine facilitates the horizontal transfer of information across the ganglion cells. The interactions among the retinal cells can be quite complex. On-center and off-center bipolar cells can be stimulated at the same time by the same cone transmitter release to depolarize and hyperpolarize, respectively. A particular cell's receptive field is that part of the retina, which when stimulated, will result in that cell's stimulation. Thus, most ganglion cells would have a larger receptive field than most bipolar cells. Where the response to the direct light on the center of a ganglion cells receptive field is antagonized by direct light on the surround of its receptive field, the effect is called center-surround antagonism. This phenomenon is important for detecting borders independent of the level of illumination. The existence of this mechanism for sharpening contrast was first suggested by the physicist Ernst Mach in the late 1800's. More detailed theories of color vision incorporate color opponent cells. On the cone level, trichromatic activity of the cone cells occurs. At the bipolar cell level, green-red opponent and blue-yellow opponent processing systems of the center-surround type, occur. For example, a cell with a green responding center would have a annular surround area, which responded in an inhibiting way to red. Similarly there can be red-center responding, green-surround inhibiting response. The other combinations involve blue and yellow in an analogous manner.
It is widely known that Galvani, around 1780, stimulated nerve and muscle response electrically by applying a voltage on a dead frog's nerve. Less well known is that in 1755 LeRoy discharged a Leyden jar, i.e., a capacitor, through the eye of a man who had been blinded by the growth of a cataract. The patient saw “flames passing rapidly downward.”
In 1958, Tassicker was issued a patent for a retinal prosthetic utilizing photosensitive material to be implanted subretinally. In the case of damage to retinal photoreceptor cells that affected vision, the idea was to electrically stimulate undamaged retinal cells. The photosensitive material would convert the incoming light into an electrical current, which would stimulate nearby undamaged cells. This would result in some kind of replacement of the vision lost. Tassicker reports an actual trial of his device in a human eye. (U.S. Pat. No. 2,760,483).
Subsequently, Michelson (U.S. Pat. No. 4,628,933), Chow (U.S. Pat. Nos. 5,016,633; 5,397,350; 5,556,423), and De Juan (U.S. Pat. No. 5,109,844) all were issued patents relating to a device for stimulating undamaged retinal cells. Chow and Michelson made use of photodiodes and electrodes. The photodiode was excited by incoming photons and produced a current at the electrode.
Normann et al. (U.S. Pat. No. 5,215,088) discloses long electrodes 1000 to 1500 microns long designed to be implanted into the brain cortex. These spire-shaped electrodes were formed of a semiconductor material.
Najafi, et al., (U.S. Pat. No. 5,314,458), disclosed an implantable silicon-substrate based microstimulator with an external device which could send power and signal to the implanted unit by RF means. The incoming RF signal could be decoded and the incoming RF power could be rectified and used to run the electronics.
Difficulties can arise if the photoreceptors, the electronics, and the electrodes all tend to be mounted at one place. One issue is the availability of sufficient area to accommodate all of the devices, and another issue is the amount of power dissipation near the sensitive retinal cells. Since these devices are designed to be implanted into the eye, this potential overheating effect is a serious consideration.
Since these devices are implants in the eye, a serious problem is how to hermetically seal these implanted units. Of further concern is the optimal shape for the electrodes and for the insulators, which surround them. In one embodiment there is a definite need that the retinal device and its electrodes conform to the shape of the retinal curvature and at the same time do not damage the retinal cells or membranes.
The length and structure of electrodes must be suitable for application to the retina, which averages about 200 microns in thickness. Based on this average retinal thickness of 200 microns, elongated electrodes in the range of 100 to 500 microns appear to be suitable. These elongated electrodes reach toward the cells to be activated. Being closer to the targeted cell, they require less current to activate it.
In order not to damage the eye tissue there is a need to maintain an average charge neutrality and to avoid introducing toxic or damaging effects from the prosthesis.
A desirable property of a retinal prosthetic system is making it possible for a physician to make adjustments on an on-going basis from outside the eye. One way of doing this would have a physician's control unit, which would enable the physician to make adjustments and monitor the eye condition. An additional advantageous feature would enable the physician to perform these functions at a remote location, e.g., from his office. This would allow one physician to remotely monitor a number of patients remotely without the necessity of the patient coming to the office. A patient could be traveling distantly and obtain physician monitoring and control of the retinal color prosthetic parameters.
Another version of the physician's control unit is a hand-held, palm-size unit. This unit will have some, but not all of the functionality of the physician's control unit. It is for the physician to carry on his rounds at the hospital, for example, to check on post-operative retinal-prosthesis implant patients. Its extreme portability makes other situational uses possible, too, as a practical matter.
The patient will want to control certain aspects of the visual image from the retinal prosthesis system, in particular, image brightness. Consequently, a patient controller, performing fewer functions than the physician's controller is included as part of the retinal prosthetic system. It will control, at a minimum, bright image, and it will control this image brightness in a continuous fashion. The image brightness may be increased or decreased by the patient at any time, under normal circumstances.
A system of these components would itself constitute part of a visual prosthetic to form images in real time within the eye of a person with a damaged retina. In the process of giving back sight to those who are unable to see, it would be advantageous to supply artificial colors in this process of reconstructing sight so that the patient would be able to enjoy a much fuller version of the visual world.
In dealing with externally mounted or externally placed means for capturing image and transmitting it by electronic means or other into the eye, one must deal with the problem of stabilization of the image. For example, a head-mounted camera would not follow the eye movement. It is desirable to track the eye movements relative to the head and use this as a method or approach to solving the image stabilization problem.
By having a method and apparatus for the physician and the technician to initially set up and measure the internal activities and adjust these, the patient's needs can be better accommodated. The opportunity exists to measure internal activity and to allow the physician, using his judgment, to adjust settings and controls on the electrodes. Even the individual electrodes would be adjusted by way of the electronics controlling them. By having this done remotely, by remote means either by telephone or by the Internet or other such, it is clear that a physician would have the capability to intervene and make adjustment as necessary in a convenient and inexpensive fashion, to serve many patients.
SUMMARY OF INVENTION
The present invention is a visual prosthesis for the restoration of sight in patients with lost or degraded visual function. The visual prosthesis includes an implantable portion which stimulates visual neural tissue according to stimulation patterns sent by a programmable video processing unit. The video processing unit controls stimulation patterns including programmable wave forms to provide monopolar, bipolar, and multipolar wave forms.
An objective of the current invention is to restore color vision, in whole or in part, by electrically stimulating undamaged retinal cells, which remain in patients with lost or degraded visual function arising, for example, from Retinitis Pigmentosa or Age-Related Macular Degeneration. This invention is directed toward patients who have been blinded by degeneration of photoreceptors; but who have sufficient bipolar cells, or other cells acting similarly, to permit electrical stimulation.
There are three main functional parts to this invention. One is external to the eye. The second part is internal to the eye. The third part is the communication circuitry for communicating between those two parts. Structurally there are two parts. One part is external to the eye and the other part in implanted within the eye. Each of these structural parts contains two way communication circuitry for communication between the internal and external parts.
The structural external part is composed of a number of subsystems. These subsystems include an external imager, an eye-motion compensation system, a head motion compensation system, a video data processing unit, a patient's controller, a physician's local controller, a physician's remote controller, and a telemetry unit. The imager is a video camera such as a CCD or CMOS video camera. It gathers an image approximating what the eyes would be seeing if they were functional.
The imager sends an image in the form of electrical signals to the video data processing unit. In one aspect, this unit formats a grid-like or pixel-like pattern that is then ultimately sent to electronic circuitry (part of the internal part) within the eye, which drives the electrodes. These electrodes are inside the eye. They replicate the incoming pattern in a useable form for stimulation of the retina so as to reproduce a facsimile of the external scene. In an other aspect of this invention other formats other than a grid-like or pixel like pattern are used, for example a line by line scan in some order, or a random but known order, point-by-point scan. Almost any one-to-one mapping between the acquired image and the electrode array is suitable, as long as the brain interprets the image correctly.
The imager acquires color information. The color data is processed in the video data processing unit. The video data processing unit consists of microprocessor CPU's and associated processing chips including high-speed data signal processing (DSP) chips.
In one aspect, the color information is encoded by time sequences of pulses separated by varying amounts of time; and, the pulse duration may be different for various pulses. The basis for the color encoding is the individual color code reference ( FIG. 2 a ). The electrodes stimulate the target cells so as to create a color image for the patient, corresponding to the original image as seen by the video camera, or other imaging means.
Color information, in an alternative aspect, is sent from the video data processing unit to the electrode array, where each electrode has been determined to stimulate preferentially one of the bipolar cell types, namely, red-center green-surround, green-center-red-surround, blue-center-yellow-surround, or yellow-center-blue-surround.
An eye-motion compensation system is an aspect of this invention. The eye tracker is based on detection of eye motion from the corneal reflex or from implanted coils of wire, or, more generally, insulated conductive coils, on the eye or from the measurement of electrical activity of extra-ocular muscles. Communication is provided between the eye tracker and the video data processing unit by electromagnetic or acoustical telemetry. In one embodiment of the invention, electromagnetic-based telemetry may be used. The results of detecting the eye movement are transmitted to a video data processing unit, together with the information from the camera means. Another aspect of the invention utilizes a head motion sensor and head motion compensation system. The video data processing unit can incorporate the data of the motion of the eye as well as that of the head to further adjust the image electronically so as to account for eye motion and head motion.
The internal structural part which is implanted internally within the eye, is also composed of a number of subsystems. These can be categorized as electronic circuits and electrode arrays, and communication subsystems, which may include electronic circuits. The circuits, the communication subsystems, and the arrays can be hermetically sealed and they can be attached one to the other by insulated wires. The electrode arrays and the electronic circuits can be on one substrate, or they may be on separate substrates joined by an insulated wire or by a plurality of insulated wires. This is similarly the case for a communication subsystem.
A plurality of predominately electronic substrate units and a plurality of predominately electrode units may be implanted or located within the eye as desired or as necessary. The electrodes are designed so that they and the electrode insulation conform to the retinal curvature. The variety of electrode arrays include recessed electrodes so that the electrode array surface coming in contact with the retinal membrane or with the retinal cells is the non-metallic, more inert insulator.
Another aspect of the invention is the elongated electrode, which is designed to stimulate deeper retinal cells by penetrating into the retina by virtue of the length of its electrodes. A plurality of electrodes is used. The elongated electrodes are of lengths from 100 microns to 500 microns. With these lengths, the electrode tips can reach through those retinal cells not of interest but closer to the target stimulation cells, the bipolar cells. The number of electrodes may range from 100 on up to 10,000 or more. With the development of electrode fabrication technology, the number of electrodes might rage up to one million or more.
Another aspect of the invention uses a plurality of capacitive electrodes to stimulate the retina, in place of non-capacitive electrodes. Another aspect of the invention is the use of a neurotrophic factor, for example, Nerve Growth Factor, applied to the electrodes, or to the vicinity of the electrodes, to aid in attracting target nerves and other nerves to grow toward the electrodes.
Hermetic sealing is accomplished by coating the object to be sealed with a substance selected from the group consisting of silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide, zirconium oxide. This hermetic sealing aspect of the invention provides an advantageous alternative to glass coverings for hermetic seals, being less likely to become damaged.
Another feature of one aspect of the structural internal-to-the-eye subsystems is that the electronics receive and transmit information in coded or pulse form via electromagnetic waves. In the case where electromagnetic waves are used, the internal-to-the-eye implanted electronics can rectify the RF, or electromagnetic wave, current and decode it. The power being sent in through the receiving coil is extracted and used to drive the electronics. In some instances, the implanted electronics acquire data from the electrode units to transmit out to the video data processing unit.
In another aspect the information coding is done with ultrasonic sound. An ultrasonic transducer replaces the electromagnetic wave receiving coil inside the eye. An ultrasonic transducer replaces the coil outside the eye for the ultrasonic case. By piezoelectric effects, the sound vibration is turned into electrical current, and energy extracted therefrom.
In another aspect of the invention, information is encoded by modulating light. For the light modulation case, a light emitting diode (LED) or laser diode or other light generator, capable of being modulated, acts as the information transmitter. Information is transferred serially by modulating the light beam, and energy is extracted from the light signal after it is converted to electricity. A photo-detector, such as a photodiode, which turns the modulated light signal into a modulated electrical signal, is used as a receiver.
Another aspect of the structural internal-to-the-eye subsystems of this invention is that the predominately electrode array substrate unit and the predominately electronic substrate unit, which are joined by insulated wires, can be placed near each other or in different positions. For example, the electrode array substrate unit can be placed subretinally and the electronic substrate unit placed epiretinally. On a further aspect of this invention, the electronic substrate unit can be placed distant from the retina so as to avoid generating additional heat or decreasing the amount of heat generated near the retinal nerve system. For example, the receiving and processing circuitry could be placed in the vicinity of the pars plana. In the case where the electronics and the electrodes are on the same substrate chip, two of these chips can be placed with the retina between them, one chip subretinal and the other chip epiretinal, such that the electrodes on each may be aligned. Two or more guide pins with corresponding guide hole or holes on the mating chip accomplish the alignment. Alternatively, two or more tiny magnets on each chip, each magnet of the correct corresponding polarity, may similarly align the sub- and epiretinal electrode bearing chips. Alternatively, corresponding parts which mate together on the two different chips and which in a fully mated position hold each other in a locked or “snap-together” relative position.
Now as an element of the external-to-the-eye structural part of the invention, there is a provision for a physician's hand-held test unit and a physician's local or remote office unit or both for control of parameters such as amplitudes, pulse widths, frequencies, and patterns of electrical stimulation.
The physician's hand-held test unit can be used to set up or evaluate and test the implant during or soon after implantation at the patient's bedside. It has, essentially, the capability of receiving what signals come out of the eye and having the ability to send information in to the retinal implant electronic chip. For example, it can adjust the amplitudes on each electrode, one at a time, or in groups. The hand-held unit is primarily used to initially set up and make a determination of the success of the retinal prosthesis.
The physician's local office unit, which may act as a set-up unit as well as a test unit, acts directly through the video data processing unit. The remote physician's office unit would act over the telephone lines directly or through the Internet or a local or wide area network. The office units, local and remote, are essentially the same, with the exception that the physician's remote office unit has the additional communications capability to operate from a location remote from the patient. It may evaluate data being sent out by the internal unit of the eye, and it may send in information. Adjustments to the retinal color prosthesis may be done remotely so that a physician could handle a multiple number of units without leaving his office. Consequently this approach minimizes the costs of initial and subsequent adjustments.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the invention will be more apparent from the following detailed description wherein:
FIG. 1A shows the general structural aspects of the retina color prosthesis system;
FIG. 1B shows the retina color prosthesis system with a structural part internal (to the eye), with an external part with subsystems for eye-motion feedback to enable maintaining a stable image presentation, and with a subsystems for communicating between the internal and external parts, and other structural subsystems;
FIG. 1C shows an embodiment of the retina color prosthesis system which is, in part, worn in eyeglass fashion;
FIG. 1D shows the system in FIG. 1C in side view;
FIG. 2A shows an embodiment of the color I coding schemata for the stimulation of the sensation of color;
FIG. 2B represents an embodiment of the color I conveying method where a “large” electrode stimulates many bipolar cells with the color coding schemata of FIG. 2A ;
FIG. 2C represents an embodiment of the color II conveying method where an individual electrode stimulates a single type of bipolar cell;
FIG. 3A represents an embodiment of the telemetry unit including an external coil, an internal (to the eye) coil, and an internal electronic chip;
FIG. 3B represents an embodiment of the telemetry unit including an external coil, an internal (to the eye) coil, an external electronic chip, a dual coil transfer unit, and an internal electrode array;
FIG. 3C shows and acoustic energy and information transfer system;
FIG. 3D shows a light energy and information transfer system;
FIG. 4 represents an embodiment of the external telemetry unit;
FIG. 5 shows an embodiment of an internal telemetry circuit and electrode array switcher;
FIG. 6A shows a monopolar electrode arrangement and illustrates a set of round electrodes on a substrate material;
FIG. 6B shows a bipolar electrode arrangement;
FIG. 6C shows a multipolar electrode arrangement;
FIG. 7 shows the corresponding indifferent electrode for monopolar electrodes;
FIG. 8A depicts the location of an epiretinal electrode array located inside the eye in the vitreous humor located above the retina, toward the lens capsule and the aqueous humor;
FIG. 8B shows recessed epiretinal electrodes where the electrically conducting electrodes are contained within the electrical insulation material; a silicon chip acts as a substrate; and the electrode insulator device is shaped so as to contact the retina in a conformal manner;
FIG. 8C is a rendering of an elongated epiretinal electrode array with the electrodes shown as pointed electrical conductors, embedded in an electrical insulator, where an pointed electrodes contact the retina in a conformal manner, however, elongated into the retina;
FIG. 9A shows the location of a subretinal electrode array below the retina, away from the lens capsule and the aqueous humor. The retina separates the subretinal electrode array from the vitreous humor;
FIG. 9B illustrates the subretinal electrode array with pointed elongated electrode, the insulator, and the silicon chip substrate where the subretinal electrode array is in conformal contact with the retina with the electrodes elongated to some depth;
FIG. 10A shows a iridium electrode that comprises a iridium slug, an insulator, and a device substrate where this embodiment shows the iridium slug electrode flush with the extent of the insulator;
FIG. 10B indicates an embodiment similar to that shown in FIG. 10 / 12 a , however, the iridium slug is recessed from the insulator along its sides, but with its top flush with the insulator;
FIG. 10C shows an embodiment with the iridium slug as in FIG. 10 / 12 b ; however, the top of the iridium slug is recessed below the level of the insulator;
FIG. 10D indicates an embodiment with the iridium slug coining to a point and insulation along its sides, as well as a being within the overall insulation structure;
FIG. 10E indicates an embodiment of a method for fabricating and the fabricated iridium electrode where on a substrate of silicon an aluminum pad is deposited; on the pad the conductive adhesive is laid and platinum or iridium foil is attached thereby; a titanium ring is placed, sputtered, plated, ion implanted, ion beam assisted deposited (IBAD) or otherwise attached to the platinum or iridium foil; silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide or other insulator will adhere better to the titanium while it would not adhere as well to the platinum or iridium foil;
FIG. 11A depicts a preferred electrode where it is formed on a silicon substrate and makes use of an aluminum pad, a metal foil such as platinum or iridium, conductive adhesive, a titanium ring, aluminum or zirconium oxide, an aluminum layer, and a mask;
FIG. 11B shows an elongated electrode formed on the structure of FIG. 11 a with platinum electroplated onto the metal foil, the mask removed and insulation applied over the platinum electrode;
FIG. 11C shows a variation of a form of the elongated electrode wherein the electrode is thinner and more recessed from the well sides;
FIG. 11D shows a variation of a form of the elongated electrode wherein the electrode is squatter but recessed from the well sides;
FIG. 11C shows a variation of a form of the elongated electrode wherein the electrode is a mushroom shape with the sides of its tower recessed from the well sides and its mushroom top above the oxide insulating material;
FIG. 11D shows a variation of a form of the elongated electrode wherein the electrode is squatter but recessed from the well sides;
FIG. 11E shows a variation of a form of the elongated electrode wherein the electrode is a mushroom shape with the sides of its tower recessed from the well sides and its mushroom top above the oxide insulating material;
FIG. 12A shows the coil attachment to two different conducting pads at an electrode node;
FIG. 12B shows the coil attachment to two different conducting pads at an electrode node, together with two separate insulated conducting electrical pathways such as wires, each attached at two different electrode node sites on two different substrates;
FIG. 12C shows an arrangement similar to that seen in FIG. 12 / 16 D, with the difference that the different substrates are very close with a non-conducting adhesive between them and an insulator such as aluminum or zirconium oxide forms a connection coating over the two substrates, in part;
FIG. 12C depicts an arrangement similar to that seen in FIG. 12 / 16 D; however, the connecting wires are replaced by an externally placed aluminum conductive trace;
FIG. 12D depicts an arrangement similar to that seen in FIG. 12 / 16 C; however, the connecting wires are replaced by an externally placed aluminum conductive trace;
FIG. 13 shows a hermetically sealed flip-chip in a ceramic or glass case with solder ball connections to hermetically sealed glass frit and metal leads;
FIG. 14 shows a hermetically sealed electronic chip as in FIG. 18 with the addition of biocompatible leads to pads on a remotely located electrode substrate;
FIG. 15 shows discrete capacitors on the electrode-opposite side of an electrode substrate;
FIG. 16A shows an electrode-electronics retinal implant placed with the electrode half implanted beneath the retina, subretinally, while the electronics half projects above the retina, epiretinally;
FIG. 16B shows another form of sub- and epi-retinal implantation wherein half of the electrode implant is epiretinal and half is subretinal;
FIG. 16C shows the electrode parts are lined up by alignment pins or by very small magnets;
FIG. 16D shows the electrode part lined up by template shapes which may snap together to hold the parts in a fixed relationship to each other;
FIG. 17A shows the main screen of the physician's (local) controller (and programmer);
FIG. 17B illustrates the pixel selection of the processing algorithm with the averaging of eight surrounding pixels chosen as one element of the processing;
FIG. 17C represents an electrode scanning sequence, in this case the predefined sequence, A;
FIG. 17D shows electrode parameters, here for electrode B, including current amplitudes and waveform timelines;
FIG. 17E illustrates the screen for choosing the global electrode configuration, monopolar, bipolar, or multipolar;
FIG. 17F renders a screen showing the definition of bipolar pairs (of electrodes);
FIG. 17G shows the definition of the multiple arrangements;
FIG. 18A illustrates the main menu screen for the palm-sized test unit;
FIG. 18B shows a result of pressing on the stimulate bar of the main menu screen, where upon pressing the start button the amplitudes A 1 and A 2 are stimulated for times t 1 , t 2 , t 3 , and t 4 , until the stop button is pressed;
FIG. 18C exhibits a recording screen that shows the retinal recording of the post-stimulus and the electrode impedance;
FIG. 19A shows a first embodiment of the physician's remote controller that has the same functionality inside as the physician's controller but with the addition of communication means such as telemetry or telephone modem;
FIG. 19B show a second embodiment of the physician's remote controller that has the same functionality inside as the physician's controller but with the addition of communication means such as telemetry or telephone modem;
FIG. 19C show a third embodiment of the physician's remote controller that has the same functionality inside as the physician's controller but with the addition of communication means such as telemetry or telephone modem; and
FIG. 20 shows the patient's controller unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is merely made for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
Objective
The objective of the embodiments of the current invention is a retinal color prosthesis to restore color vision, in whole or in part, by electrically stimulating undamaged retinal cells, which remain in patients with, lost or degraded visual function. Embodiments of this retinal color prosthesis invention are directed toward helping patients who have been blinded by degeneration of photoreceptors and other cells; but who have sufficient bipolar cells and the like to permit the perception of color vision by electric stimulation. By color vision, it is meant to include black, gray, and white among the term color.
General Description
Functionally, there are three main parts to an embodiment of this retinal color prosthesis invention. See FIG. 1 a . FIG. 1 a is oriented toward showing the main structural parts and subsystems, with a dotted enclosure to indicate a functional intercommunications aspect. The first part of the embodiment is external ( 1 ) to the eye. The second part is implanted internal ( 2 ) to the eye. The third part is means for communication between those two parts ( 3 ). Structurally there are two parts. One part is external ( 1 ) to the eye and the other part ( 2 ) is implanted within the eye. Each of these structural parts contains two way communication circuitry for communication ( 3 ) between the internal ( 2 ) and external ( 1 ) parts.
The external part of the retinal color prosthesis is carried by the patient. Typically, the external part including imager, video data processing unit, eye-tracker, and transmitter/receiver are worn as an eyeglass-like unit. Typical of this embodiment, a front view of one aspect of the structural external part ( 1 ) of the color retinal prosthesis is shown in FIG. 1 c and a side view is shown in FIG. 1 d , ( 1 ). In addition, there are two other units which may be plugged into the external unit; when this is done they act as part of the external unit. The physician's control unit is not normally plugged into the external part worn by the patient, except when the physician is conducting an examination and adjustment of the retinal color prosthetic. The patient's controller may or may not be normally plugged in. When the patient's controller is plugged in, it can also receive signals from a remote physician's controller which then acts in the same way as the plug-in physician's controller.
Examining further the embodiment of the subsystems of the external part, see FIG. 1 b . These include an external color imager ( 111 ), an eye-motion compensation system ( 112 ), a head-motion compensation system ( 131 ), a processing unit ( 113 ), a patient's controller ( 114 ), a physician's local controller ( 115 ), a physicians hand-held palm-size pocket-size unit ( 130 ), a physician's remote controller ( 117 ), and a telemetry means ( 118 ). The color imager is a color video camera such as a CCD or CMOS video camera. It gathers an image approximating what the eyes would be seeing if they were functional.
An external imager ( 111 ) sends an image in the form of electrical signals to the video data processing unit ( 113 ). The video data processing unit consists of microprocessor CPU's and associated processing chips including high-speed data signal processing (DSP) chips. This unit can format a grid-like or pixel-like pattern that is sent to the electrodes by way of the telemetry communication subsystems ( 118 , 121 ). See FIG. 1 b . In this embodiment of the retinal color prosthesis ( FIG. 1 b , ( 121 )), these electrodes are incorporated in the internal-to-the eye implanted part.
These electrodes, which are part of the internal implant ( 121 ), together with the telemetry circuitry (l 21 ) are inside the eye. With other internally implanted electronic circuitry ( 121 ), they cooperate with the electrodes so as to replicate the incoming pattern, in a useable form, for stimulation of the retina so as to reproduce a facsimile perception of the external scene. The eye-motion ( 112 ) and head-motion ( 131 ) detectors supply information to the video data processing unit ( 113 ) to shift the image presented to the retina ( 120 ).
There are three preferred embodiments for stimulating the retina via the electrodes to convey the perception of color. Color information is acquired by the imaging means ( 111 ). The color data is processed in the video data processing unit ( 113 ).
First Preferred Color Mode
Color information (See FIG. 2 a ), in the first preferred embodiment, is encoded by time sequences of pulses ( 201 ) separated by varying amounts of time ( 202 ), and also with the pulse duration being varied in time ( 203 ). The basis for the color encoding is the individual color code reference ( 211 through 217 ). The electrodes stimulate the target cells so as to create a color image for the patient, corresponding to the original image as seen by the video camera, or other imaging means. Using temporal coding of electrical stimuli placed (cf. FIG. 2 b , 220 , FIG. 2 c , 230 ) on or near the retina ( FIG. 2 b and FIG. 2 c , 221 , 222 ) the perception of color can be created in patients blinded by outer retinal degeneration. By sending different temporal coding schemes to different electrodes, an image composed of more than one color can be produced. FIG. 2 shows one stimulation protocol. Cathodic stimuli ( 202 ) are below the zero plane ( 220 ) and anodic stimuli ( 203 ) are above. All the stimulus rates are either “fast” ( 203 ) or “slow” ( 202 ) except for green ( 214 ), which includes an intermediate stimulus rate ( 204 ). The temporal codes for the other colors are shown as Red ( 211 ), as Magenta ( 212 ), as Cyan ( 213 ), as Yellow ( 215 ), as Blue ( 216 ), as Neutral ( 217 ). This preferred embodiment is directed toward electrodes which are less densely packed in proximity to the retinal cells.
Second Preferred Color Mode
Color information, in a second preferred embodiment, is sent from the video data processing unit to the electrode array, where each electrode has been determined by test to stimulate one of a bipolar type: red-center green-surround, green-center-red-surround, blue-center-yellow-surround, or yellow-center-blue-surround. In this embodiment, electrodes which are small enough to interact with a single cell, or at most, a few cells are placed in the vicinity of individual bipolar cells, which react to a stimulus with nerve pulse rates and nerve pulse structure (i.e., pulse duration and pulse amplitude). Some of the bipolar cells, when electrically, or otherwise, stimulated, will send red-green signals to the brain. Others will send yellow-blue signals. This refers to the operation of the normal retina. In the normal retina, red or green color photoreceptors (cone cells) send nerve pulses to the red-green bipolar cell which then pass some form of this information up to the ganglion cells and then up to the visual cortex of the brain. With small electrodes individual bipolar cells can be excited in a spatial, or planar, pattern. Small electrodes are those with tip from 0.1 μm to 15 μm, and which individual electrodes are spaced apart from a range 8 μm to 24 μm, so as to approximate a one-to-one correspondence with the bipolar cells. The second preferred embodiment is oriented toward a more densely packed set of electrodes.
Third Preferred Color Mode
A third preferred mode is a combination of the first and of the second preferred modes such that a broader area coverage of the color information encoded by time sequences of pulses, of varying widths and separations and with relatively fewer electrodes is combined with a higher density of electrodes, addressing more the individual bipolar cells.
First Order and Higher Effects
Regardless of a particular theory of color vision, the impinging of colored light on the normal cones, and possibly rods, give rise in some fashion to the perception of color, i.e., multi-spectral vision. In the time-pulse coding color method, above, the absence of all, or sufficient, numbers of working cones (and rods) suggests a generalization of the particular time-pulse color encoding method. The generalization is based on the known, or partly known, neuron conduction pathways in the retina. The cone cells, for example, signal to bipolar cells, which in turn signal the ganglion cells. The original spatial-temporal-color (including black, white) scheme for conveying color information as the cone is struck by particular wavelength photons is then transformed to a patterned signal firing of the next cellular level, say the bipolar cells, unless the cones are absent or don't function. Thus, this second level of patterned signal firing is what one wishes to supply to induce the perception of color vision.
The secondary layer of patterned firing may be close to the necessary primary pattern, in which case the secondary pattern (S) may be represented as P*(1+ε). The * indicates matrix multiplication. P is the primary pattern, represented as a matrix
P = ⌈ p 11 p 1 j ⌉ ⌊ p k 1 p k j ⌋
where P represents the light signals of a particular spatial-temporal pattern, e.g., flicker signals for green. The output from the first cell layer, say the cones, is then S, the secondary pattern. This represents the output from the bipolar layer in response to the input from the first (cone) layer. If S=P*(1+ε), where 1 represents a vector and ε represents a small deviation applied to the vector 1 , then S is represented by P to the lowest order, and by P*(1+ε) to the next order. Thus, the response may be seen as a zero order effect and a first order linear effect. Additional terms in the functional relationship are included to completely define the functional relationship. If S is some non-linear function of P, finding S by starting with P requires more terms then the linear case to define the bulk of the functional relationship. However, regardless of the details of one color vision theory or another, on physiological grounds S is some function of P. As in the case of fitting individual patients with lenses for their glasses, variations of parameters are expected in fitting each patient to a particular temporal coding of electrical stimuli.
Scaling Data from Photoreceptors to Bipolar Cells
As cited above, Greenberg (1998), indicates that electrical and photic stimulation of the normal retina operate via similar mechanisms. Thus, even though electrical stimulation of a retina damaged by outer retinal degeneration is different from the electrical stimulation of a normal retina, the temporal relationships are expected to be analogous.
To explain this, it is noted that electrical stimulation of the normal retinal is accomplished by stimulating the photoreceptor cells (including the color cells activated differentially according to the color of light impinging on them). For the outer retinal degeneration, it is precisely these photoreceptor cells which are missing. Therefore, the electrical stimulation in this case proceeds by way of the cells next up the ladder toward the optic nerve, namely, the bipolar cells.
The time constant for stimulating photoreceptor is about 20 milliseconds. Thus the electrical pulse duration would need to be at least 20 milliseconds. The time constant for stimulating bipolar cells is around 9 seconds. These time constants are much longer than for the ganglion cells (about 1 millisecond). The ganglion cells are another layer of retinal cells closer to the optic nerve. The actual details of the behavior of the different cell types of the retina are quite complicated including the different relationships for current threshold versus stimulus duration (cf. Greenberg, 1998). One may, however, summarize an apparent resonant response of the cells based on their time constants corresponding to the actual pulse stimulus duration.
In FIG. 2 , which is extrapolated from external-to-the-eye electrical stimulation data of Young (1977) and from light stimulation data of Festinger, Allyn, and White (1971), there is shown data that would be applicable to the photoreceptor cells. One may scale the data down based on the ratio of the photoreceptor time constant (about 20 milliseconds) to that of the bipolar cells (about 9 milliseconds). Consequently, 50 milliseconds on the time scale in FIG. 2 now corresponds to 25 milliseconds. Advantageously, stimulation rates and duration of pulses, as well as pulse widths may be chosen which apply to the electrode stimulation of the bipolar cells of the retina.
Eye Movement/Head Motion Compensation
In a preferred embodiment, an external imager such as a color CCD or color CMOS video camera ( 111 ) and a video data processing unit ( 113 ), with an external telemetry unit ( 118 ) present data to the internal eye-implant part. Another aspect of the preferred embodiment is a method and apparatus for tracking eye movement ( 112 ) and using that information to shift ( 113 ) the image presented to the retina. Another aspect of the preferred embodiment utilizes a head motion sensor ( 131 ) and a head motion compensation system ( 131 , 113 ). The video data processing unit incorporates the data of the motion of the eye as well as that of the head to further adjust the image electronically so as to account for eye motion and head motion. Thus electronic image compensation, stabilization and adjustment are provided by the eye and head movement compensation subsystems of the external part of the retinal color prosthesis.
Logarithmic Encoding of Light
In one aspect of an embodiment ( FIG. 1 b ), light amplitude is recorded by the external imager ( 111 ). The video data processing unit uses a logarithmic encoding scheme ( 113 ) to convert the incoming light amplitudes into the logarithmic electrical signals of these amplitudes ( 113 ). These electrical signals are then passed on by telemetry ( 118 ), ( 121 ), to the internal implant ( 121 ) which results in the retinal cells ( 120 ) being stimulated via the implanted electrodes ( 121 ), in this embodiment as part of the internal implant ( 121 ). Encoding is done outside the eye, but may be done internal to the eye, with a sufficient internal computational capability.
Energy and Signal Transmission
Coils
The retinal prosthesis system contains a color imager ( FIG. 1 b , 111 ) such as a color CCD or CMOS video camera. The imaging output data is typically processed ( 113 ) into a pixel-based format compatible with the resolution of the implanted system. This processed data ( 113 ) is then associated with corresponding electrodes and amplitude and pulse-width and frequency information is sent by telemetry ( 118 ) into the internal unit coils, ( 311 ), ( 313 ), ( 314 ) (see FIG. 3 a ). Electromagnetic energy, is transferred into and out from an electronic component ( 311 ) located internally in the eye ( 312 ), using two insulated coils, both located under the conjunctiva of the eye with one free end of one coil ( 313 ) joined to one free end of the second coil ( 314 ), the second free end of said one coil joined to the second free end of said second coil. The second coil ( 314 ) is located in proximity to a coil ( 311 ) which is a part of said internally located electronic component, or, directly to said internally located electronic component ( 311 ). The larger coil is positioned near the lens of the eye. The larger coil is fastened in place in its position near the lens of the eye, for example, by suturing. FIG. 3 b represents an embodiment of the telemetry unit temporally located near the eye, including an external temporal coil ( 321 ), an internal (to the eye) coil ( 314 ), an external-to-the-eye electronic chip ( 320 ), dual coil transfer units ( 314 , 323 ), ( 321 , 322 ) and an internal-to-the-eye electrode array ( 325 ). The advantage of locating the external electronics in the fatty tissue behind the eye is that there is a reasonable amount of space there for the electronics and in that position it appears not to interfere with the motion of the eye.
Ultrasonic Sound
In another aspect the information coding is done with ultrasonic sound and in a third aspect information is encoded by modulating light. An ( FIG. 3 c ) ultrasonic transducer ( 341 ) replaces the electromagnetic wave receiving coil on the implant ( 121 ) inside the eye. An ultrasonic transducer ( 342 ) replaces the coil outside the eye for the ultrasonic case. A transponder ( 343 ) under the conjunctiva of the eye may be used to amplify the acoustic signal and energy either direction. By piezoelectric effects, the sound vibration is turned into electrical current, and energy extracted therefrom.
Modulated Light Beam
For the light modulation ( FIG. 3 d ) case, a light emitting diode (LED) or laser diode or other light generator ( 361 ), capable of being modulated, acts as the information transmitter. Information is transferred serially by modulating the light beam, and energy is extracted from the light signal after it is converted to electricity. A photo-detector ( 362 ), such as a photodiode, which turns the modulated light signal into a modulated electrical signal, is used as a receiver. A set of a photo-generator and a photo-detector are on the implant ( 121 ) and a set is also external to the eye
Prototype-Like Device
FIG. 4 shows an example of the internal-to-the-eye and the external-to-the eye parts of the retinal color prosthesis, together with a means for communicating between the two. The video camera ( 401 ) connects to an amplifier ( 402 ) and to a microprocessor ( 403 ) with memory ( 404 ). The microprocessor is connected to a modulator ( 405 ). The modulator is connected to a coil drive circuit ( 406 ). The coil drive circuit is connected to an oscillator ( 407 ) and to the coil ( 408 ). The coil ( 408 ) can receive energy inductively, which can be used to recharge a battery ( 410 ), which then supplies power. The battery may also be recharged from a charger ( 409 ) on a power line source ( 411 ).
The internal-to-the eye implanted part shows a coil ( 551 ), which connects to both a rectifier circuit ( 552 ) and to a demodulator circuit ( 553 ). The demodulator connects to a switch control unit ( 554 ). The rectifier ( 552 ) connects to a plurality of diodes ( 555 ) which rectify the current to direct current for the electrodes ( 556 ); the switch control sets the electrodes as on or off as they set the switches ( 557 ). The coils ( 408 ) and ( 551 ) serve to connect inductively the internal-to-the-eye ( 500 ) subsystem and the external-to-the patient ( 400 ) subsystem by electromagnetic waves. Both power and information can be sent into the internal unit. Information can be sent out to the external unit. Power is extracted from the incoming electromagnetic signal and may be accumulated by capacitors connected to each electrode or by capacitive electrodes themselves.
Simple Electrode Implant
FIG. 6 a illustrates a set of round monopolar electrodes ( 602 ) on a substrate material ( 601 ). FIG. 7 shows the corresponding indifferent electrode ( 702 ) for these monopolar electrodes, on a substrate ( 701 ), which may be the back of ( 601 ). FIG. 6 b shows a bipolar arrangement of electrodes, both looking down onto the plane of the electrodes, positive ( 610 ) and negative ( 611 ), and also looking at the electrodes sideways to that view, positive ( 610 ) and negative ( 611 ), sitting on their substrate ( 614 ). Similarly for FIG. 6 c where a multipole triplet is shown, with two positive electrodes ( 621 ) and one negative electrode, looking down on their substrate plane, and looking sideways to that view, also showing the substrate ( 614 ).
Epiretinal Electrode Array
FIG. 8 a depicts the location of an epiretinal electrode array ( 811 ) located inside the eye ( 812 ) in the vitreous humor ( 813 ) located above the retina ( 814 ), toward the lens capsule ( 815 ) and the aqueous humor ( 816 );
One aspect of the present embodiment, shown in FIG. 8 b , is the internal retinal color prosthetic part, which has electrodes ( 817 ) which may be flat conductors that are recessed in an electrical insulator ( 818 ). One flat conductor material is a biocompatible metallic foil ( 817 ). Platinum foil is a particular type of biocompatible metal foil. The electrical insulator ( 818 ) in one aspect of the embodiment is silicone.
The silicone ( 818 ) is shaped to the internal curvature of the retina ( 814 ). The vitreous humor ( 813 ), the conductive solution naturally present in the eye, becomes the effective electrode since the insulator ( 818 ) confines the field lines in a column until the current reaches the retina ( 814 ). A further advantage of this design is that the retinal tissue ( 814 ) is only in contact with the insulator ( 818 ), such as silicone, which may be more inactive, and thus, more biocompatible than the metal in the electrodes. Advantageously, another aspect of an embodiment of this invention is that adverse products produced by the electrodes ( 817 ) are distant from the retinal tissue ( 814 ) when the electrodes are recessed.
FIG. 8 c shows elongated epiretinal electrodes ( 820 ). The electrically conducting electrodes ( 820 ) says are contained within the electrical insulation material ( 818 ); a silicon chip ( 819 ) acts as a substrate. The electrode insulator device ( 818 ) is shaped so as to contact the retina ( 814 ) in a conformal manner.
Subretinal Electrode Array
FIG. 9 a shows the location of a subretinal electrode array ( 811 ) below the retina ( 814 ), away from the lens capsule ( 815 ) and the aqueous humor ( 816 ). The retina ( 814 ) separates the subretinal electrode array from the vitreous humor ( 813 ). FIG. 9 b illustrates the subretinal electrode array ( 811 ) with pointed elongated electrodes ( 817 ), the insulator ( 818 ), and the silicon chip ( 819 ) substrate. The subretinal electrode array ( 811 ) is in conformal contact with the retina ( 814 ) with the electrodes ( 817 ) elongated to some depth.
Electrodes
Iridium Electrodes
Now FIG. 10 will illuminate structure and manufacture of iridium electrodes ( FIGS. 10 a - e ). FIG. 10 a shows an iridium electrode, which comprises an iridium slug ( 1011 ), an insulator ( 1012 ), and a device substrate ( 1013 ). This embodiment shows the iridium slug electrode flush with the extent of the insulator. FIG. 10 b indicates an embodiment similar to that shown in FIG. 10 a , however, the iridium slug ( 1011 ) is recessed from the insulator ( 1012 ) along its sides, but with its top flush with the insulator. When the iridium electrodes ( 1011 ) are recessed in the insulating material ( 1012 ), they may have the sides exposed so as to increase the effective surface area without increasing geometric area of the face of the electrode. If an electrode ( 1011 ) is not recessed it may be coated with an insulator ( 1012 ), on all sides, except the flat surface of the face ( 1011 ) of the electrode. Such an arrangement can be embedded in an insulator that has an overall profile curvature that follows the curvature of the retina. The overall profile curvature may not be continuous, but may contain recesses, which expose the electrodes.
FIG. 10 c shows an embodiment with the iridium slug as in FIG. 10 b , however, the top of the iridium slug ( 1011 ) is recessed below the level of the insulator; FIG. 10 d indicates an embodiment with the iridium slug ( 1011 ) coming to a point and insulation along its sides ( 1021 ), as well as a being within the overall insulation structure ( 1021 ). FIG. 10 e indicates an embodiment of a method for fabricating the iridium electrodes. On a substrate ( 1013 ) of silicon, an aluminum pad ( 1022 ) is deposited. On the pad the conductive adhesive ( 1023 ) is laid and platinum or iridium foil ( 1024 ) is attached thereby. A titanium ring ( 1025 ) is placed, sputtered, plated, ion implanted, ion beam assisted deposited (IBAD) or otherwise attached to the platinum or iridium foil ( 1024 ). Silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide ( 1012 ) or other insulator can adhere better to the titanium ( 1025 ) while it would not otherwise adhere as well to the platinum or iridium foil ( 1024 ). The depth of the well for the iridium electrodes ranges from 0.1 μM to 1 mm.
Elongated Electrodes
Another aspect of an embodiment of the invention is the elongated electrode, which are designed to stimulate deeper retinal cells, in one embodiment, by penetrating the retina. By getting closer to the target cells for stimulation, the current required for stimulation is lower and the focus of the stimulation is more localized. The lengths chosen are 100 microns through 500 microns, including 300 microns. FIG. 8 c is a rendering of an elongated epiretinal electrode array with the electrodes shown as pointed electrical conductors ( 820 ), embedded in an electrical insulator ( 818 ), where the elongated electrodes ( 817 ) contact the retina in a conformal manner, however, penetrating into the retina ( 814 ).
These elongated electrodes, in an aspect of this of an embodiment of the invention may be of all the same length. In a different aspect of an embodiment, they may be of different lengths. Said electrodes may be of varying lengths ( FIG. 8, 817 ), such that the overall shape of said electrode group conforms to the curvature of the retina ( 814 ). In either of these cases, each may penetrate the retina from an epiretinal position ( FIG. 8 a , 811 ), or, in a different aspect of an embodiment of this invention, each may penetrate the retina from a subretinal position ( FIG. 9 b , 817 ).
One method of making the elongated electrodes is by electroplating with one of an electrode material, such that the electrode, after being started, continuously grows in analogy to a stalagmite or stalactite. The elongated electrodes are 100 to 500 microns in length, the thickness of the retina averaging 200 microns. The electrode material is a substance selected from the group consisting of pyrolytic carbon, titanium nitride, platinum, iridium oxide, and iridium. The insulating material for the electrodes is a substance selected from the group silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide.
Platinum Electrodes
FIG. 11 ( a - e ) demonstrates a preferred structure of, and method of, making, spiked and mushroom platinum electrodes. Examining FIG. 11 a one sees that the support for the flat electrode ( 1103 ) and other components such as electronic circuits (not shown) is the silicon substrate ( 1101 ). An aluminum pad ( 1102 ) is placed where an electrode or other component is to be placed. In order to hermetically seal-off the aluminum and silicon from any contact with biological activity, a metal foil ( 1103 ), such as platinum or iridium, is applied to the aluminum pad ( 1102 ) using conductive adhesive ( 1104 ). Electroplating is not used since a layer formed by electroplating, in the range of the required thinness, has small-scale defects or holes which destroy the hermetic character of the layer. A titanium ring ( 1105 ) is next placed on the platinum or iridium foil ( 1103 ). Normally, this placement is by ion implantation, sputtering or ion beam assisted deposition (IBAD) methods. Silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide ( 1106 ) is placed on the silicon substrate ( 1101 ) and the titanium ring ( 1105 ). In one embodiment, an aluminum layer ( 1107 ) is plated onto exposed parts of the titanium ring ( 1105 ) and onto the silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide ( 1106 ). In this embodiment the aluminum ( 1107 ) layer acts as an electrical conductor. A mask ( 1108 ) is placed over the aluminum layer ( 1107 ).
In forming an elongated, non-flat, electrode ( FIG. 11 b ), platinum is electroplated onto the platinum or iridium foil ( 1103 ). Subsequently, the mask ( 1108 ) is removed and insulation ( 1110 ) is applied over the platinum electrode ( 1109 ).
In FIG. 11 c , a platinum electrode ( 1109 ) is shown which is more internal to the well formed by the silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide and its titanium ring. The electrode ( 1109 ) is also thinner and more elongated and more pointed. FIG. 11 d shows a platinum electrode formed by the same method as was used in FIGS. 11 a , 11 b , and 11 c . The platinum electrode ( 1192 ) is more internal to the well formed by the silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide and its titanium ring as was the electrode ( 1109 ) in FIG. 11 c . However it is less elongated and less pointed.
The platinum electrode is internal to the well formed by the silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide and its titanium ring; said electrode whole angle at it's peak being in the range from 1° to 120°; the base of said conical or pyramidal electrode ranging from 1 micron to 500 micron; the linear section of the well unoccupied by said conical or pyramidal electrode ranging from zero to one-third.
A similar overall construction is depicted in FIG. 11 e . The electrode ( 1193 ), which may be platinum, is termed a mushroom shape. The maximum current density for a given metal is fixed. The mushroom shape presents a relatively larger area than a conical electrode of the same height. The mushroom shape advantageously allows a higher current, for the given limitation on the current density (e.g., milliamperes per square millimeter) for the chosen electrode material, since the mushroom shape provides a larger area.
Inductive Coupling Coils
Information transmitted electromagnetically into or out of the implanted retinal color prosthesis utilizes insulated conducting coils so as to allow for inductive energy and signal coupling. FIG. 12 b shows an insulated conducting coil and insulated conducting electrical pathways, e.g., wires, attached to substrates at what would otherwise be electrode nodes, with flat, recessed metallic, conductive electrodes ( 1201 ). In referring to wire or wires, insulated conducting electrical pathways are included, such as in a “two-dimensional” “on-chip” coil or a “two-dimensional” coil on a polyimide substrate, and the leads to and from these “two-dimensional” coil structures. A silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide ( 1204 ) is shown acting as both an insulator and an hermetic seal. Another aspect of the embodiment is shown in FIG. 12 d . The electrode array unit ( 1201 ) and the electronic circuitry unit ( 1202 ) can be on one substrate, or they may be on separate substrates ( 1202 ) joined by an insulated wire or by a plurality of insulated wires ( 1203 ). Said separate substrate units can be relatively near one another. For example, they might lie against a retinal surface, either epiretinally or subretinally placed. Two substrates units connected by insulated wires may carry more electrodes than if only one substrate with electrodes was employed, or it might be arranged with one substrate carrying the electrodes, the other the electronic circuitry. Another arrangement has the electrode substrate or substrates placed in a position to stimulate the retinal cells, while the electronics are located closer to the lens of the eye to avoid heating the sensitive retinal tissue.
In all of the FIGS. 12 a , 12 b , and 12 c , a coil ( 1205 ) is shown attached by an insulated wire. The coil can be a coil of wire, or it can be a “two dimensional” trace as an “on-chip” component or as a component on polyimide. This coil can provide a stronger electromagnetic coupling to an outside-the-eye source of power and of signals. FIG. 12 c shows an externally placed aluminum (conductive) trace instead of the electrically conducting wire of FIG. 12 d . Also shown is an electrically insulating adhesive ( 1208 ) which prevents electrical contact between the substrates ( 1202 ) carrying active circuitry ( 1209 ).
Hermetic Sealing
Hermetic Coating
All structures, which are subject to corrosive action as a result of being implanted in the eye, or, those structures which are not completely biocompatible and not completely safe to the internal cells and fluids of the eye require hermetic sealing. Hermetic sealing may be accomplished by coating the object to be sealed with silicon carbide, diamond-like coating, silicon nitride and silicon oxide in combination, titanium oxide, tantalum oxide, aluminum nitride, aluminum oxide or zirconium oxide. These materials also provide electrical insulation. The method and apparatus of hermetic sealing by aluminum and zirconium oxide coating is described in a pending U.S. patent application Ser. No. 08/994,515, now U.S. Pat. No. 6,043,437. The methods of coating a substrate material with the hermetic sealant include sputtering, ion implantation, and ion-beam assisted deposition (IBAD).
Hermetic Box
Another aspect of an embodiment of the invention is hermetically sealing the silicon chip ( 1301 ) by placing it in a metal or ceramic box ( 1302 ) of rectangular cross-section with the top and bottom sides initially open ( FIG. 13 ). The box may be of one ( 1302 ) of the metals selected from the group comprising platinum, iridium, palladium, gold, and stainless steel. Solder balls ( 1303 ) are placed on the “flip-chip”, i.e., a silicon-based chip that has the contacts on the bottom of the chip ( 1301 ). Metal feedthroughs ( 1304 ) made from a metal selected from the group consisting of radium, platinum, titanium, iridium, palladium, gold, and stainless steel. The bottom cover ( 1306 ) is formed from one of the ceramics selected from the group consisting of aluminum oxide or zirconium oxide. The inner surface ( 1305 ), toward the solder ball, ( 1303 )) of the feed-through ( 1304 ) is plated with gold or with nickel. The ceramic cover ( 1306 ) is then attached to the box using a braze ( 1307 ) selected from the group consisting of: 50% titanium together with 50% nickel and gold. Electronics are then inserted and the metal top cover (of the same metal selected for the box) is laser welded in place.
Separate Electronics Chip Substrate and Electrode Substrate
In one embodiment of the invention ( FIG. 14 ), the chip substrate ( 1401 ) is hermetically sealed in a case ( 1402 ) or by a coating of the aluminum, zirconium, or magnesium oxide coating. However, the electrodes ( 1403 ) and its substrate ( 1404 ) form a distinct and separate element. Insulated and hermetically sealed wires ( 1405 ) connect the two. The placement of the electrode element may be epiretinal, while the electronic chip element may be relatively distant from the electrode element, as much distant as being in the vicinity of the eye lens. Another embodiment of the invention has the electrode element placed subretinally and the electronic chip element placed toward the rear of the eye, being outside the eye, or, being embedded in the sclera of the eye or in or under the choroid, blood support region for the retina. Another embodiment of the invention has the electronic chip element implanted in the fatty tissue behind the eye and the electrode element placed subretinally or epiretinally.
Capacitive Electrodes
A plurality of capacitive electrodes can be used to stimulate the retina, in place of non-capacitive electrodes. A method of fabricating said capacitive electrode uses a pair of substances selected from the pair group consisting of the pairs iridium and iridium oxide; and, titanium and titanium nitride. The metal electrode acts with the insulating oxide or nitride, which typically forms of its own accord on the surface of the electrode. Together, the conductor and the insulator form an electrode with capacitance.
Mini-capacitors ( FIG. 15 ) can also be used to supply the required isolating capacity. The capacity of the small volume size capacitors ( 1501 ) is 0.47 microfarads. The dimensions of these capacitors are individually 20 mils (length) by 20 mils (width) by 40 mils (height). In one embodiment of the invention, the capacitors are mounted on the surface of a chip substrate ( 1502 ), that surface being opposite to the surface containing the active electronics elements of the chip substrate.
Electrode/Electronics Component Placement
In one embodiment ( FIG. 16 a ), the internal-to-the-eye implanted part consists of two subsystems, the electrode component subretinally positioned and the electronic component epiretinally positioned. The electronics component, with its relatively high heat dissipation, is positioned at a distance, within the eye, from the electrode component placed near the retina that is sensitive to heat.
An alternative embodiment shown in FIG. 16 b is where one of the combined electronic and electrode substrate units is positioned subretinally and the other is located epiretinally and both are held together across the retina so as to efficiently stimulate bipolar and associated cells in the retina.
An alternative embodiment of the invention has the electronic chip element implanted in the fatty tissue behind the eye and the electrode element placed subretinally or epiretinally, and power and signal communication between them by electromagnetic means including radio-frequency (RF), optical, and quasi-static magnetic fields, or by acoustic means including ultrasonic transducers.
FIG. 16 c shows how the two electronic-electrode substrate units are held positioned in a prescribed relationship to each other by small magnets. Alternatively the two electronic-electrode substrate units are held in position by alignment pins. Another aspect of this is to have the two electronic-electrode substrate units held positioned in a prescribed relationship to each other by snap-together mating parts, some exemplary ones being shown in FIG. 16 d.
Neurotrophic Factor
Another aspect of the embodiment is the use of a neurotrophic factor, for example, Nerve Growth Factor, applied to the electrodes, or to the vicinity of the electrodes, to aid in attracting target nerves and other nerves to grow toward the electrodes.
Eye-Motion Compensation System
Another aspect of the embodiment is an eye-motion compensation system comprising an eye-movement tracking apparatus ( FIG. 1 b , 112 ); measurements of eye movement; a transmitter to convey said measurements to video data processor unit that interprets eye movement measurements as angular positions, angular velocities, and angular accelerations; and the processing of eye position, velocity, acceleration data by the video data processing unit for image compensation, stabilization and adjustment.
Ways of eye-tracking ( FIG. 1 b , 112 ) include utilizing the corneal eye reflex, utilizing an apparatus for measurements of electrical activity where one or more coils are located on the eye and one or more coils are outside the eye, utilizing an apparatus where three orthogonal coils placed on the eye and three orthogonal coils placed outside the eye, utilizing an apparatus for tracking movements where electrical recordings from extra-ocular muscles are measured and conveyed to the video data processing unit that interprets such electrical measurements as angular positions, angular velocities, and angular accelerations. The video data processing unit uses these values for eye position, velocity, acceleration to compute image compensation, stabilization and adjustment data which is then applied by the video data processor to the electronic form of the image.
Head Sensor
Another aspect of the embodiment utilizes a head motion sensor ( 131 ). The basic sensor in the head motion sensor unit is an integrating accelerometer. A laser gyroscope can also be used. A third sensor is the combination of an integrating accelerometer and a laser gyroscope. The video data processing unit can incorporate the data of the motion of the eye as well as that of the head to further adjust the image electronically so as to account for eye motion and head motion.
Physician's Local Control Unit
Another aspect includes a retinal prosthesis with (see FIG. 1 b ) a physician's local external control unit ( 115 ) allowing the physician to exert setup control of parameters such as amplitudes, pulse widths, frequencies, and patterns of electrical stimulation. The physician's control unit ( 115 ) is also capable of monitoring information from the implanted unit ( 121 ) such as electrode current, electrode impedance, compliance voltage, and electrical recordings from the retina. The monitoring is done via the internal telemetry unit, electrode and electronics assembly ( 121 ).
An important aspect of setting up the retinal color prosthesis is setting up electrode current amplitudes, pulse widths, and frequencies so they are comfortable for the patient. FIGS. 17 a - c and FIGS. 18 a - c illustrate some of the typical displays. A computer-controlled stimulating test that incorporates patient response to arrive at optimal patient settings may be compared to being fitted for eyeglasses, first determining diopter, then cylindrical astigmatic correction, and so forth for each patient. The computer uses interpolation and extrapolation routines. Curve or surface or volume fitting of data may be used. For each pixel, the intensity in increased until a threshold is reached and the patient can detect something in his visual field. The intensity is further increased until the maximum comfortable brightness is reached. The patient determines his subjective impression of one-quarter maximum brightness, one-half maximum brightness, and three-quarters maximum brightness. Using the semi-automated processing of the patient-in-the-loop with the computer, the test program runs through the sequences and permutations of parameters and remembers the patient responses. In this way apparent brightness response curves are calibrated for each electrode for amplitude. Additionally, in the same way as for amplitude, pulse width and pulse rate (frequency), response curves are calibrated for each patient. The clinician can then determine what the best settings are for the patient.
This method is generally applicable to many, if not all, types of electrode based retinal prostheses. Moreover, it also is applicable to the type of retinal prosthesis, which uses an external light intensifier shining upon essentially a spatially distributed set of light sensitive diodes with a light activated electrode. In this latter case, a physician's test, setup and control unit is applied to the light intensifier which scans the implanted photodiode array, element by element, where the patient can give feedback and so adjust the light intensifier parameters.
Remote Physician's Unit
Another aspect of an embodiment of this invention includes (see FIG. 1 b ) a remote physician control unit ( 117 ) that can communicate with a patient's unit ( 114 ) over the public switched telephone network or other telephony means. This telephone-based pair of units is capable of performing all of the functions of the of the physician's local control unit ( 115 ).
Physician's Unit Measurements, Menus and Displays
Both the physician's local ( 115 ) and the physician's remote ( 117 ) units always measure brightness, amplitudes, pulse widths, frequencies, patterns of stimulation, shape of log amplification curve, electrode current, electrode impedance, compliance voltage and electrical recordings from the retina.
FIG. 17 a shows the main screen of the Physician's Local and Remote Controller and Programmer. FIG. 17 b illustrates the pixel selection of the processing algorithm with the averaging of eight surrounding pixels chosen as one element of the processing. FIG. 17 c represents an electrode scanning sequence, in this case the predefined sequence, A. FIG. 17 d shows electrode parameters, here for electrode B, including current amplitudes and waveform timelines. FIG. 17 e illustrates the screen for choosing the global electrode configuration, monopolar, bipolar, or multipolar. FIG. 17 f renders a screen showing the definition of bipolar pairs (of electrodes). FIG. 17 g shows the definition of the multipole arrangements.
FIG. 18 a illustrates the main menu screen for the palm-sized test unit. FIG. 18 b shows a result of pressing on the stimulate bar of the (palm-sized unit) main menu screen, where upon pressing the start button the amplitudes A 1 and A 2 are stimulated for times t 1 , t 2 , t 3 , and t 4 , until the stop button is pressed. FIG. 18 c exhibits a recording screen that shows the retinal recording of the post-stimulus and the electrode impedance.
FIGS. 19 a , 19 b , and 19 c show different embodiments of the Physician's Remote Controller, which has the same functionality inside as the Physician's Local Controller but with the addition of communication means such as telemetry or telephone modem.
Patient's Controller
Corresponding to the Physician's Local Controller, but with much less capability, is the Patient's Controller. FIG. 20 shows the patient's local controller unit. This unit can monitor and adjust brightness ( 2001 ), contrast ( 2002 ) and magnification ( 2003 ) of the image on a non-continuous basis. The magnification control ( 2003 ) adjusts magnification both by optical zoom lens control of the lens for the imaging means ( FIG. 1, 111 ), and by electronic adjustment of the image in the data processor ( FIG. 2, 113 ).
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | The present invention is a visual prosthesis for the restoration of sight in patients with lost or degraded visual function. The visual prosthesis includes an implantable portion which stimulates visual neural tissue according to stimulation patterns sent by a programmable video processing unit. The video processing unit controls stimulation patterns including programmable wave forms to provide monopolar, bipolar, and multipolar wave forms. | 7 |
This application claims benefit of Ser. No. 60/198,203 filed on Apr. 19, 2000.
BACKGROUND OF THE INVENTION
1. Field
The invention relates to the use of dimethyl carbonate (“DMC”) for the N-methylation of indole compounds.
2. Description
The compound 3-(1-methylindol-3-yl)4-(1-methyl-6-nitroindol-3-yl)-1 H-pyrrole-2,5-dione is a selective inhibitor of protein kinase C (“PKC”) and is useful as an antimitotic agent for oral treatment of solid tumors as well as treating autoimmune diseases such as rheumatoid arthritis. This compound is described in U.S. Pat. No. 5,057,614, the contents of which are herein incorporated by reference. A synthetic route for preparing this compound uses methyl iodide as a methylating agent (see for example, U.S. application Ser. No. 09/268,887, the contents of which are herein incorporated by reference, which shows the use of methyl iodide for the N-methylation of an indole to synthesize similar compounds). Unfortunately, methyl iodide is highly toxic and has a low boiling point. The release of methyl iodide into the air is highly restricted. Accordingly, there exists a need for environmentally friendly methods for methylating indole compounds.
The following scheme shows a method for preparing 3-(1-methyl-3-indolyl)4-(1-methyl-6-nitro-3-indolyi)-1 H-pyrrole-2,5-dione.
Common methylating agents, such as methyl halides (MeX; X═CI, Br, I) and dimethylsulfate (“DMS”, can be used to methylate O—, C— and N— under mild reaction conditions. However, as described above for methyl iodide, these agents pose severe concerns from environmental and process safety standpoints. On the other hand, dimethyl carbonate is a comparatively safe, non toxic and environmentally friendly methylating agent. The by-products of its use, methanol and carbon dioxide, are not associated with disposal problems. Moreover, for the manufacture of antimitotic agents of the above class, which require two indole ring methylations, the need is double. Although it has been reported (Tondo, P., Selva, M., and Bomben, A., Org, Synth . 1998, 76, 169) that DMC can be used to methylate the alpha position of an arylacetonitrile, nowhere has it been suggested to use DMC for methylating indole ring containing compounds, much less the N-methylation of indole rings.
Unfortunately, the use of DMC in prior art processes typically requires high reaction temperatures (>180° C.), a stainless steel autoclave, high pressure, and a large excess of dimethyl carbonate (as solvent and methylating agent). With the help of catalysts, lower reaction temperatures (100° C.) can be used. However, such catalysts (e.g. crown ether) are generally very toxic and pressurized reaction chambers are required.
The inventive use of dimethyl carbonate for N-methylation of an indole ring forms a part of the subject invention and was disclosed in U.S. Provisional Patent Application No. 60/171,557, filed Dec. 22, 1999, which is not publicly available. Although disclosed in this provisional application, the subject invention was not invented by the inventors named in the mentioned provisional patent application and forms no part of the invention claimed in that application.
Therefore, the subject invention fulfills a need in the art for a green process for methylating the nitrogen atom in an indole compound under conditions that do not require high pressure or temperature.
SUMMARY OF THE INVENTION
The subject invention provides a process for manufacturing a methylated indole compounds of the formula:
where R 1 is selected from the group consisting of halogen, C1-C6 alkyl, C 1 -C 6 alkenyl, —OCH 3 , —NO 2 , —CHO, —CO 2 CH 3 , and —CN, and R 2 is selected from the group consisting of C 1 -C 6 alkyl, —CO 2 CH 3 , —CN, —CHO, —NH 2 , —N(C 1 -C 6 alkyl) 2 , —(CH 2 ) n COOH, and —(CH 2 ) n CN, where n is an integer from 1 to 4, inclusive. The process comprises reacting a compound of the formula:
wherein R 1 and R 2 are as above, with dimethyl carbonate in the presence of a suitable base or catalyst at ambient pressure.
Typically, the reacting is at a temperature between about 120° C. and about 134° C., more preferrably between about 126° C. and about 130° C.
It is preferred that the reacting is in the presence of a solvent, such as N,N-dimethylformamide and 1-methyl-2-pyrrolidinone, the most preferred solvent being N,N-dimethylformamide.
Favorably, the reacting is in the presence of a phase transfer catalyst, such as tetrabutylammonium bromide or 18-crown-6, the most favorable catalyst being tetrabutylammonium bromide.
The process can involve reacting is in the presence of a base, such as potassium hydroxide, sodium hydroxide, and potassium carbonate, the most favorable base being potassium carbonate.
Of course the reacting can in the presence of both a base and a catalyst. For example, it is favored where the base is selected from the group consisting of potassium hydroxide, sodium hydroxide, and potassium carbonate, and the catalyst is a phase transfer catalyst. Favored bases are selected from the group consisting of potassium hydroxide, sodium hydroxide, and potassium carbonate, and favored catalysts are selected from the group consisting of tetrabutylammonium bromide and 18-crown-6.
The reaction time can vary but is readily determined by the skilled artisan. Favorable reations times are between 0.75 hour and 36 hours, preferrably between 1 hour and 26 hours, and most preferrably between 1 hour and 10 hours.
Favored compounds include those where R 1 is at position 6 and R 2 is hydrogen (R 1 is favorably nitro) and those where R 1 is hydrogen and R 2 is acetonitrile.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described in terms of its preferred embodiments. These embodiments are set forth to aid in understanding the invention but are not to be construed as limiting.
The subject N-methylation process typically requires only 2.2 equivalents of dimethyl carbonate, reasonable temperature, and ambient pressure. The term “ambient pressure” is used herein to reflect normal atmospheric pressure. The exemplified processes below generally needs only catalytic amounts of tetrabutylammonium bromide (“TBAB”) or 18-crown-6 without the use of a base. Altematively, or additionally, a base such as potassium hydroxide, sodium hydroxide, or potassium carbonate can by utilized. Both potassium carbonate and TBAB are easily eliminated from the product by the following an isolation procedure that involves the addition of water. Catalytic amounts of TBAB or 18-crown-6, as well as appropriate amounts of base, for example potassium hydroxide, sodium hydroxide or potassium carbonate, are readily determinable by the skilled artisan. Generally, these amounts will be for TBAB in the range of about five percent (5%) by weight to about eighty percent (80%) by weight of catalyst to substrate. A preferred range is from about twenty percent (20%) by weight to about forty percent (40%) by weight of catalyst to substrate, with the range of from about twenty percent (20%) by weight to about thirty percent (30%) by weight of catalyst to substrate being most preferred. For 18-crown-6, the amounts will generally be in the range of about five percent (5%) by weight to about ten percent (10%) by weight of catalyst to substrate. Preferably, the 18-crown-6 is present at about five percent (5%) by weight of catalyst to substrate.
The subject process can proceed by mixing an indole substrate with dimethyl carbonate in the presence of a base or a catalyst in a suitable solvent, such as N,N-dimethylformamide (“DMF”) or 1-methyl-2-pyrrolidinone (“NMP”), followed by heating the reaction mixture to reflux for a short time (normally 2 to 3 hours). The choice of reaction temperature is readily determinable by the skilled artisan. The reaction temperature will normally be above the boiling point of the reagent, around 90° C. for DMC. The reaction can be quenched by adding water, after which the product can be obtained either by filtration or by extraction with a suitable solvent. The subject process typically results in the desired product in good yield with high quality. For example, when 6-nitroindole was used to conduct the reaction, 96% of 1-methyl-6-nitroindole was obtained in 99.5% (by weight) purity. Only 0.3% of one impurity was detected.
The process described below is a general procedure. If the product is not solid, filtration is not necessary, instead, the desired product can be extracted from the aqueous mixture by using a suitable solvent, for example, tert-butyl methyl ether, or ethyl acetate.
The effect of various substituents on the methylation of an indole system using DMC was investigated. Table 1 records the effects of several electron-withdrawing functional groups on the N-methylation reaction. There was not much difference found in terms of either reason time or the yields obtained of N-methylated indoles when the functional groups are present on the phenyl ring or the pyrrole ring of the indole system. All substrates tested with this method afforded high yields (>95%), except in the case of indole-3-carboxaldehyde where the corresponding N-methylated indole was obtained in 85% yield.
TABLE 1
Effect of Electron Withdrawing Substituents of the
N-Methylation of Indoles
Desired product
R
reaction time (h)
yield (%)
3-CN
3.5
97
4-NO 2
2
96
5-NO 2
3
97
6-NO 2
2
97
5-Br
3.5
95
6-Cl
3.5
96
3-CHO
3.5
85
3-CO 2 CH 3
3.5
96
The R group can be at any position of the indole system except position 1. The reaction between indole-3-carboxylic acids and dimethyl carbonate was also investigated. The selectivity between O-methylation and N-methylation was not as high as would be expected. However, as expected, under the reaction conditions, esterfication of a carboxyl group was somewhat faster than N-methylation. For example, the reaction of indole-3-propionic acid with dimethyl carbonate in the presence of potassium carbonate in OMF afforded both an O,N-dimethylated substance in 65% yield after 4 hours at refluxing temperature, together with 30% of the O-methylated product. After the reaction mixture was heated to reflux for another 4 hours, only O,N-dimethylated product was obtained in 93% isolated yield. As demonstrated in Table 2, similar results were observed with indole-3-acetic acid. But when indole-3-carboxylic acid was subjected to the typical reaction conditions, along with 50% of the dimethylated product obtained, 45% of N-methylindole was isolated, formed as a result of decarboxylation of indole-3-carboxylic acid at the reaction temperature (128° C.).
TABLE 2
Differences in the Rates of N- and O-Methylation of
Indolecarboxylic Acids with Dimethyl Carbonate.
Reaction
n
time (h)
Product yield (%)
0
5
R = R 1 = Me (50)
N-Methylindole (45)
1
6
R = R 1 = Me (89)
R =Me, R 1 =H (8)
8
R =R 1 =Me: 95
2
4
R =R 1 =Me(65)
R = Me, R 1 = H (30)
8
R = R 1 = Me (93)
As above, the substituent could be attached at any position of the indole nucleus except at position 1.
With dimethyl carbonate as a methylating agent, the N-methylation of indole system containing electron-donating groups was also studied. For an example, N-methylation of 5-methoxyindole with dimethyl carbonate at reflux temperature for 5 hours gave 1-methyl-5-methoxyindole in 97% isolated yield. However, other indole substrates, such as gramine, indole-3-methanol, indole3-ethanol and tryptamine gave a complex mixture of unidentified products. These results indicated that N-methylation with dimethyl carbonate is not applicable to such indole systems.
To further illustrate the utility of this method, indole-3-acetonitrile was used as a substrate to examine the selectivity between methylation of an indole nitrogen and C-methylation of an activated methylene group present in the molecule. As can be seen in Table 3 however, dimethyl carbonate can be used to preferentially N-methylate indole-3-acetonitriles with only a small amount of concurrent C-methylation by varying the reaction conditions. In the presence of potassium carbonate, indole-3-acetonitrile gave, along with 89% of the expected product 1-methylindol-3-acetonitrnle, the C,N-dimethylated by-product, rac.-2-(1-methylindol-3-yl)propionitrile in 8% yield. With the assistance of a phase transfer catalyst (“PTC”), such as 18-crown-6 or tetrabutylammonium bromide, the formation of the dimethylated by-product was suppressed to about 3%. Under the latter reaction conditions, about 90% of the desired product, 1-methylindole-3-acetonitrile was isolated.
TABLE 3
Selectivity between N- and C-methylation of Indole-3-Acetonitrile
Composition of
crude reaction product
Isolated
(anal. HPLC)
yield
base
catalyst
I
II
I + II
K 2 CO 3
89%
8%
89%
K 2 CO 3
n-Bu 4 NBr
86.6%
9.7%
90.5%
n-Bu 4 NBr
93.8%
2.9%
91.5%
KOH
n-Bu 4 NBr
94.4%
3.1%
80%
NaOH
18-
91%
3%
78%
crown-6
EXAMPLES
The experiments in the following examples have actually been performed.
Example 1
Preparation of 1-methylindole-3-acetonitrile
A 500 mL, three-necked flask equipped with a thermocouple, condenser, and addition funnel was charged with indole-3-acetonitrile (10.0 g, 0.064 mol), potassium carbonate (5.0 g, 36 mmol), N,N-dimethylformamide (60 mL) and dimethyl carbonate (11.0 mL, 0.13 mol). The resulting mixture was heated to 124±1° C. The progress of the reaction was monitored by HPLC. After 10 h at this temperature, the presence of the starting indole could not be detected. The reaction mixture was then cooled to zero to −5° C. Water (140 mL) was added which resulted in the formation of a precipitate. The mixture was stirred at −5° C. for 1 hour, then the solid was collected by filtration, washed with water (150 mL), and dried under high vacuum at 45° C. for 24 h to give 1-methylindole-3-acetonitrile (I and II, 9.69 g, 89%) as a brown solid.
Example 2
Synthesis of 1-methylindole-3-acetonitrile and rac.-2-(1-methylindol-3-yl)propionitrile.
A mixture of indole-3-acetonitrile (5.0 g, 32.01 mmol), potassium carbonate (powder, 2.5 g), dimethyl carbonate (10 mL, 118.8 mmol), N,N-dimethylformamide (40 mL) and tetrabutylammonium bromide 0.5 g were mixed together and heated to 126° C. for 6 h. Then a second portion of dimethyl carbonate (3 mL, 35.6 mmol) was added and mixture was refluxed for another 17 h. Starting material was still present, so an third portion of dimethyl carbonate (3 mL, 35.6 mmol ) was added and the reaction mixture was refluxed for another 3 h. Analysis of the reaction mixture at this point showed it to be mainly a mixture of two compounds, 1-methylindole-3-acetonitrile (86.6%) along with a second minor component identified as rac.-2-(1-methylindol-3-yl)propionitrile (9.7%). Starting indole could not be detected. The reaction mixture was cooled to room temperature, then was diluted with water (80 mL) and extracted with tert-butyl methyl ether (100 mL) The separated organic layer was washed twice with water (100 mL) then the solution was concentrated under vacuum to ˜20 mL. The concentrate was cooled in an ice-bath as heptane (100 mL) was added drop-wise with vigorous stirring. The mixture was cooled to −15° C. and the resulting solid was filtered off, washed with heptane (50 mL) and dried under vacuum at 25° C. to give 1-methylindole-3-acetonitrile (1) and rac.-2-(1-methylindol-3-yl)propionitrile (II).
Example 3
Preparation of 1-methylindole-3-acetonitrile.
A 1 L, three-necked flask equipped with a thermocouple, condenser, and addition funnel was charged with indole-3-acetonitrile (58.0 g, 90% pure=0.334 mol), tetrabutylammonium bromide (11.6 g, 36 mmol), N,N-dimethylformamide (348 mL) and dimethyl carbonate (92.8 mL, 1.10 mol) and the resulting mixture was heated to 126±1° C. The progress of the reaction was monitored by HPLC and after 3 h at this temperature, the presence of remaining starting indole could not be detected. After the reaction mixture was then cooled to zero to −5° C., water (696 mL) was added which resulted in the formation of a precipitate. The mixture was stirred at −5° C. for 1 hour, then the solid was collected by filtration, washed with water (150 mL) and dried under high vacuum at 45° C. for 24 h to give 1-methylindole-3-acetonitrile (52.0 g, 91.5%) as a brown solid.
Example 4
Synthesis of 1-methylindole-3-acetonitrile and rac.-2-(l -methylindol-3-yl)propionitrile.
A mixture of indole-3-acetonitrile (4.0 g, 25.6 mmol), potassium hydroxide (pallet, 2.5 g), dimethyl carbonate (8 mL, 94.9 mmol), N,N-dimethylformamide (50 mL) and tetrabutylammonium bromide 0.5 g were mixed together and heated to 128° C. for 10 h. Analysis of the reaction mixture at this point showed it to be mainly a mixture of two compounds, 1-methylindole-3-acetonitrile (94.4%) along with a second minor component identified as rac.-2-(1-methylindol-3-yl)propionitrile (3.1%). Starting indole could not be detected. The reaction mixture was cooled to room temperature, then was diluted with water (120 mL). The mixture was cooled to −15° C., and the precipitate was formed. The mixture was stirred at this temperature for 1 h. The resulting solid was filtered off, washed with heptane (50 mL) and dried under vacuum at 25° C. to give 3.60 g of 1-methylindole−3-acetonitrile(l) and C,N-dimethylated by-product (II).
Example 5
Synthesis of 1-methylindole-3-acetonitrile and rac.-2-(l-methylindol−3-yl)propionitrile.
A 250 mL, three-necked flask was charged with indole-3-acetonitrile (5.0 g, 32.0 mmol), sodium hydroxide (pallet, 2.5 g), dimethyl carbonate (6.6. mL, 78.3 mmol), N,N-dimethylformamide (40 mL), and 25 mg of 18-crown-6. The resulting mixture was heated to 127 ° C. for 10 h. Analysis of the reaction mixture at this point showed it to be mainly a mixture of two compounds, 1-methylindole-3-acetonitrile (90.8%) along with a second minor component identified as rac.-2-(1-methylindol-3-yl)propionitrile (3.0%). No starting indole was detected. The reaction mixture was cooled to room temperature, then was diluted with water (100 mL). The mixture was cooled to −15° C., and a precipitate formed. The mixture was stirred at this temperature for 1 h. The resulting solid was filtered off, washed with heptane (50 mL), and dried under vacuum at 25° C. to give 4.3 g of 1-methylindole-3-acetonitrile(l) and C,N-dimethylated by-product (II).
Example 6
Preparation of 1-methylindole-3-carbonitrile.
A mixture of indole-3-carbonitrile (1.0 g, 7.03 mmole), potassium carbonate (0.5 g), N,N-dimethytformamide (10 mL) and dimethyl carbonate (1.8 mL, 21.4 mmol) was stirred and heated to reflux (˜130° C.). The reaction (monitored by HPLC) was complete within 3.5 h. The reaction mixture was then cooled to 3° C. and ice cold water (25 mL) was added slowly. The resulting oily suspension was extracted with tert-butyl methyl ether (40 mL) and the organic phase was washed with water (3×25 mL), dried and evaporated in vacuo to obtain 1.07 g of the product, 1-methylindole-3-carbonitrile, as a dark oil (97.4% yield).
Example 7
Preparation of 5-bromo-1-methylindole.
5-Bromoindole (3.0 g, 15.38 mmol), potassium carbonate (1.5 g), N,N-dimethylformamide (20 mL) and dimethyl carbonate (3.9 mL, 46 mmol) were stirred and heated to reflux (˜130° C.) for 3.5 h. The reaction was monitored by HPLC. The mixture was then cooled to ˜3° C., and the slow addition of ice cold water (50 mL) resulted in the separation of the product as a light brown oil. The mixture was extracted with tert-butyl methyl ether (40 mL) and the organic layer was washed with water (3×25 mL). The solvent was evaporated under reduced pressure to furnish 3.06 g of 5-bromo-1-methylindole as a light brown oil (94.8% yield).
Example 8
Preparation of 6-chloro-1-methylindole.
6-Chloroindole (1.0 g, 6.59 mmol), potassium carbonate (0.5 g), N,N-dimethylformamide (10 mL) and dimethyl carbonate (1.7 mL, 20.21 mmol) were stirred and heated to reflux (˜130° C.). The starting indole was consumed within 3.5 h (as determined by HPLC). After the mixture was then cooled to ˜3° C., ice cold water (50 mL) was added and the resulting oily suspension was extracted with tert-butyl methyl ether (40 mL). The separated organic layer was washed with water (3×25 mL), then was evaporated under vacuum to furnish 5-chloro-1-methylindole as a light yellow oil (1.05 g, 96.1% yield).
Example 9
Preparation of 1-methylindole-3-carboxaldehyde.
A mixture of indole-3-carboxaldehyde (3 g, 20.67 mmol), potassium carbonate (1.5 g), N,N-dimethylformamide (20 mL) and dimethyl carbonate (5.2 mL, 61 mmol) were stirred and heated to reflux (˜130° C.). At various time intervals, the progress of the reaction was monitored by HPLC and it was shown to be complete within 3.5 h. The reaction mixture was cooled down to ˜3° C. and ice cold water (60 mL) was slowly added. The resulting dark oily suspension was extracted with tert-butyl methyl ether (60 mL) and the organic layer was washed with water (2×50 mL). The organic extract was evaporated under reduced pressure to provide 1-methylindole−3-carboxalehyde as a dark brown oil (1.98 g, 85% yield).
Example 10
Preparation of 1-methylindole-3-carboxylic acid methyl ester.
Indole-3-carboxylic acid methyl ester (5.0 g, 28.54 mmol), potassium carbonate (2.5 g), N,N-dimethylformamide (35 mL) and dimethyl carbonate (7.2 mL, 85 mmol) were combined and the stirred mixture was heated to reflux (˜130° C.). Within 3.5 h, the reaction had gone to completion as determined by HPLC analysis. After the reaction mixture was cooled to ˜3° C., ice cold water (100 mL) was slowly added. The resulting slightly off-white solid was recovered by filtration and was washed with water (2×50 mL). The solid was not purified further, but was dried in vacuo at 45° C. for 24 h to provide 5.2 g of 1-methylindole-3-carboxylic acid methyl ester (96.3% yield).
Example 11
Preparation of 5-methoxy-1-methylindole.
A mixture of 5-methoxyindole (1 g, 6.79 mmol), potassium carbonate (0.5 g), N,N-dimethylformamide (10 mL) and dimethyl carbonate (1.7 mL, 20 mmol) was stirred and heated to reflux (˜130° C.). The progress of the reaction was monitored by HPLC. Within 5 h, the starting indole had been consumed and after the mixture was cooled to ˜3° C., it was treated with ice cold water (30 mL). The formed precipitate was filtered off, then was washed in turn with water (2×30 mL) and hexanes (30 mL). The colorless product was dried under vacuum at 25° C. for 48 h to afford 5-methoxy-1-methylindole (1.067 g, 97.4% yield).
Example 12
Preparation of 1-methylindole.
Indole (10 g, 85.4 mmole), potassium carbonate (5 g), N,N-dimethylformamide (70 mL) and dimethyl carbonate (11 mL, 0.13 mol) were mixed together and refluxed (˜130° C.) for 2 h. At this point TLC analysis of the reaction showed two compounds, the N-methylated indole along with a significant amount of starting material. The reaction mixture was cooled down to ˜50° C. and a second portion of dimethyl carbonate (5.5 mL, 0.065 mol) was added. The mixture was heated at reflux for another 7 h until TLC analysis indicated total consumption of starting indole. The reaction mixture was cooled down to room temperature and it was slowly diluted with water (150 mL). The resulting mixture was extracted with tert-butyl methyl ether (150 mL) and the separated organic layer was washed with water (2×100 mL). The solvent was evaporated in vacuao to furnish 10.8 g of 1-methylindole as light yellow oil (96.5% yield).
Example 13
Preparation of 1-methylindoline.
Indoline (3 g, 0.025 mol), potassium carbonate (1.59), N,N-dimethylformamide (20 mL) and dimethyl carbonate (6.4 mL ,0.076 mol) were mixed together and heated to reflux (around 130 ° C.) for 14 h. The reaction, monitored by HPLC, went to completion within 14 h. The reaction mixture was cooled down to room temperature, then was slowly diluted with water (50 mL) and extracted with tert-butyl methyl ether (60 mL ). The organic extract was washed with water (3×50 mL) and the solution was evaporated to constant weight under reduced pressure to furnish 3.13 g of the product, N-methylindoline as a light yellow oil (95% yield).
Example 14
Synthesis of 1-methyl-5-nitroindole.
A 500 mL, three-necked flask equipped with a thermocouple, condenser, and addition funnel was charged with 5-nitroindole (20.0 g, 12.3 mmol), potassium carbonate (4.0 g, 29 mmol), N,N-dimethylformamide (80 mL) and dimethyl carbonate (22 mL, 26.14 mmol). The resulting mixture was heated to reflux. The reaction was monitored by HPLC or TLC (solvent system: 30% ethyl acetate in heptane). An analysis of the reaction mixture after 3 h at reflux, by the above methods, failed to detect any remaining 5-nitroindole. The reaction mixture was then cooled to 10±5° C. and diluted with water (160 mL) which resulted in the formation of a yellow precipitate. After the mixture was stirred at room temperature for 2 h, the solid was collected by filtration, then was washed with water (100 mL) and dried under high vacuum at 60-65° C. for 24 h to give 1-methyl-4-nitroindole (21.1 g, 97.1%) as a yellow solid.
Example 15
Synthesis of 1-methyl-4-nitroindole.
1-methyl-4-nitroindole was prepared from 4-nitroindole in 96% yield using the same experimental conditions and isolation procedure described in Example 11 for the preparation of the isomeric 1-methyl-4-nitroindole.
Example 16
Preparation of 1-methylindole-3-carboxylic acid methyl ester and 1-methylindole.
To a three-necked round bottom flask was charged 3-indolecarboxylic acid (2.5 g, 15.51 mmol), potassium carbonate (powder, 1.25 g), N,N-dimethylformamide (20 mL) and dimethyl carbonate (3.9 mL, 46.3 mmol). As the stirred mixture was heated to reflux (130° C.), the disappearance of starting indole was monitored by HPLC. After 5 h the reaction was complete, then the mixture was cooled to room temperature and was partitioned between water (50 mL) and tert-butyl methyl ether (100 mL). The separated organic layer was washed with water (2×50 mL) and the volatiles were evaporated under reduced pressure. Purification of the obtained crude by using column chromatography over silica gel furnished 1-methylindole-3-carboxylic acid methyl ester (50% yield) and the decarboxylated byproduct 1-methylindole (45% yield).
Example 17
Preparation of 1-methylindole-3acetic acid methyl ester and 1-indole-3-acetic acid methyl ester.
To a three-necked round bottom flask was charged indole-3-acetic acid (3.0 g, 17.12 mmol), potassium carbonate (powder, 1.5 g), N,N-dimethylformamide (20 mL) and dimethyl carbonate (4.3 mL, 51.07 mmol). The resulting mixture was heated to reflux (˜130° C.) for 6 h at which time analysis of the reaction by HPLC indicated the starting material had been consumed. After the reaction mixture was cooled to room temperature, it was partitioned between water (50 mL) and tert-butyl methyl ether (60 mL). The separated organic layer was washed with water (2×50 mL) and the solvent was evaporated under reduced pressure. The crude product, shown by HPLC analysis to contain 1-methylindole-3-acetic acid methyl ester (89%) and 1-indole-3-acetic acid methyl ester (8%), was separated into the individual components by using column chromatography over silica gel. Total yield 3.2 g, 2.8 g for 1-methylindole-3-acetic acid methyl ester and 0.40 g for 1-indole-3-acetic acid methyl ester.
Example 18
Preparation of 1-methylindole-3-propionic acid methyl ester and 1-indole-3-propionic acid methyl ester.
A stirred mixture of indole-3-propionic acid (1.0 g, 5.28 mmol), potassium carbonate (powder, 0.25 g), N,N-dimethylformamide (10 mL) and dimethyl carbonate (1.33 mL, 15.7 mmol) was heated to reflux (˜130° C.). After the reaction had been stirred for 5 h at reflux, no detectable levels of starting material remained, as determined by HPLC analysis. The reaction mixture was cooled to room temperature, then was diluted with water (25 mL ) and extracted with tert-butyl methyl ether (40 mL). The organic layer was washed with water (2×50 mL) and the solution was concentrated under reduced pressure. The crude product, shown by HPLC analysis to contain 1-methylindole-3-propionic acid methyl ester (65%) and 1-indole-3-propionic acid methyl ester (30%), was separated into the individual products by using column chromatography over silica gel. Total yield 1.01 g, 0.66 g for 1-methylindole-3-propionic acid methyl ester. 0.35 g for 1-indole-3-propionic acid methyl ester.
Example 19
Preparation of 1-methyl-6-nitroindole.
A 1L, three-necked flask equipped with a thermocouple, condenser, and addition funnel was charged with 6-nitroindole (60.0 g, 0.37 mol), potassium carbonate (12.0 g, 87 mmol), N,N-dimethylformamide (240 mL) and dimethyl carbonate (66 mL, 0.784 mol) and the resulting stirred mixture was heated to 126±3° C. The progress of the reaction was monitored by HPLC or TLC (solvent system: 30% ethyl acetate in heptane). After 1 h at this temperature, residual 6-nitroindole could not be detected. Then, the reaction mixture was cooled to 10±5° C. and slowly diluted with water (480 mL). As the water was added, a yellow precipitate formed. The resulting mixture was stirred at room temperature for 2 h, then the solid was recovered by filtration, washed with water (250 mL) and dried under high vacuum at 60-65° C. for 24 h to give 62.6 g of 1-methyl6-nitroindole (96.1% yield) as a yellow solid. | A process for manufacturing a methylated indole compounds of the formula:
where R 1 is selected from the group consisting of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkenyl, —OCH 3 , —NO 2 , —CHO, —CO 2 CH 3 , and —CN, and R 2 is selected from the group consisting of C 1 -C 6 alkyl, —CO 2 CH 3 , —CN, —CHO, —NH 2 , —N(C 1 -C 6 alkyl) 2 , —(CH 2 ) n COOH, and —(CH 2 ) n CN, where n is an integer from 1 to 4, inclusive, involves reacting a compound of the formula:
with dimethyl carbonate in the presence of a base or a catalyst at ambient pressure. | 2 |
FIELD OF THE INVENTION
This invention relates to seismometers and like instruments.
BACKGROUND OF THE INVENTION
The invention is particularly concerned with sensitive precision instruments of the kind in which a mass which is sufficiently great to constitute an inertial frame of reference is suspended so as to be free to move, by rotation or by translation, with respect to the instrument as a whole, so that motion of the instrument can be detected or measured. For ease of reference, such instruments as a class will be referred to herein as pendulum instruments. Pendulum instruments include accelerometers, velocimeters, displacement meters including inclinometers, gravity meters, and some kinds of inertial navigation instruments, as well as seismometers of the kind in which a mass is suspended in a frame which is intended in use to contact, and be moved by, the surface of the earth (or any other body whose seismic vibrations are to be measured). In principle, the vibrations cause the frame to move, and the mass is sufficiently freely suspended and sufficiently massive to form its own frame of reference, and the relative motion between the mass and the frame is detected and measured.
By limiting the degrees of freedom relative to the frame in which the mass can move, the seismometer can be set up to measure movement on one particular axis. This may be rectilinear motion, and this is approximated to in many pendulum-type seismometers by arcuate motion, when a long pendulum moves in a short arc.
In general, therefore, the invention is concerned with pendulum instruments in which a mass is prevented from moving in undesired directions, but is allowed to move as freely as possible in one or more other directions. The invention is specifically concerned with such instruments in which there is a mechanical linkage by which the mass is suspended and constrained with respect to the frame.
In instruments of this kind, the design of the suspension can be critical to the performance of the instrument. The suspension must be strong enough to reliably support the mass and prevent its movement in unwanted directions, yet be stable, smooth and substantially free of friction.
Given that the suspension must be resistant to movement of the mass off its intended axis, but compliant to movement of the mass in a direction in which the desired seismic disturbances are to be detected, and considering the magnitude of the mass involved and the desired sensitivity of the instrument, it is clearly desirable to provide means for locking the mass against movement with respect to the frame, so that the instrument can be transported and handled safely, without risk of damaging the delicate components. In practice, this poses problems, because it is extremely difficult to manufacture a locking mechanism that perfectly engages the mass without exerting unwanted stresses on the suspension. Indeed, it is common for suspension components to be stressed and ultimately to fracture after repeated locking and unlocking cycles.
SUMMARY OF THE INVENTION
It is an object of this invention to address this problem.
We have found that, rather than trying to solve this problem by ever more precise manufacturing, or strengthening the suspension, the problem can in fact be avoided.
According to the invention a pendulum instrument mechanism, and a method of locking it, comprise some or all of the elements and features disclosed in the following description. The scope of the invention extends to all novel aspects whether individually or in combination with other features as described herein.
More specifically, in one aspect of the invention a pendulum instrument mechanism of the kind comprising a mass connected to a frame by suspension means which constrains the mass to move substantially freely within a limited set of degrees of freedom comprises means for sequentially disengaging the mass from the frame at the suspension means, clamping the mass to the frame to lock the mechanism, unclamping the mass from the frame to unlock the mechanism, and re-engaging the mass with the frame through the suspension means.
Similarly, a method of locking and unlocking a pendulum instrument mechanism of the kind comprising a mass, a frame, and suspension means connecting mass and frame which constrains the mass to move substantially freely within a limited set of degrees of freedom comprises sequentially disengaging the mass from the frame at the suspension means, clamping the mass to the frame to lock the mechanism, unclamping the mass from the frame to unlock the mechanism, and re-engaging the mass with the frame through the suspension means.
In this way, by disengaging the suspension, which is a mechanical arrangement resistant to movement in a certain range of directions, or degrees of freedom, before clamping the mass with respect to the frame for transportation purposes, and by releasing the clamped mass before reconnecting it through the suspension mechanism, excessive stresses on the suspension caused by locking up the mass to the frame can be entirely avoided, and suspension strains and fractures due to this cause can be eliminated.
The mass referred to above comprises all that inertial body that moves, in the seismometer, with respect to the frame, and not specifically the massive weight in which the mass is largely concentrated. Thus, in a pendulum-type instrument in which a weight is carried on a pivoted boom, the mass referred to above can be considered to be the whole of the weighted boom, and in accordance with the invention it is of course this component that is the mass that is connected by a pivoted suspension means to the frame, and locked to the frame for transport.
Disengaging the mass from the frame at the suspension means may take place in two stages; firstly, releasing the connection, and secondly, separating the mass from the frame by movement away from the suspension point. Similarly, re-engaging the mass to the frame may comprise initially bringing the mass and the frame together again at the suspension point, followed by positively reconnecting the mass and the frame through the suspension means.
Guide means may be associated with the separation step to aid the proper clamping of the mass to the frame during the locking step, and the proper re-engagement of the mass with the frame at the reconnection of the suspension means. Such guide means may be advanced prior to the completion of the disengagement of the mass from the frame at the suspension means, and optionally prior to the initial disconnection, and may be withdrawn after the relocation of the mass with respect to the frame at the suspension means, and optionally not until after their positive reconnection.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention is shown by way of example in the accompanying drawings, in which:
FIG. 1 is an isometric front view of a seismometer mechanism, to a small degree cut away and exploded for the sake of clarity;
FIG. 2 is a vertical cross-section through the mechanism shown in FIG. 1, looking inwardly from just inside the left hand frame upright, the mechanism being shown unlocked;
FIG. 3 is a view corresponding to that of FIG. 2, but the mechanism being shown locked;
FIG. 4 is a cross-sectional view similar to that of FIG. 2, but taken closer to the centre line of the instrument, the mechanism being shown unlocked; and
FIG. 5 is a cross-section taken at the same location as FIG. 4, but the mechanism being shown locked.
DETAILED DESCRIPTION OF THE INVENTION
It will be appreciated that the mechanism shown in the drawings will normally be housed in an outer canister, and will contain in particular a substantial quantity of electronics control and measuring components, which may be entirely conventional in nature. These have therefore been omitted as unnecessary to the understanding of the present invention.
The mechanism shown in the drawings is for a seismometer of the inverted pendulum kind, in which a mass is supported on a pivot over a base. The instrument will detect vibrations in a horizontal direction perpendicular to the horizontal pivot axis.
Specifically, the frame 10 of the mechanism includes a base 11, a left hand upright 12, a right hand upright 13 and a top cross beam 14. The mass comprises a boom 20 and all its associated fittings, as described below.
The boom is a solid body, generally rectangular in shape, fitting inside the upper part of the frame 10, and provided at each side with two downwardly extending legs 21. Towards the bottom of each leg are cylindrical pivot clamps 22, each of which holds a boom mounting pivot 24.
The boom mounting pivots are each formed of leaf springs set in two mutually perpendicular planes. Adjacent pairs of ends of the leaf springs are linked together by part-cylindrical shells, so the two shells form components that can hinge with respect to each other about the line on which the leaf springs cross each other. The two opposed part-cylindrical shells are contained within two axially aligned cylindrical rings, one end of one shell being made fast to one ring and the opposite end of the other shell being made fast to the other ring. In this way, the pivot axis is the line on which the two leaf spring planes intersect, which is the central axis of the two adjacent cylindrical rings, and the ring on one side can rotate about this axis with respect to the other ring, in a smooth and substantially friction free manner. Pivots of this kind are well known in the art, and include "Free-Flex" pivots manufactured by the Bendix Fluid Power Division of Allied Bendix Aerospace.
It is accordingly one of the cylindrical rings of the pivot that is clamped in each boom leg, and the adjacent cylindrical ring projects freely on the inner side of the respective leg 21, towards and aligned with the opposite pivot 24.
The base 11 of the seismometer frame includes a pair of pivot mounting blocks 26, each of which is provided with a pivot-receiving V groove 28 on its top surface. These V grooves are aligned with each other and are so positioned as to provide supports for the inner rings of the boom pivots 24.
The pivots are retained in the V grooves by two respective pivot clamp levers 30, which are themselves pivotally mounted to the frame at one end (the rear of the mechanism as seen in FIG. 1), and are pulled downwardly over the pivot 24 by respective pivot clamp lever return springs 32 which are anchored to the front of the pivot mounting block. It can be seen, therefore, that the massive boom 20 is connected to the frame 10 by suspension means including the pivots 24 which constrain the boom to move solely by rotation on the one pivot axis in the frame, and that the massive boom is engaged with the frame by the pressure of the pivot clamp levers over the pivot rings resting in the pivot receiving V grooves of the pivot mounting block on the frame.
As regards the mass comprising the boom 20 and its associated fittings, these fittings include a movement detector 40, which is of the capacitative displacement transducer type with magnetic servo feedback, and includes a coil former 42 rigidly mounted off the front face of the top of the boom 20. The coil former lies between, but spaced from, a magnet 44 and a keeper 46 rigidly fixed to the top cross beam 14 and to the upper ends of the uprights 12, 13 of the frame 10. The boom also carries, below the detector, a centering motor 47 and adjustment weight assembly 49, which are used in a conventional manner to make fine adjustments to the centre of gravity of the boom.
The inverted pendulum constituted by the massive pivoted boom assembly must be stabilised, so that it is upright in its rest position, and this is accomplished, again in a conventional manner, by means of a long narrow stabilising leaf spring 50 which is clamped upright to the rear edge of the base 11 and carries at its upper end, at the height of the top of the boom, a horizontal stabilising wire 52 which extends towards the top of the boom, where it is clamped. The stabilising wire 52 is axially stiff, but compliant as regards vertical movement of one end with respect to the other.
The top cross beam 14 of the frame includes two laterally spaced upper boom locking screws passing therethrough, which terminate at their lower tips in conical probes 56. The top edge of the boom 20 is provided with corresponding conical recesses 58 below the respective probes 56. The intention is that the boom will be locked by lifting it, as will be described, so that the probes firmly engage the recesses, and unlocked by lowering it so that the probes and recesses separate and once again allow adequate free motion of the boom.
The direct means of lifting the boom comprises boom locking lever 60, which is pivotally mounted at the centre rear of the mechanism and passes forwardly, between the legs 21 of the boom, and between the two pivot clamping levers 30. The upper surface of the locking lever 60 carries a boom locking stud 62, which has a frustoconical nose, and a corresponding conical recess 64 is formed immediately above it in the lower edge of the upper part of the boom. Subject to disengagement of the boom from the frame at the pivots, it can be seen that if boom locking lever 60 can be raised, boom locking stud 62 will engage the recess 64 and then lift the boom until recesses 58 on the upper edge engage the conical probes 56, by means of which three points of engagement the boom can be clamped in the frame by means of upward pressure on the boom locking lever.
Releasing the suspension and clamping the boom, and the reverse process, is carried out and controlled by means of cams on a camshaft 70 mounted on the front of the mechanism below the front ends of the pivot clamp levers 30 and boom locking lever 60. There are two cams 72 for actuating the pivot clamp levers, and a central cam 74 for actuating the boom locking lever. The camshaft has a drive gear pinion 76 on its left hand end, which is engaged by motor drive pinion 78 of camshaft motor 86 which is mounted on the front of the mechanism in mounting block 88.
Boom locking lever cam 74 is of substantially the same profile as pivot clamp lever cams 72, but the boom locking lever 60 is slightly higher in the frame than the pivot clamp levers, so that, as the camshaft rotates, the pivot clamp levers are lifted by the cams 72 before the boom locking lever 60 is lifted by the cam 74. This means that the pivot connection in the suspension is released, by raising the pivot clamp levers against the tension of their return springs 32, before the boom locking lever starts to lift the boom; and when it does so, the inner pivot rings are lifted from the pivot-receiving V grooves 28 to complete the suspension disengagement by separating the massive boom entirely from the frame. Further rotation of the camshaft continues to lift the respective levers, and ultimately the boom is firmly clamped against the conical probe tips of the upper locking screws 54. It will be appreciated that there is absolutely no stress on the suspension in this locked condition. To unlock the mechanism, camshaft 70 is further rotated by the motor 86, the boom locking lever 60 is allowed to fall under the weight of the boom, and additionally the tension in the suspension clamp lever return springs 32 draws the pivot clamp levers 30 down above the pivot rings until the pivots 24 are restored to their proper positions on the pivot-receiving V grooves 28, where they are thereafter positively held by increasing return spring tension as the cams 72 separate entirely from the clamp levers 30.
It will be appreciated that the pivot clamp lever cams 72 could in principle be eliminated, if the pivot clamp lever return springs were not so strong as to damage the pivots in any way when the boom was raised by the boom locking lever. The mass would be effectively disengaged from the frame when subject only to weak return spring tension. However, it is generally preferred to eliminate all forces acting between mass and frame at the pivot, as illustrated, or other suspension point.
Camshaft 70 is also provided with two boom guide webs 80, at locations which correspond to the position of the outside faces of boom legs 21, inside the frame uprights 12, 13. The guide webs rotate with the camshaft, and are provided with outwardly angled leading edges 82. The webs are sufficiently thin that they are somewhat resilient as regards outward lateral pressure, and the arrangement is such that as the camshaft rotates the tapered leading edges of the webs touch and then pass outside the legs 21, and the following flat faces of the webs embrace the legs 21 under slight pressure. The purpose of this arrangement is to guide the boom during its locking and unlocking cycle, resisting sideways movements and aiding the proper clamping of the massive boom to the frame during the locking step, and the proper re-engagement of the boom with the frame when the pivots are re-engaged with the pivot-receiving V grooves.
The guide webs 80 have substantially the shape of a sector of a circle, so that their leading edges 82 can be advanced to the boom just prior to the initial lifting of pivot clamping levers 30, remain in contact with the boom during the whole of the locking and unlocking operations, and release the boom after the pivots have been clamped in their V grooves. Clearance grooves 84 are provided in the base 11 of frame 10 to accommodate the guide webs.
It will be noted that when the suspension is disengaged, and before the boom is locked, the boom remains connected to the frame through the stabilising spring 50 and wire 52, but these do of course undergo no permanent strain and form no part of the suspension means in accordance with the invention. The invention is not concerned with such effectively compliant connections, but with partially stiff suspension systems, in which a mass is constrained to move substantially freely in a limited set of degrees of freedom, and most commonly in a single degree of freedom, in this particular embodiment an arc which, if it is short enough compared to its radius, approaches rectilinear motion.
Although the embodiment of the invention that has been described with reference to the drawings is a seismometer mechanism designed to respond to horizontal motions, the principle can be easily adapted to instruments for measuring vertical displacements. For example, the boom can be held horizontal by means of a torsion spring applied at the pivots, and the centering operation would be carried out not by shifting the centre of gravity of the boom but by adjusting the tension of the torsion spring. The invention can also be applied to other pendulum instruments of the kind described, as well as to seismometers.
Further, the invention is applicable to other forms of suspension, and is not limited to pivots mounted in releasable clamping blocks. | An inverted pendulum seismometer mechanism has a massive boom (20) mounted in friction free crossed leaf spring pivot bearings (24) clamped in V grooves 28 on a frame (10). To lock the boom for transport, without straining the bearings, a camshaft (70) turns and, sequentially, cams (72) lift pivot clamping levers (30), guide webs (80) embrace the boom, and a cam (74) lifts the boom off the V grooves until probes (56) on adjustable locking screws (54) in the frame top cross beam (14) engage recesses (58) in the top end of the boom. Further rotation of the camshaft reverses the sequence to reconnect the boom to the frame in an operative state. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a signalling and/or help request system.
2. Discussion of the Background
As is known, in big cities, particularly during celebrations, manifestations or any occasion involving large crowds, risk situations occur continually in which help is required either of the authorities or specific groups of people trained to deal with specific problems. This is especially true of tourists or visitors on business, who are unfamiliar with the city and fall prey to bag-snatchers, muggers, etc. The need to send out a position signal or request for help may also arise in the case of sickness, or in the event of tourists or visiting businessmen losing their way in a foreign city and, not speaking the language, being unable to ask directions of passers-by.
Public telephones are not always a solution, owing to lack of change, telephone cards, or a nearby telephone booth, or on account of the urgency of the situation; and portable telephones are not yet of such a price as to be generally available, especially when such risk situations are only occasional.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a signalling and/or help request system designed to overcome the aforementioned problems.
According to the present invention, there is provided a signalling and/or help request system, characterized by comprising:
a remote transmitter for transmitting an alarm signal;
a receiving/conveying device cooperating with said transmitter, fitted to a lamp of the public lighting system, and connected to the electricity mains and to a communications network to transmit a message including an identification code;
a centralized receiving device for receiving messages transmitted by said receiving/conveying device, and generating an information and/or help request output signal.
BRIEF DESCRIPTION OF DRAWINGS
A preferred, non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 shows an overall view of the system according to the invention;
FIG. 2 shows a more detailed view of part of the system according to the invention;
FIG. 3 shows an operation block diagram of the system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Number 1 in FIG. 1 indicates the system as a whole, which comprises a portable transmitter 3; a receiving/conveying device 4 suitable for transmitter 3 and fitted to a lamp 5 of the public lighting system to receive a help request from transmitter 3 and transmit messages along the electricity line of the lamp; and a centralized signal receiving and processing system 7 connected to the electricity line.
More specifically, and with reference also to FIGS. 2 and 3, transmitter 3 is preferably a commercial remote-control transmitter, for example, of the type commonly used to open gates and doors, and advantageously comprises a single button 10, which, when pressed (block 30 in FIG. 3), enables a circuit to transmit an analog or digital alarm signal (block 31). Alternatively, provision may be made for two or more buttons for transmitting different signals and help requests, in which case, a different alarm signal (code) is transmitted when each button is pressed. The alarm signal may be transmitted by radio or any other wireless (e.g. infrared) transmission technique. Transmitter 3 may preferably also operate as a receiver for receiving a confirmation code generated by receiver 4, and, for this purpose, may comprise an indicator light 11 (e.g. coloured LED) to show the help request has been transmitted.
Receiving/conveying device 4 comprises a receiver 13; a conveyed-wave transmitting device 14; and a shunt element 15. More specifically, receiver 13 is preferably a commercial type, and comprises known electric circuits for receiving the alarm signal transmitted by transmitter 3 (block 32 in FIG. 3) and transmitting a signal to conveyed-wave transmitting device 14 (block 33). Receiver 13 may also comprise circuits for supplying transmitter 3 with a reception confirmation signal, as stated above.
Conveyed-wave transmitting device 14 may also be a commercial type, e.g. of the sort used on intercoms, and, upon a signal being received by receiver 13, generates a message comprising a help request code and a specific identification code (block 34 in FIG. 3). This signal is supplied to shunt element 15, which transmits the message onto the electricity mains 16 to which lamp 5 is connected. To enable troublefree installation of the system, the shunt element is advantageously enclosed in a casing fittable easily (e.g. screwed or inserted) onto the lamp-holder 18 of lamp 5.
Centralized signal receiving and processing system 7 comprises a conveyed-wave receiving device 20 and a processing unit 21.
More specifically, conveyed-wave receiving device 20 is appropriately connected to electricity mains 16 to extract the messages transmitted via a number of lamps 5 (e.g. all the lamps in a given part of the city--block 35 in FIG. 3), and converts the received message into serial digital form and transmits it to processing unit 21, preferably a computer (block 36). Transmission may be effected in any form, by means of a serial cable connection 23 and public telephone network (indicated schematically by block 24 in FIG. 1), or by radio or any other suitable communications network. Device 20 is suitably located to receive the messages, and a number of devices 20 may be located in different parts of the city, in which case, a concentrator may be provided between the various devices 20 and computer 21.
The software of computer 21 is such as to control the messages received via device 20 and generate operator signals. More specifically, computer 21 may be equipped with graphic programs for displaying the toponymy and/or topography (lamp) of the call, or with an alphanumeric and acoustic system for generating written operator messages and acoustic signals (block 37 in FIG. 3).
Computer 21 may be set up in an appropriate location, such as a local or central police station, or a special center for dealing with help calls.
Operation of system 1 will be clear from the foregoing description. In particular, the present system provides for a surveillance network covering a wide territory, such as that of a large city (but also small towns or lighted suburban roads), in an extremely straightforward low-cost manner, by exploiting the existing electricity mains and using low-cost, easy-to-install devices. Moreover, transmitter 3 is cheap and compact enough to enable anyone to make use of such a surveillance network.
Clearly, changes may be made to the system as described and illustrated herein without, however, departing from the scope of the present invention. In particular, transmitter 3 may, as stated, be a straightforward type for transmitting a straightforward signal, or more complex for transmitting and/or confirming even complex messages. As opposed to conveyed-wave transmission over an electricity line, transmission between receiver 4 and device 20 may also be effected using other techniques, e.g. by radio, in which case, the electricity mains connection serves solely to supply receiver 4. Similarly, as stated, transmission between transmitter 3 and receiver 4, and between device 20 and computer 21 may be effected using any appropriate technique, and centralized signal control may be adapted to meet various requirements. | A signaling and/or help request system. A remote transmitter transmits an alarm signal which is received by a receiving/convening device which cooperates with the transmitter. The receiving/conveying device is fitted to a street lamp to transmit a message including an identification code to the electrical supply means. a receiving unit connected to the supply means extracts the messages supplied by the receiving/conveying device and supplies them through a network to a centralized receiver to generate a help request output signal. | 6 |
STATEMENT OF GOVERNMENT INTEREST
[0001] A portion of the work described herein was supported by government-sponsored grants from the National Institutes of Health, Grant Nos. AI 56575 and GM 62160. The United States government has certain rights in this invention.
FIELD OF THE INVENTION
[0002] The present invention relates to methods of preparing allylic sulfides. More particularly, the present invention relates to methods of preparing allylic sulfides utilizing a [2,3]-sigmatropic rearrangement of a selenosulfide or disulfide compound.
BACKGROUND OF THE INVENTION
[0003] The development of methods for the functionalization of biopolymers, especially peptides and proteins, under the mildest possible conditions, dubbed ligation, is a current frontier in organic chemistry. 1-13 If such methods are to be truly useful and applicable to biochemical and biological systems, very high chemoselectivity, stability, and compatibility with protic solvents, and even aqueous media, are absolute requirements. The azide group 14 has proven to be very versatile in this respect and forms the basis for two of the more important ligation methods, namely the Staudinger ligation 15-28 and Click chemistry, 29-40 as well as of a variety of other reactions useful in this context. 41-47 Other methods include those relying on the chemoselective condensation of hydroxylamines and hydrazines with aldehydes and ketones, and related reactions, in aqueous solution. 1, 2, 48-51
[0004] Thiols, and in particular cysteine residues, have proven popular targets for chemoselective ligation. 1, 2, 52 Native Chemical Ligation for the synthesis of peptides and proteins, and its enzyme-promoted biochemical equivalent, expressed protein ligation, 53-55 are such reactions, which take advantage of the sulfhydryl (i.e., thiol) group and which use this group to great advantage in the highly chemoselective formation of amide bonds in aqueous solution. 10, 26, 56-74 Another thiol-based method, the selective formation of mixed disulfides, is both one of the oldest and most enduring of ligation methods. 1, 2, 75-81 The mildness of the disulfide ligation and its established chemoselectivity for the cysteine thiol in the presence of all the proteinogenic amino acids stands in stark contrast to the various other methods for cysteine functionalization, most of which involve the capture of the cysteine thiol by electrophilic species, and which consequently have obvious potential chemoselectivity issues. 1, 2, 82 The practicality of the disulfide ligation, with its direct applicability to cysteine-containing peptides, also contrasts with the various ingenious indirect methods that have been developed for the preparation of S-functionalized cysteine derivatives, 52 including, for example, the Michael addition of thiols to dehydroalanine units, 83 the alkylation of thiolates with peptide-based β-halo-alanine units, 84-86 and other electrophiles, 87, 88 the opening of peptide-based aziridines by thiolates, 89, 90 and the synthesis of peptides with previously functionalized cysteine building blocks, 91-93 each of which requires the synthesis of modified peptides. The many advantages of the disulfide ligation are offset, however, by its impermanence, which results from the lability of the disulfide bond in the presence of thiols and other reducing agents.
[0005] Consideration of the practical advantages of the disulfide ligation, and the disadvantages of its impermanence, led us to investigate methods for rendering it permanent. In this regard, we have found that the allylic seleneosulfides and disulfides of complex molecules such as peptides and carbohydrates can undergo efficient dechalocogenative rearrangement to allylic sulfides under appropriate conditions. 94, 95
[0006] The phosphine-promoted desulfurative allylic rearrangement of diallyl disulfides to give allyl sulfides 96-100 proceeds by way of a [2,3]-sigmatropic rearrangement via a diallyl thiosulfoxide intermediate 101, 102 and, thus, is related to the well known Evans-Mislow rearrangement of allylic sulfoxides. 103 This dechalcogenative rearrangement, which may also be induced to operate in the reverse direction on treatment of allyl sulfides with elemental sulfur, 104 and which is potentially important in the chemistry of essential oils derived from garlic, 105 appeared to us to hold promise as a convenient means of providing a permanent ligation from a disulfide moiety, if it could be caused to function at ambient temperatures in protic solvents. The seminal work of Höfle and Baldwin revealed that the rearrangement is rapid in benzene at room temperature provided that the presumed thiosulfoxide intermediate is removed from the equilibrium. Thus, the diallyl disulfides 1 and 2 rearrange via the thiosulfoxides 3 and 4 to the thermodynamically more stable disulfides 5 and 6 via two sequential sigmatropic rearrangements with half-lives of 79 and 14 minutes, respectively, at 24° C. (Scheme 1) 101
[0000]
[0007] As shown in Scheme 2, in the absence of a thiophile, simple alkyl allyl sulfides 7 and 8 were found by Höfle and Baldwin to be stable at room temperature and could be purified by vacuum distillation, whereas 10 and 11 were reported to lose sulfur spontaneously at room temperature, albeit without mention of a timescale for this process. 101 A comparable dependence of rearrangement rate on substituent pattern was observed by Moore and Trego in their early work on the reaction. 96 Pseudo first order rate constants were measured by Höfle and Baldwin for the reaction of the alkyl allyl disulfides 7-11 with triphenylphosphine in benzene at 60° C. leading to the conclusion that increased bulk around the thiosulfoxide reduces its concentration in the equilibrium and so retards reduction. 101 While this remains possible, it is more likely that the equilibrium is shifted more toward the thiosulfoxide when a more highly substituted alkene is formed at the expense of a less substituted one, and when a more highly substituted C—S bond is replaced by a less substituted one. 101
[0000]
[0008] A single example of the corresponding deselenative rearrangement of a diallyl diselenide, that of di(geranyl) diselenide to geranyl linalyl selenide, was reported to proceed with a half life of approximately 2.5 hours at 25° C. on exposure to excess triphenylphosphine in chloroform, thereby indicating the selenium version of this reaction to be considerably faster than the original sulfur protocol. 106 Guillemin and coworkers subsequently were able to obtain crude preparations (˜80% pure) of diallyl diselenide, dicrotyl diselenide, and diprenyl diselenide, characterize them spectroscopically, and study their reactions with tributylstannane, indicating such diselenides to have at least moderate stability at room temperature. 107
SUMMARY OF THE INVENTION
[0009] The present invention provides a dechalcogenative method for the preparation of an allylic sulfide, which is particularly well suited for use with complex molecules such as peptides and carbohydrates. The resulting allylic sulfides are useful as intermediates in a number of chemical transformations in the preparation of drugs and biochemical reagents. The method comprises contacting an activated chalcogenide of Formula (I) with a thiol of Formula (II) for a period of time sufficient to form an intermediate of Formula (III). Sufficient activation energy is then supplied to the intermediate of Formula (III) in a suitable solvent (e.g., an alcohol, an aqueous buffer or an aqueous buffer mixed with an organic solvent), preferably in the absence of a phosphine reagent, to induce a [2,3]-sigmatropic rearrangement, thereby forming an allylic sulfide of Formula (IV), with concomitant loss of chalcogen Z, as set forth in Reaction Scheme (A).
[0000]
[0010] In the formulas set forth in Reaction Scheme (A), X is an activating group selected from the group consisting of CN, S-pyridyl, SO 2 -aryl (preferably SO 2 Ph), and SO 3 Y; Y is an alkali metal (e.g., Na or K); Z is Se or S; R 1 , R 2 , R 3 , R 4 , and R 5 are each independently H, a hydrocarbon moiety, or a substituted hydrocarbon moiety; and R is an organic moiety. In a preferred embodiment, X is an activating group selected from the group consisting of S-pyridyl, S-heteroaryl, SO 2 -aryl, and SO 3 Y; Y is an alkali metal ion; Z is S; R 1 , R 2 , R 3 , R 4 , and R 5 are each independently H or a hydrocarbon moiety; and R is an organic moiety.
[0011] Hydrocarbon moieties can be saturated or unsaturated, and include, for example, alkyl groups, substituted alkyl groups, aryl groups, S-heteroaryl groups, and substituted-aryl groups, most preferably alkyl groups. Substituted hydrocarbon moieties can be alkyl and/or aryl groups substituted with one or more functional group, including a hydroxyl group, an ether group, an amino group, a carboxyl group, an ester group, an amide group, a carbonyl group, an acetal group, a hemiacetal group, a thiol, a thioether, a phosphonate group, a phosphate group, a phosphate ester group, a phosphoramide group, a halide, a heterocyclic group, a fully or partially fluorinated alkyl group, a polyethylene glycol group, a carbohydrate or derivatized carbohydrate, a peptide, a chromophoric group, a fluorophoric group, and the like, as desired.
[0012] Preferred organic moieties, derived from thiol-substituted compounds, include alkyl groups, substituted-alkyl groups, aryl groups, substituted-aryl groups, amino acids, carbohydrates, peptides, or groups consisting of two or more of the foregoing bound together. Particularly preferred organic moieties are complex molecules such as amino acids, peptides (e.g., polypeptides and proteins), carbohydrates (e.g., sugars and polysaccharides), nucleic acids, and peptide nucleic acids, more preferably peptides.
[0013] Preferably, the thiol of Formula (H) is a thio-substituted peptide or a thio-substituted carbohydrate.
[0014] Any suitable solvent can be used in the present invention. Preferred solvents include polar solvents such as acetonitrile, anhydrous or aqueous lower alcohols (e.g., C 1 -C 3 alcohols such as methanol, ethanol, and isopropanol), an aqueous buffer, an aqueous buffer mixed with an organic solvent, and appropriate mixtures thereof.
[0015] The activation energy required to drive the rearrangement to completion is preferably provided by applying heat (e.g., in a refluxing solvent or under microwave irradiation), with or without a catalyst, such as an amine (e.g., piperidine) to facilitate the rearrangement.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] The following discussion describes preferred aspects of the present invention, and is not to be construed as limiting the scope thereof.
[0017] As used herein and in the appended claims, the term “substituted” as applied to hydrocarbons and other organic molecules, means that the hydrocarbon or other organic molecule includes one or more functional group such as a hydroxyl group, an ether group, an amino group, a carboxyl group, an ester group, an amide group, a carbonyl group, an acetal group, a hemiacetal group, a thiol, a thioether, a phosphonate group, a phosphate group, a phosphate ester group, a phosphoramide group, a halide, a heterocyclic group, and the like, as desired.
[0018] As used herein and in the appended claims, the term “alkyl” encompasses saturated hydrocarbon groups, as well as non-aromatic unsaturated hydrocarbon groups, such as alkenyl groups and alkynyl groups.
[0019] As used herein and in the appended claims, the term “peptide” and grammatical variations thereof, refers to compounds including at least two amino acid residues bound together by a peptide (amide) bond, including dipeptides, oligopeptides, polypeptides, proteins, and any derivatives thereof (e.g., including a protecting group, a carbohydrate group, a lipid group, and the like bound to an amino acid residue in the peptide).
[0020] Preliminary Studies. As shown in Table 1, allylic pyridyl sulfides, 1, 2, 108 allylic thiosulfonates, 81 and allylic Bunte salts (S-allyl thiosulfates) 109, 100 all proved suitable for the transfer of allylic sulfides to a range of simple thiols. The phosphine-promoted rearrangement of the resulting disulfide, however, was not so facile in all cases. For example, it was necessary to heat the alkyl geranyl disulfide 18 with triphenylphosphine in toluene at reflux in order to achieve efficient conversion to the rearranged linalyl sulfide 19 (Table 1, entry 1). It is important to note that, consistent with the goal of developing a practical process suitable for application to biologically relevant systems, the reactions were carried out with a minimal excess of phosphine, unlike the work of Höfle and Baldwin. 101 The difference in the amount of phosphine presumably accounts for the differences in reaction times and temperatures observed. Under the same conditions the phenyl geranyl disulfide 20, however, gave the unrearranged phenyl geranyl sulfide 21 (Table 1, entry 2), thereby drawing attention to the relatively fine dividing line between the desired dechalcogenative allylic rearrangement and the better known nucleophilic removal of a sulfur atom from a disulfide, which is an undesirable side reaction. 111
[0021] As is evident from the comparison of entries 1 and 2 in Table 1, the replacement of an alkylthiyl moiety by an arylthiyl group is sufficient to tip the balance in favor of nucleophilic attack by the phosphine on the native disulfide. Entry 3 of Table 1 illustrates how the replacement of triphenylphosphine by the more nucleophilic hexaethylphosphoramide enabled the reaction temperature to be reduced to ambient room temperature, but with continued formation of the simple desulfurization product. Finally, Table 1, entry 4, indicates that the use of hexaethylphosphoramide is not preferred, at least in the context of amino acid and peptide-based systems, owing to both transesterification and racemization evidenced by incorporation of deuterium from the solvent at the α-center.
[0000]
TABLE 1
Thiol + Donor → Disulfide
Disulfide + PR 3 → Product
Disulfide
Temp
Product
Entry
Thiol
Donor
(% yield)
Solv
(° C.)
PR 3
(% yield)
1
CH 3 (CH 2 ) 7 SH
A
110
D
2
PhSH
A
110
D
3
PhSH
B
RT
E
4
C
RT
E
A = toluene;
B = hexadeuteriobenzene;
C = tetradeuteriomethanol;
D = triphenylphosphine;
E = hexaethylphosphoramide
RT = ambient room temperature
[0022] Allylic Selenosulfide Rearrangement. The clean formation of simple mixed alkyl selenosulfides can be realized at room temperature by the reaction of Se-alkyl seleno-Bunte salts with thiols. 112, 113 Accordingly, a number of Se-allyl seleno Bunte salts were prepared by the reaction of potassium seleno sulfate, prepared in situ from potassium sulfite and selenium powder, with allyl halides. These compounds were typically orange crystalline solids that, while not indefinitely stable, could be handled in air at room temperature. Reaction with a range of aliphatic thiols then resulted in the formation of a series of selenosulfides, that could be readily detected by thin layer chromatography and/or NMR spectroscopy, but which were allowed to undergo the subsequent deselenative rearrangement, either with or without the addition of phosphine as required (Scheme 3, Table 2).
[0000]
[0023] In a preferred embodiment of the present invention, the allyl selenosulfides are prepared by the reaction of allyl selenocyanates 107 with thiols, a process that also takes place readily at room temperature (Scheme 3), and which had been reported for the formation of simple diaryl selenosulfides. 114 The formation of allyl selenosulfides from the reaction of allylselenols with disulfides was not investigated because of anticipated difficulties in the preparation and handling of the allylic selenols. 107 Overall, it is clear from Table 2 that allyl selenocyanates can generally be prepared in higher yields than the corresponding Se-allyl seleno Bunte salts, but that in most cases both selenenylation systems perform the transfer of the Se-allyl group to the thiol comparably well, as evidenced by the yield of the subsequent rearrangement products.
[0024] It is of some interest to note that the primary allylic selenocyanates prepared and employed in this study were readily handled at room temperature and showed no tendency to undergo rapid rearrangement. This observation parallels that of Riague and Guillemin, who had earlier prepared several of the same allylic selenocyanates and reported their purification by vacuum distillation, 115 but it stands in contrast to the reported chemistry of simple allylic thiocyanates which are reported to undergo [2,3]-sigmatropic rearrangement to the corresponding allylic isothiocyanates in a matter of hours at room temperature. 116 Carbohydrate-based allylic thiocyanates, however, require higher temperatures for rearrangement. 117 Based on the work of Sharpless with 2-methyl-3-selenocyanato-1-heptene, secondary and presumably tertiary selenocyanates can be expected to undergo a [1,3]-sigmatropic rearrangement to their primary regioisomers. 106
[0000]
TABLE 2
Disulfide
Product
% Yield
% Yield from
from Donor
Disulfide *
for X=
for X=
Entry
Thiol
Donor
SO 3 − K +
CN
Product
SO 3 − K +
CN
1
CH 3 (CH 2 ) 15 SH
56
84
74 (0)
70 (0)
2
56
84
70 (0)
70 (0)
3
56
84
61 (2.5)
80 (0)
4
56
84
50 ★ (2.5)
55 ♦ (2.5)
5
56
84
58 (2.5)
75 (0)
6
58
73
62 (2.5)
68 (0)
7
58
73
60 (2.5)
71 (0)
8
58
73
60 (2.5)
65 (0)
9
CH 3 (CH 2 ) 15 SH
40
80
62 (2.5)
70 (2.5)
10
40
80
46 (2.5)
66 (2.5)
11
40
80
43 (2.5)
55 (2.5)
12
40
80
51 (2.5)
50 (2.5)
13
35
85
47 (2.5)
40 (2.5)
14
28
75
31 (2.5)
65 (2.5)
In Table 2, all reactions were conducted in MeOH at room temperature unless otherwise specified;.
* the number of equivalents of triphenylphosphine used in the rearrangement is shown in parenthesis ( ) below the product % yield;
♦ the rearrangement was run at 65° C.;
★ the rearrangement was run in CDCl 3 at 65° C.
[0025] The transfer of a simple allyl or methallyl group did not necessitate the addition of phosphine and proceeded spontaneously over a 2 hour period at room temperature. In the case of geranyl and farnesyl Se-Bunte salts and selenocyanates, proceeding with allylic rearrangement to the linalyl and nerolidyl sulfides, respectively, spontaneous rearrangement was not observed and it was necessary to add phosphine to provoke the loss of selenium. The more difficult rearrangement of the geranyl and farnesyl systems corresponds to the pattern observed originally with the allylic disulfides (Scheme 2), with the prenyl system 9 undergoing the phosphine-promoted rearrangement least rapidly. This is likely the consequence of the formation of the less stable isoprenyl substitution pattern. The anomeric thiol 38 rearranged slowly over a period of several days at room temperature in the presence of phosphine, and much more rapidly at 65° C. The fluorous substituted methallyl system 53, unlike the simple methallyl transfer reactions, necessitated the addition of phosphine in order to proceed at room temperature. These latter two observations are readily understood in terms of the mechanism of Scheme 3, with the formation of the intermediate selenosulfoxide disfavored by either an electron-withdrawing substituent on the allyl group or by the involvement of the sulfur atom in an exo-anomeric type interaction that serves to remove electron density from sulfur. When the reaction takes place with the formation of a new stereogenic center this was typically obtained as an almost equimolar mixture of two diastereomers and, accordingly, no attempt was made to distinguish the isomers.
[0026] The range of examples presented in Table 2, which were all conducted at room temperature with the exception of the carbohydrate-based example, displays the broad functional group compatibility of the method. A series of further experiments in which the reaction of cysteine derivative 25 with the methallyl seleno Bunte salt 42 and triphenylphosphine was conducted in methanol at room temperature in the presence of equimolar amounts of N-benzyloxycarbonyl tyrosine benzyl ester, N-benzyloxycarbonyl methionine, Nα-benzyloxycarbonyl lysine methyl ester, N-benzyloxycarbonyl arginine methyl ester, and N-benzyloxycarbonyl aspartic acid α-methyl ester, with no loss of yield and with recovery of the spectator amino acid, further confirmed the applicability of the reaction in the presence of most standard functional groups.
[0027] Unfortunately, all attempts at the preparation of tertiary allylic seleno Bunte salts or the equivalent selenocyanates, such as would be necessary for the introduction of a simple geranyl or farnesyl group to a sulfide, failed. This result is not surprising in view of the instability of secondary allylic selenocyanate and even phenylselenides noted by Sharpless. 106
[0028] Allylic Disulfide Rearrangement. The early work on the allylic disulfide rearrangement (Scheme 2) 96, 101 indicated the considerable effect of substituents in the allylic moiety on reaction rate with the secondary and tertiary allylic disulfides undergoing rearrangement several orders of magnitude more rapidly than their primary counterparts in hot benzene, thereby providing grounds for hope that the rearrangement could be induced to function as required at room temperature with the correct substituent pattern. In addition, consideration of the mechanism of the allylic disulfide rearrangement leads to the hypothesis that the reaction should be facilitated in polar solvents capable of stabilizing the dipolar thiosulfoxide intermediate. We assign the dipolar structure to the thiosulfoxides, a class of compounds, which have not been isolated or characterized spectroscopically, by reasonable analogy with the sulfoxides. Thiosulfinates (ROS(S)OR) have been isolated and studied crystallographically, spectroscopically, and computationally, with the evidence pointing to the polar structure. 118 Indeed, the early workers in the field noted a 6-fold to 10-fold increase in the rate of desulfurative rearrangement of 1,3-dimethylbut-2-enyl t-butyl disulfide with triphenylphosphine on going from benzene to ethanol/benzene (9/2) at 80° C., 96 and Höle and Baldwin commented on the instability of methanolic solutions of 10 and 11 with respect to rearrangement, as compared to the neat samples. 101
[0029] A series of secondary and tertiary allylic thiols were prepared by the [3,3]-sigmatropic rearrangement of a variety of primary allylic thiocarbonyl derivatives (Scheme 4, Table 3). 119-129 While this chemistry was straightforward, caution was necessary in the conversion of the rearrangement products to the thiols as these were found to undergo a known 121 1,3-shift to the isomeric primary allylic thiols under basic conditions. The optimum conditions for this cleavage involved the reduction of the thiol carbamates with lithium aluminum hydride, 121 and the cleavage of the dithiocarbonates with ethanolamine. The thiols were then allowed to react with either 2,2′-dipyridyl disulfide, 2,2′-di(5-nitropyridyl) disulfide, or 2,2′-di(1,3-benzothiazolyl) disulfide 1, 2, 75-77, 108, 130-133 for conversion to the corresponding allyl heteroaryl disulfides and ultimate transfer to the target thiols (Scheme 4, Table 3). It is noteworthy that sulfenylating agents derived from hindered allylic thiols have drawn little attention so far, with only a limited number of allylic benzothiazolyl disulfides being described in the literature. 134, 135 In addition to these allylic heteroaryl disulfides, we also prepared a single example (75) of an S-allyl Se-phenyl selenosulfide, by reaction of the thiol with N-phenylselenophthalimide, as it had been reported that the selenosulfides were more effective at sulfenyl transfer than the corresponding disulfides. 80
[0000]
[0000]
TABLE 3
Allylic
Rearranged
Xanthates
Thiocarbamate
Thiol
Disulfide
(% yield)
(% yield)
(% yield)
(% yield)
4-NO 2 -2-Py
65 (86)
Bt
66 (81)
[0030] These allylic heteroaryl disulfides exhibited smooth sulfenyl transfer to a selection of primary thiols in either benzene or methanol/acetonitrile mixtures at room temperature (Table 4). Addition of either triphenylphosphine or (4-dimethylaminophenyl)diphenylphosphine then promoted the desired desulfurative allylic rearrangement. For those reactions that were carried out in benzene, the sulfenyl transfer was affected at room temperature, after which the phosphine was added and the reaction mixture heated to reflux to provoke the rearrangement. On the other hand, when reactions were conducted in methanol and acetonitrile no heating was required for the entire sequence, which is consistent with mechanistic considerations. With the more highly substituted allyl heteroaryl disulfides, sulfenyl transfer was relatively slow, but was accelerated very significantly by the addition of triethylamine. Interestingly, sulfenyl transfer from the selenosulfide 75 was also slow, but was accelerated in the presence of triethylamine. The accelerated reactions reported in the literature for sulfenyl transfer from selenosulfides, as compared to disulfides, also appear to be the result of the inclusion of triethylamine. 80 No obvious consequence in terms of reactivity was observed when the sulfenyl transfer group was changed from 5-nitro-2-pyridyl, to 2-pyridyl, to 2-benzothiazolyl, but the differing polarities of the corresponding heteroaryl sulfides formed as byproducts can be used to advantage in the case of otherwise difficult purifications. Similarly, no significant difference in the rate of the desulfurative rearrangement was observed on changing from triphenylphosphine to (4-dimethylaminophenyl)diphenylphosphine 84, but the latter did afford a practical advantage in terms of purification of the final products.
[0031] The desulfurative rearrangement of the secondary allylic disulfides takes place with high E-selectivity as anticipated on the basis of related [2,3]-sigmatropic rearrangements such as the Evans-Mislow rearrangement 103 or the [2,3]-Wittig rearrangement. 136-138 With the tertiary allylic disulfides, E/Z mixtures of the rearranged products are formed that slightly favor the E-isomer. Interestingly, in the case of the nerolidyl selenosulfide 75 the product 86 was obtained as a more complex mixture of isomers, presumably due to isomerization of the central alkene in the resulting farnesyl chain by the selenide byproducts in combination with light. 139 When the reaction of the cysteine derivative 83 with the sulfenyl transfer agent 66 and triphenylphosphine was carried out in a mixture of deuteriomethanol and deuterioacetonitrile no incorporation of deuterium at the amino acid α-center was observed, indicating that the reaction conditions do not provoke racemization.
[0032] The examples presented in Table 4 attest to the broad functional group compatibility of the formation and desulfurative rearrangement of secondary and tertiary allylic disulfides and draw attention to the complementary nature of the process with the deselenative allylic selenosulfide protocol, with all classes of primary, secondary, and tertiary allylic sulfides accessible by one of the two reaction sequences at room temperature and without the need for electrophilic reagents.
[0000]
TABLE 4
Sulfenating
Product
Thiol
agent
Solv.
PR 3
T ° C.
(% yield)
C 6 H 6
PPh 3
reflux
C 6 H 6
PPh 3
reflux
C 6 H 6
PPh 3
reflux
A
84
RT
A
PPh 3
RT
A
PPh 3
RT
A
84
RT
A
PPh 3
RT
A
PPh 3
RT
A
PPh 3
RT
A
PPh 3
RT
A
PPh 3
RT
In Table 4, Solvent A is MeOH/MeCN (1:1);
Phosphine (PR 3 ) 84 is (4-Me 2 N—C 6 H 4 )diphenylphosphine.
[0033] Use in Aqueous Media. The applicability of the desulfurative allylic rearrangement in aqueous media was first probed with glutathione 93 and sulfenylating agent 64. Disulfide 64 was reacted with glutathione 93 in a 2/1/1 mixture of Tris Buffer/CH 3 CN/THF, with a substrate concentration of about 0.02 M at room temperature, followed by addition of triphenylphosphine, which smoothly yielded the lipidated glutathione 94 in 70% yield (Scheme 5).
[0000]
[0034] The chemoselectivity of the rearrangement was further explored with the commercial decapeptide fibronectin fragment 95. 140, 141 This decapeptide was selected as a proving ground due to the dense array of the more challenging amino acid side chains that it presents. As with glutathione 93, sulfenylation of the cysteine moiety of the decapeptide 95, followed by phosphine-promoted rearrangement, was accomplished at room temperature in aqueous buffer, with the aid of organic co-solvents, and resulted in the isolation of the lipidated decapeptide 96 in 70% yield (Scheme 6). The location of the tridecene chain on the cysteine group in 96 was established by tandem MS/MS experiments.
[0000]
[0035] As a final demonstration of the protocol in aqueous media we prepared an octapeptide 101 in which the cysteine residue was located four residues from a C-terminal methionine unit, so as to mimic the Cys-AA 1 -AA 2 -Met sequence targeted by the farnesyl transferase enzymes. 142-144 The other amino acids in this synthetic peptide were selected so as to provide a measure of steric hindrance to the cysteine moiety. Two tetrapeptides were assembled by routine methods, 145, 146 and 97, which was destined to become the N-terminal fragment of the target, was saponified, converted to the ethylthio ester 98 with HATU and ethanethiol, 147, 148 and finally released from the carbamate protecting group in the standard manner (Scheme 7). This sequence resulted in an inseparable mixture of two diastereomers 99 at the C-terminal alanine, a problem known to plague thioester synthesis for native chemical ligation. The use of the PyBop activation method for thiol ester formation, as applied recently by the Kajihara group, appears to hold promise for the non-racemizing synthesis of C-terminal thiol esters, but no attempt was made to apply it in the present synthesis. 149 Coupling of thioester 99 with tetrapeptide 100 under conditions of native chemical ligation afforded the target octapeptide 101 in 51% yield as a 1.3/1 mixture of two diastereomers, which was separated by preparative RP-HPLC. The major diastereoisomer, presumed to be the all L-octapeptide, was then allowed to react with the nerolidyl benzothiazolyl disulfide 74 under buffered aqueous conditions at room temperature, followed by addition of triphenylphosphine leading, overall, to the farnesylated octapeptide 102 in 66% isolated yield (Scheme 7). This farnesylation reaction occurred with the formation of E/Z-isomers mixtures in approximately equal ratio in line with the model experiments in organic solution (Table 4).
[0000]
[0036] The examples of Schemes 5-7 are distinct from other recent functionalizations of sulfur in cysteine containing peptides 52 as they require neither the use of electrophilic reagents, 1, 2, 82 nor the incorporation of modified amino acid residues into the peptide backbone prior to functionalization, 83-90 nor the synthesis of peptides with previously functionalized amino acid building blocks. 91-93 These factors combine to render this chemistry both highly chemoselective, and highly efficient in terms of steps required on the actual peptide target. In contrast to other methods involving the addition of nucleophilic thiols to dehydroalanine groups inserted into peptides, 83 the products are obtained as single diastereomers with the sole exception being the formation of E/Z-mixtures when the allylic sulfide contains a trisubstituted alkene.
[0037] Rearrangement in the Absence of Phosphines. We have noted that the attempted purification of the cysteine derived disulfide 103 by chromatography over silica gel resulted in the isolation of 13% of the allylically rearranged thioether 85 along with the disulfide itself (Scheme 8). 95 On standing in deuteriochloroform that had not been treated to remove acidic impurities the same disulfide 103 underwent partial rearrangement to 85 with loss of sulfur. 95 In addition, morpholine or piperidine have been reported to drive the related allylic sulfoxide/sulfenate rearrangement. 103 We have now found that the allylic disulfide rearrangement can be efficiently performed in the absence of a phosphine.
[0000]
[0038] The apparent acid-catalyzed rearrangement of 103 to 85 with loss of sulfur did not provide a satisfactory general method for the rearrangement. However, after some investigation, we have found that the activation energy necessary to facilitate the rearrangement can be achieved, with no added phosphine, by stirring the disulfide with two equivalents of an amine catalyst (piperidine) at room temperature in a solvent such as methanol or simply by heating to reflux in the solvent, with or without a catalyst. Examples of rearrangements so-conducted are presented in Table 5 using a sulfenyl transfer reagent 104 derived by removal of the silyl group from sulfenyl donor 79. Appropriate control experiments conducted with triphenylphosphine at room temperature are also reported in Table 5.
[0000]
TABLE 5
PPh 3
Piperidine
Heat
Thiol
% Yield
% Yield
% Yield
Entry
RSH
Product
E/Z ratio
E/Z ratio
E/Z ratio
1
45 E only
62 2.6:1
78 E only
2
—
—
67 E only
3
—
—
68 E only
4
CH 3 (CH 2 ) 7 SH
—
—
75 E only
5
4-Me-Ar—SH
18 E only
66 2.5:1
66 E only
6
PhSH
—
—
63 E only
7
4-Cl-Ar—SH
—
—
62 E only
8
4-NO 2 -Ar—SH
—
—
20 E only
9
2-Py—SH
—
—
45 E only
10
2-HO—Ar—SH
—
—
57 E only
[0039] Both the piperidine and the refluxing methanol conditions for the first time enable the efficient desulfurative rearrangement of ally aryl disulfides in the absence of a phosphine, thereby opening up new avenues for the synthesis of ally aryl sulfides and extending the overall scope of the reaction. The rearrangements of the allyl aryl disulfides presented in Table 5, and conducted in the absence of phosphine, but with the aid of either piperidine or hot methanol, are to be contrasted with the attempted promotion of such a rearrangement set out in Table 1, when the excision of sulfur was observed without the allylic rearrangement. This process can also be applied to a tertiary thiol. In addition, no racemization was observed in the case of the cysteine derivative, as determined in the usual manner by the use of deuteriomethanol as solvent.
[0040] Conclusions. The deselenative allylic rearrangement of primary allyl selenosulfides and the desulfurative rearrangement of secondary and tertiary allylic are powerful and complementary techniques for the synthesis of primary, secondary, and tertiary allylic sulfides at room temperature. The preparation of the selenosulfides and disulfides requires no electrophilic reagent, leading to highly chemoselective methods for the permanent modification of thiols. The chemoselectivity of the two reactions enables their application to unprotected peptides in aqueous media in the presence of all types of standard amino acid side chains, thereby providing a powerful means for the direct and permanent modification of cysteine containing peptides.
[0041] The use of the terms “a” and “an” and “the” and similar references in the context of describing the invention (especially in the context of the following claims) are 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.
[0042] 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.
REFERENCES
[0000]
(1) Hermanson, G. T. Bioconjugate Techniques ; Academic Press: San Diego, 1996.
(2) Lundblad, R. L. Chemical Reagents for Protein Modification; 3 ed.; CRC Press: Boca Raton, 2005.
(3) van Swieten, P. F.; Leeuwenburgh, M. F.; Kessler, B. M.; Overkleeft, H. S. Org. Biomol. Chem. 2005, 3, 20-27.
(4) Peri, F.; Nicotra, F. Chem Comm 2004, 623-627.
(5) Pratt, M. R.; Bertozzi, C. R. Chem. Soc. Rev 2005, 34, 58-68.
(6) Prescher, J. A.; Dube, D. H.; Bertozzi, C. R. Nature 2004, 430, 873-877.
(7) Hang, H. C.; Bertozzi, C. R. Acc. Chem. Res. 2001, 34, 727-736.
(8) Nilsson, B. L.; Hondal, R. J.; Soellner, M. B.; Raines, R. T. J. Am. Chem. Soc. 2003, 125, 5268-5269.
(9) Bode, J. W. Curr. Op. Drug Disc. Dev. 2006, 9, 765-775.
(10) Nilsson, B. L.; Soellner, M. B.; Raines, R. T. Ann. Rev. Biophys. Biomol. Structure 2005, 34, 91-118.
(11) Kalia, J.; Raines, R. T. ChemBioChem 2006, 7, 1376-1383.
(12) Lin, H.; Walsh, C. T. J. Am. Chem. Soc. 2004, 126, 13998-14003.
(13) Langenhan, J. M.; Thorson, J. S. Current Organic Synthesis 2005, 2, 59-81.
(14) Agard, N. J.; Baskin, J. M.; Prescher, J. A.; Lo, A.; Bertozzi, C. R. ACS Chem. Biol. 2006, 1,644-648.
(15) Köhn, M.; Breinbauer, R. Angew. Chem. Int. Ed. 2004, 43, 3106-3116.
(16) Lin, F. L.; Hoyt, H. M.; van Halbeek, H.; Bergman, R. G.; Bertozzi, C. R. J. Am. Chem. Soc. 2005, 127, 2686-2695.
(17) Grandjean, C.; Boutonnier, A.; Guerreiro, C.; Fournier, J.-M.; Mulard, L. A. J. Org. Chem. 2005, 70, 7123-7132.
(18) Hang, H. C.; Yu, C.; Pratt, M. R.; Bertozzi, C. R. J. Am. Chem. Soc. 2004, 126, 6-7.
(19) Lemieux, G. A.; de Graffenreid, C. L.; Bertozzi, C. R. J. Am. Chem. Soc. 2003, 125, 4708-4709.
(20) Saxon, E.; Luchansky, S. J.; Hang, H. C.; Yu, C.; Lee, S. C.; Bertozzi, C. R. J. Am. Chem. Soc. 2002, 124, 14893-14902.
(21) Saxon, E.; Bertozzi, C. R. Science 2000, 287, 2007-2010.
(22) Saxon, E.; Armstrong, J. I.; Bertozzi, C. R. Org. Lett. 2000, 2, 2141-2143.
(23) Bianchi, A.; Bernardi, A. J. Org. Chem. 2006, 71, 4565-4577.
(24) Kim, H.; Cho, J. K.; Aimoto, S.; Lee, Y.-S. Org. Lett. 2006, 8, 1149-1151.
(25) Soellner, M. B.; Nilsson, B. L.; Raines, R. T. J. Am. Chem. Soc. 2006, 128, 8820-8828.
(26) Liu, L.; Hong, Z.-Y.; Wong, C.-H. ChemBioChem 2006, 7, 429-432.
(27) Soellner, M. B.; Tam, A.; Raines, R. T. J. Org. Chem. 2006, 71, 9824-9830.
(28) Doores, K. J.; Mimura, Y.; Dwek, R. A.; Rudd, P. M.; Elliott, T.; Davis, B. G. Chem. Commun. 2006, 1401-1403.
(29) Kolb, H. C.; Finn, M. G.; Sharpless, K. B. Angew. Chem. Int. Ed. 2001, 40, 2004-2021.
(30) Lutz, J.-F. Angew. Chem. Int. Ed. 2007, 46, 1018-1025.
(31) Breinbauer, R.; Köhn, M. ChemBioChem 2003, 4, 1147-1149.
(32) Manetsch, R.; Krasinski, A.; Radic, Z.; Raushel, J.; Taylor, P.; Sharpless, K. B.; Kolb, H. C. J. Am. Chem. Soc. 2004, 126, 12809-12818.
(33) Devaraj, N. K.; Miller, G. P.; Ebina, W.; Kakaradov, B.; Collman, J. P.; Kool, E. T.; Chidsey, C. E. D. J. Am. Chem. Soc. 2005, 127, 8600-8601.
(34) Whiting, M.; Muldoon, J.; Lin, Y.-C.; Silverman, S. M.; Lindstrom, W.; Olson, A. J.; Kolb, H. C.; Finn, M. G.; Sharpless, K. B.; Elder, J. H.; Fokin, V. V. Angew. Chem. Int. Ed. 2006, 45, 1435-1439.
(35) Srinivasan, R.; Uttamchandani, M.; Yao, S. Q. Org. Lett. 2006, 8, 713-716.
(36) Chittaboina, S.; Xie, F.; Wang, Q. Tetrahedron Lett. 2005, 46, 2331-2336.
(37) Hotha, S.; Kashyap, S. J. Org. Chem. 2006, 71, 364-367.
(38) Gauchet, C.; Labadie, G. R.; Poulter, C. D. J. Am. Chem. Soc. 2006, 128, 9274-9275.
(39) Wan, Q.; Chen, J.; Chen, G.; Danishefsky, S. J. J. Org. Chem. 2006, 71, 8244-8249.
(40) van der Peet, P.; Gannon, C. T.; Walker, I.; Dinev, Z.; Angelin, M.; Tam, S.; Ralton, J. E.; McConville, M. J.; Williams, S. J. ChemBioChem 2006, 7, 1384-1391.
(41) Shangguan, N.; Katukojvala, S.; Greenberg, R.; Williams, L. J. J. Am. Chem. Soc. 2003, 125, 7754-7755.
(42) Merkx, R.; Brouwer, A. R.; Rijkers, D. T. S.; Liskamp, R. M. J. Org. Lett. 2005, 7, 1125-1128.
(43) Kolakowski, R. V.; Shangguan, N.; Sauers, R. R.; Williams, L. J. J. Am. Chem. Soc. 2006, 128, 5695-5702.
(44) Knapp, S.; Darout, E. Org. Lett. 2005, 7, 203-206.
(45) Kolakowski, R. V.; Shangguan, N.; Williams, L. J. Tetrahedron Lett. 2006, 47, 1163-1166.
(46) Barlett, K. N.; Kolakowski, R. V.; Katukojvala, S.; Williams, L. J. Org. Lett. 2006, 8, 823-826.
(47) Wu, X.; Hu, L. J. Org. Chem. 2007, 72, 765-774.
(48) Dirksen, A.; Hackeng, T. M.; Dawson, P. E. Angew. Chem. Int. Ed. 2006, 45, 7581-7584.
(49) Liu, H.; Wang, L.; Brock, A.; Wong, C.-H.; Schultz, P. G. J. Am. Chem. Soc. 2003, 125, 1702-1703.
(50) Pearce, 0. M. T.; Fisher, K. D.; Humphries, J.; Seymour, L. W.; Smith, A.; Davis, B. G. Angew. Chem. Int. Ed. 2005, 44, 1057-1061.
(51) Kubler-Kielb, J.; Pozsgay, V. J. Org. Chem. 2005, 70, 6987-6990.
(52) Pachamuthu, K.; Schmidt, R. R. Chem. Rev. 2006, 106, 160-187.
(53) Muir, T. W.; Sondhi, D.; Cole, P. A. Proc. Natl. Acad. Sci. USA 1998, 95, 6705.
(54) Noren, C. J.; Wang, J. M.; Perler, F. B. Angew. Chem. Int. Ed. 2000, 39, 450.
(55) Muralidharan, V.; Muir, T. W. Nat. Methods 2006, 3, 429.
(56) Dawson, P. E.; Muir, T. W.; Clark-Lewis, I.; Kent, S. B. H. Science 1994, 266, 776-779.
(57) Kochendoerfer, G. G.; Kent, S. B. H. Curr. Opinion. Chem. Biol. 1999, 3, 665-671.
(58) Dawson, P. E.; Kent, S. B. H. Ann. Rev. Biochem. 2000, 69, 923-960.
(59) Coltart, D. M. Tetrahedron 2000, 56, 3449-3491.
(60) Yeo, D. S. Y.; Srinivasan, R.; Chen, G. Y. J.; Yao, S. Q. Chem. Eur. J. 2004, 10, 4664-4672.
(61) Bang, D.; Kent, S. B. H. Proc. Natl. Acad. Sci., U.S.A. 2005, 102, 5014-5019.
(62) Bang, D.; Kent, S. B. H. Angew. Chem. Int. Ed. 2004, 43, 2534-2538.
(63) Dose, C.; Seitz, O. Org. Lett. 2005, 7, 4365-4368.
(64) Johnson, E. C. B.; Durek, T.; Kent, S. B. H. Angew. Chem. Int. Ed. 2006, 45, 3283-3287.
(65) Johnson, E. C. B.; Kent, S. B. H. J. Am. Chem. Soc. 2006, 128, 6640-6646.
(66) Brik, A.; Yang, Y.-Y.; Ficht, S.; Wong, C.-H. J. Am. Chem. Soc. 2006, 128, 5626-5627.
(67) Brik, A.; Ficht, S.; Yang, Y.-Y.; Bennett, C. S.; Wong, C.-H. J. Am. Chem. Soc. 2006, 128, 15026-15033.
(68) Yan, L. Z.; Dawson, P. E. J. Am. Chem. Soc. 2001, 123, 526-533.
(69) Hondal, R. J.; Nilsson, B. L.; Raines, R. T. J. Am. Chem. Soc. 2001, 123, 5140-5141.
(70) Botti, P.; Carrasco, M. R.; Kent, S. B. H. Tetrahedron Lett. 2001, 42, 1831-1833.
(71) Clive, D. L. J.; Hisaindee, S.; Coltart, D. M. J. Org. Chem. 2003, 68, 9247-9254.
(72) Tchertchian, S.; Hartley, O.; Botti, P. J. Org. Chem. 2004, 69, 9208-9214.
(73) Chen, G.; Warren, D. J.; Chen, J.; Wu, B.; Wan, Q.; Danishefsky, S. J. J. Am. Chem. Soc. 2006, 128, 7460-7462.
(74) Wu, B.; Chen, J.; Warren, J. D.; Chen, G.; Hua, Z.; Danishefsky, S. J. Angew. Chem. Int. Ed. 2006, 45, 4116-4125.
(75) Kenyon, G. L.; Bruice, T. W. Methods Enzym. 1977, 47, 407-430.
(76) Wynn, R.; Richards, F. M. Methods Enzym. 1995, 251, 351-356.
(77) Faulstich, H.; Heintz, D. Methods Enzym. 1995, 251, 357-366.
(78) Macindoe, W. M.; van Oijen, A. H.; Boons, G.-J. Chem. Commun. 1998, 847-848.
(79) Grayson, E. J.; Ward, S. J.; Hall, A. J.; Rendle, P. M.; Gamblin, D. P.; Batsanov, A. S.; Davis, B. G. J. Org. Chem. 2005, 70, 9740-9754.
(80) Gamblin, D. P.; Garnier, P.; van Kasteren, S.; Oldham, N. J.; Fairbanks, A. J.; Davis, B. G. Angew. Chem. Int. Ed. 2004, 43, 828-833.
(81) Gamblin, D. P.; Garnier, S. J.; Ward, N. J.; Oldham, A. J.; Fairbanks, A. J.; Davis, B. G. Org. Biomol. Chem. 2003, 1, 3642-3644.
(82) Ludolph, B.; Eisele, F.; Waldmann, H. J. Am. Chem. Soc. 2002, 124, 5954-5955.
(83) Zhu, Y.; van der Donk, W. A. Org. Lett. 2001, 3, 1189-1192.
(84) Thayer, D. A.; Yu, H. N.; Galan, M. C.; Wong, C.-H. Angew. Chem. Int. Ed. 2005, 44, 4596-4599.
(85) Jobron, L.; Hummel, G. Org. Lett. 2000, 2, 2265-2267.
(86) Pachamuthu, K.; Zhu, X.; Schmidt, R. R. J. Org. Chem. 2005, 70, 3720-3723.
(87) Cohen, S. B.; Halcomb, R. L. Org. Lett. 2001, 3, 405-407.
(88) Cohen, S. B.; Halcomb, R. L. J. Am. Chem. Soc. 2002, 124, 2534-2543.
(89) Galonic, D. P.; van der Donk, W.; Gin, D. Y. J. Am. Chem. Soc. 2004, 126, 12712-12713.
(90) Galonic, D. P.; Ide, N. D.; van der Donk, W. A.; Gin, D. Y. J. Am. Chem. Soc. 2005, 127, 7359-7369.
(91) Palomo, J. M.; Lumbierres, M.; Waldmann, H. Angew. Chem. Int. Ed. 2006, 45, 477-481.
(92) Durek, T.; Alexandrov, K.; Goody, R. S.; Hildebrand, A.; Heinemann, I.; Waldmann, H. J. Am. Chem. Soc. 2004, 126, 16368-16378.
(93) Kragol, G.; Lumbierres, M.; Palomo, J. M.; Waldmann, H. Angew. Chem. Int. Ed. 2004, 43, 5839-5842.
(94) Crich, D.; Krishnamurthy, V.; Hutton, T. K. J. Am. Chem. Soc. 2006, 128, 2544-2545.
(95) Crich, D.; Brebion, F.; Krishnamurthy, V. Org. Lett. 2006, 8, 3593-3596.
(96) Moore, C. G.; Trego, G. R. Tetrahedron 1962, 18, 205-218.
(97) Evans, M. B.; Higgins, G. M. C.; Moore, C. G.; Porter, M.; Saville, B.; Smith, J. F.; Trego, B. R.; Watson, A. A. Chem . & Ind. 1960, 897.
(98) Blackburn, G. M.; 011 is, W. D. J. Chem. Soc., Chem. Commun. 1968, 1261-1262.
(99) Barnard, D.; Houseman, T. H.; Porter, M.; Tidd, B. K. J. Chem. Soc., Chem. Commun. 1969, 371-372.
(100) Pilgram, K.; Phillips, D. D.; Korte, F. J. Org. Chem. 1964, 29, 1844-1847.
(101) Höfle, G.; Baldwin, J. E. J. Am. Chem. Soc. 1971, 93, 6307-6308.
(102) Kutney, G. W.; Turnbull, K. Chem. Rev. 1982, 82, 333-357.
(103) Evans, D. A.; Andrews, G. C. Acc. Chem. Res. 1974, 7, 147-155.
(104) Baechler, R. D.; Hummel, J. P.; Mislow, K. J. Am. Chem. Soc. 1973, 95, 4442-4444.
(105) Block, E.; Iyer, R.; Grisoni, S.; Saha, C.; Belman, S.; Lossing, F. P. J. Am. Chem. Soc. 1988, 110, 7813-7827.
(106) Sharpless, K. B.; Lauer, K. B. J. Org. Chem. 1972, 37, 3973-3974.
(107) Riague, E. H.; Guillemin, J.-C. Organometallics 2002, 21, 68-73.
(108) Stoner, E. J.; Negrón, G.; Gaviño, R. In Handbook of Reagents for Organic Synthesis: Reagents for Glycoside, Nucleotide, and Peptide Synthesis ; Crich, D., Ed.; Wiley: Chichester, 2005, pp 330-338.
(109) Klayman, D. L.; White, J. D.; Sweeney, T. R. J. Org. Chem. 1964, 29, 3737-3738.
(110) Milligan, B.; Swan, J. M. J. Chem. Soc. 1963, 6008-****.
(111) Harpp, D. N.; Gleason, J. G. J. Am. Chem. Soc. 1971, 93, 2437-2445.
(112) Patarasalculchai, N.; Southwell-Keely, P. T. Phosphorus and Sulfur 1985, 22, 277-282.
(113) Klayman, D. L.; Günther, W. H. H., Eds. Organic selenium compounds: their chemistry and biology ; Wiley Interscience: New York, 1973.
(114) Clark, E. R.; Al-Turaihi, M. A. S. J. Organomet. Chem. 1977, 134, 181-187.
(115) Guillemin, J. C., Bouayad, A., Vijaykumar D. ChemComm 2000, 13, 1163-1164.
(116) Emerson, D. W.; Booth, J. K. J. Org. Chem. 1965, 30, 2480-2481.
(117) Ferrier, R. J.; Vethaviyaser, N. J. Chem. Soc. (C) 1971, 1907-1913.
(118) Zysman-Colman, E.; Nevins, N.; Eghbali, N.; Snyder, J. P.; Harpp, D. N. J. Am. Chem. Soc. 2005, 128, 291-304.
(119) Garmaise, D. l.; Uchiyama, A.; McKay, A. F. J. Org. Chem. 1962, 27, 4509-4512.
(120) Ferrier, R. J.; Vethaviyasar, N. J. Chem. Soc., Chem. Commun. 1970, 1385-1387.
(121) Hackler, R. E.; Balko, T. W. J. Org. Chem. 1973, 38, 2106-2110.
(122) Harano, K.; Taguchi, T. Chem. Pharm. Bull. 1975, 23, 467-472.
(123) Harano, K.; Taguchi, T. Chem. Pharm. Bull. 1972, 20, 2348-2356.
(124) Harano, K.; Taguchi, T. Chem. Pharm. Bull. 1972, 20, 2357-2365.
(125) Nakai, T.; Mimura, T.; Ari-Izumi, A. Tetrahedron Lett. 1977, 2425-2428.
(126) Ueno, Y.; Sano, H.; Okawara, M. Tetrahedron Lett. 1980, 21, 1767-1770.
(127) Eto, M.; Tajiri, O.; H., N.; K., H. Tetrahedron 1998, 54, 8009-8014.
(128) Nakai, T.; Ari-Izumi, A. Tetrahedron Lett. 1976, 17, 2335-2338.
(129) Harano, K.; Ohizumi, N.; Hisano, T. Tetrahedron Lett. 1985, 26, 4203-4206.
(130) Talgoy, M. M.; Bell, A. W.; Duckworth, H. W. Can. J. Biochem. 1979, 57, 822-833.
(131) Kimura, T.; Matsueda, R.; Nakagawa, Y.; Kaiser, E. T. Anal. Biochem. 1982, 122, 274-282.
(132) Brzezinska, E.; Ternay, A. L. J. Org. Chem. 1994, 59, 8239-8244.
(133) Rabanal, F.; DeGrado, W. F.; Dutton, P. L. Tetrahedron Lett. 1996, 37, 1347-1350.
(134) Watson, A. A. J. Chem. Soc. (C) 1964, 2100-2107.
(135) Morrison, N. J. J. Chem. Soc ., Perkin Trans. 11984, 101-106.
(136) Nakai, T.; Mikami, K. Chem. Rev. 1986, 86, 885-902.
(137) Nakai, T.; Mikami, K. In Org. React .; Paquette, L. A., Ed.; John Wiley & Sons: New York, 1994; Vol. 46, pp 105-209.
(138) Mikami, K.; Nakai, T. Synthesis 1991, 594-604.
(139) Barrett, A. G. M.; Barton, D. H. R.; Johnson, G.; Nagubandi, S. Synthesis 1978, 741.
(140) Boucaut, J.-C.; Darribère, T.; Poole, T. J.; Aoyama, H.; Yamada, K. M.; Thierry, J. P. J. Cell. Biol. 1984, 99, 1822-1830.
(141) Yamada, K. M.; Kennedy, D. W. J. Cell. Biol. 1984, 99, 29-36.
(142) Casey, P. J. Science 1995, 266, 221-.
(143) Kale, T. A.; Hsieh, S.-a. J.; W., R. M.; Distefano, M. D. Curr. Top. Med. Chem. 2003, 3, 1043-1074.
(144) Brunsveld, L.; Kuhlmann, J.; Alexandrov, K.; Wittinghofer, A.; Goody, R. S.; Waldmann, H. Angew. Chem. Int. Ed. 2006, 45, 6622-6646.
(145) Bodanszky, M.; Bodanszky, A. The Practice of Peptide Synthesis; 2nd ed.; Springer-Verlag: Heidelberg, 1994.
(146) Goodman, M.; Mahwah, A. F.; Moroder, L.; Toniolo, C., Eds. Houben-Weyl. Methods in Organic Chemistry. Synthesis of Peptides and Peptidomimetics ; Thieme: Stuttgart, 2002-2003; Vol. E22a-e.
(147) Schnolzer, M.; Alewood, P.; Jones, A.; Alewood, D.; Kent, S. B. H. Int. J. Peptide Protein Res. 1992, 40, 180-193.
(148) Clippingdale, A. B.; Barrow, C. J.; Wade, J. D. J. Pept. Sci. 2000, 6, 225.
(149) Kajihara, Y.; Yoshihara, A.; Hirano, K.; Yamamoto, N. Carbohydr. Res. 2006, 341, 1333-1340. | A dechalcogenative method for the preparation of an allylic sulfide comprises contacting an activated chalcogenide of Formula (I) with a thiol of Formula (II) for a period of time sufficient to form an intermediate of Formula (III), and supplying sufficient activation energy to the intermediate of Formula (III), in a suitable solvent, preferably in the absence of a phosphine or other thiophile, to induce a [2,3]-sigmatropic rearrangement therein to form an allylic sulfide of Formula (IV), with concomitant loss of chalcogen Z, as set forth in the following reaction scheme, wherein X is an activating group selected from the group consisting of CN, S-pyridyl, S-heteroaryl, SO2-aryl, and SO3Y; Y is an alkali metal ion; Z is Se or S; R1, R2, R3, R4, and R5 are each independently H or a hydrocarbon moiety; and R is an organic moiety. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a controlled-deflection type of roll used to process traveling webs, such as paper in a papermaking machine. More particularly, this invention relates to a controlled deflection roll which operates at elevated temperatures to heat the web. Even more particularly, this invention relates to a barrier within such a controlled-deflection roll which separates the extremely hot hydraulic fluid used to actuate the roll shell deflection apparatus, and the heat of the hydraulic fluid, from the bearing lubricant. Still more particularly, this invention relates to a barrier having one or more fluid chambers which contain a cooling liquid which is separate from either the internal hydraulic fluid or the bearing lubricant and which establishes a heat barrier between the internal hydraulic fluid and the bearing lubricant.
2. Description of the Prior Art
As controlled-deflection rolls have developed, and as papermaking has evolved into a more efficient hot-press water removal technology, the operating temperatures of controlled-deflection rolls have increased, particularly in the press section of a papermaking machine to remove moisture, and in the calender section to improve sheet properties. In early designs of controlled deflection rolls, the same oil was often used to both lubricate the bearings and the interface between the shoe, or shoes, which move against and support the roll shell to modify its deflection to maintain the profile of the roll shell along its nip line of contact with a mating roll in a desired contour. The operating temperatures were not excessively high because nip pressures were generally lower, rolls were generally shorter in length, speeds were lower, and the rolls in the press and calender sections in a papermaking machine were not run hot. Often, more than one of these factors was present.
as nip pressures and machine speeds increased, and as papermaking machines became wider, and with the advent of so-called hot pressing wherein the press section of the papermaking machine is desired to run hotter in order to enhance the removal of as much moisture from the traveling paper web as far upstream in the papermaking process as possible, the operating temperature of the hydraulic actuating fluid within controlled-deflection rolls increased to a level beyond that at which the roll shell support bearings, and their lubricant, could operate at the load levels and service life required of them. Similarly, modern calendering techniques also utilize higher roll temperatures. Even if special high temperature bearing lubricant was used, its exposure to either the thinner, less viscous hydraulic fluid used to actuate the deflection correcting apparatus and lubricate its interface with the roll shell, or to the temperature of the hydraulic fluid, or both, was deleterious to the lubrication of the bearings and to their service life. Further, merely sealing the roll shell support bearings from physical contact with the internal hydraulic fluid does not insulate the bearings from the deleterious effects of the increased heat of the hydraulic fluid.
In some prior lubrication arrangements in controlled-deflection types of rolls, the bearings were lubricated with oil which, in turn, was directed into the roll where it either was used to actuate the roll shell support shoe, or mixed with such oil before they were recirculated out of the roll. While such an arrangement operates satisfactorily, it either requires the same lubricant to be used to lubricate the bearings and to actuate the shoe apparatus to control the roll shell deflection, or, if separate lubricants are used, they must necessarily be mixed within the roll and become undesirable for recirculation and subsequent use in either of these functions.
SUMMARY OF THE INVENTION
This invention is best utilized in the type of controlled deflection roll where the roll shell support roller bearings are replaced by hydrostatic bearings within the roll shell, such as shown and described in U.S. Pat. No. 4,821,384 (Arav), or where the roll shell support roller bearings are positioned outside of the roll end seals, such as shown and described in U.S. Pat. No. 4,837,907 (Roerig et al). The disclosure of both of these patents, which are commonly assigned with this invention, are hereby incorporated by reference to the extent which their disclosure complements the disclosure of this invention. This invention establishes a fluid barrier and heat shield between the bearings and the hot hydraulic fluid within the roll used to actuate the roll shell deflection correcting shoes or pistons. In certain types of configurations where drive gears rotate the roll shell, this invention also establishes a fluid barrier and heat shield between the drive gear on the roll and the hot hydraulic fluid. In a preferred embodiment, a hollow, two- chamber barrier is provided about the stationary roll shaft and the outer, rotating components of the roll. The barrier, which does not rotate, comprises inner and outer spool members which are mounted between the stationary shaft and a stationary seal sleeve, respectively, radially inwardly of the roll shell, or an extension thereof.
A cooling liquid is introduced into one of the circumferentially extending chambers and circulated in an outer, hollow cylindrical (annular) space extending about both chambers between the seal sleeve and roll shell which also conducts the cooling liquid into the second chamber from which it is removed from the roll.
The barrier is axially interposed between the inner cavity of the controlled deflection roll and the bearings rotatably supporting the bearing box, seal sleeve and gears, when used. The annular space between the barrier chambers is contiguous with the inner wall of the roll shell or its extension. The bearings and gears, being axially outside of the barrier, are thus isolated from the interior cavity of the roll, both physically and thermally, by the cooling liquid within the barrier chambers and annular space. This establishes a cooling zone. In a contemplated embodiment, the cooling liquid can be pressurized higher than the hydraulic fluid and circulated into, and out of, the inner cavity of the roll in a controlled manner by inward leakage past the chamber sealing surfaces to prevent hydraulic fluid within the roll from migrating to the bearings.
The barrier is capable of maintaining a cooling liquid barrier between the roll shell and roll shaft while providing both axial and radial movement of the roll shell relative to the roll shaft. This accommodates both radial movement of the roll shell during the nip loading, nip relieving or nip contour correction operations of the roll as well as axial expansion of the roll shell due to thermal expansion of the metallic components as the roll becomes heated. In addition, the apparatus accommodates both misalignment caused by shaft deflection during operation and rotary motion of the roll shell while providing rotational sealing of the roll shell.
Since the roll shell, or extension thereof, which is rotatably aligned relative to the bearing box and seal sleeve by bearings, has an inner surface in continuous contact with the cooling liquid to control the temperature of the metal contacting the bearings, a heat shield is established against the passage of heat either by conduction through metal or by contact with the flow of hydraulic fluid.
The bearing lubricant is completely isolated from both the cooling liquid in the barrier chambers and the hydraulic fluid in the roll cavity. Thus, like the bearings themselves, the temperature of the bearing lubricant can be controlled, as desired. In addition, the purity and lubricating characteristics of the bearing lubricant can be controlled independently of both the cooling liquid in the barrier chambers and the hydraulic fluid in the roll cavity.
Accordingly, an object of this invention is to provide a heat shield and liquid barrier between the hydraulic fluid used to actuate a controlled-deflection roll and the bearings rotatably supporting the bearing box, seal sleeve and gears, when used.
Another object of this invention is to provide a barrier for a controlled-deflection roll which accommodates rotary, radial, axial and misalignment motion while maintaining a heat shield and liquid barrier within the roll.
Still another object of this invention is to provide a barrier for a controlled-deflection roll which utilizes a cooling liquid which is separate from the bearing lubricant contour modifying capabilities of the roll shell
A feature of this invention is the provision of redundant rotational and misalignment seals between the bearings or drive gears and the interior of the controlled-deflection roll.
Another feature of this invention is the provision of a recirculated cooling liquid in conjunction with a barrier which can accommodate radial and rotary motion between the rotating roll shell and the stationary roll shaft, and misalignment of the shaft.
An object, feature and advantage of this invention is the provision of apparatus for cooling the roll shell, or extension thereof, intermediate the effective face surface of the roll shell and the bearings rotatably supporting the bearing box.
Still another object, feature and advantage of the invention is the added safety and reliability of the roll provided by utilizing seals at both ends of the cooling zone which effectively provides redundant sealing
These, and other objects, features and advantages of this invention will become readily apparent to those skilled in the art upon reading the description of the preferred embodiments in conjunction with the attached drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-elevational view, in section, of one end of a controlled-deflection roll showing a two-chamber barrier disposed intermediate the bearing box support bearings and the interior cavity of the roll.
FIG. 2 and FIG. 2A are end views, in section, of a controlled-deflection roll wherein the support shoes have moved the roll shell into nipping engagement with another roll (FIG. 2) and out of nipping engagement with a mating roll (FIG. 2A).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a controlled-deflection roll 10 has a stationary center shaft 12 which is fixedly mounted in a spherical bushing 14 which, in turn, is supported in a mounting, or stand, 16 which may take the form of a stationary mounting attached to the foundation, or structural framework in a papermaking machine, or mountings attached to movable arms in a papermaking machine.
Throughout this discussion, it is understood that both ends of the controlled-deflection roll described are essentially the same and that the barrier forming the basis of this invention can be located at either or, preferably, both ends of the roll. Accordingly, only one end of the controlled-deflection roll is shown and will be described
over the roll shaft and defines, with the shaft, a cavity 20 within the interior of the roll. Mounted within one or more openings in the roll shaft is one or more shoes 22,24 which are diametrically opposed and which are separately actuatable and deactuatable to move the roll shell translationally upwardly or downwardly and into, or out of, nipping engagement with a mating roll as shown in FIGS. 2, 2A. The manner in which the shoe, or shoes, 22,24 can be supplied with hydraulic fluid, or have hydraulic fluid removed therefrom, to move the shoes into, or out of, engagement with the inner surface 26 of the roll shell to either load the roll shell into nipping engagement with a mating roll, or to modify the roll shell deflection, or crown, contour is well-known to those skilled in the art and will, accordingly, not be discussed in further detail other than to show, somewhat schematically, the selective application of hydraulic fluid 28, such as oil, via conduits 29, 29a to shoes 22, 24 as designated by arrows 31,31a. Similarly, it is well understood within the papermaking trade that upper shoe 22, or lower shoe 24, can comprise a plurality of axially aligned shoes or a single shoe and can operate either hydrostatically or hydrodynamically at its, or their, interface with the interior surface of the roll shell. For the purposes of this invention, all that need be understood is that the interface of each of the one or more shoes supporting the roll shell into, or out of, nipping engagement N with a mating roll along the nip plane P is lubricated with the same hydraulic fluid which actuates the shoe, or shoes. The nip plane extends along the nip line of contact and the longitudinal axes of roll 10 and the mating roll 11.
The hydraulic fluid used to actuate and lubricate the support shoes 22,24 collects within the interior cavity 20 of the roll in a pool 28 which is shown near the end of the roll shell adjacent the shoe 24 and sealing structure comprising seals 30,32 and end caps 34,36.
For the purposes of this discussion, the effective face of the controlled-deflection roll can be said to begin at a point radially outwardly from the end of the shoe 22 beneath that portion of the shell and extend inwardly, as designated by F, to the corresponding place at the other end of the roll.
At the end of the roll shell, a hollow, cylindrical spacer 38 having axially inwardly and axially outwardly collars 40, 42 is attached to the end of the roll shell by suitable means, such as cap screws 44 to form an axial extension of the roll shell. The outer end of spacer 38 is attached to a bearing ring 46 in substantially the same manner. The bearing ring can also serve as a ring gear for rotatably driving the roll shell. A bearing box 48 encloses the bearing ring and defines a space about the bearing ring which is sealed radially outwardly and radially inwardly from the bearing ring with seals 50, 52. The bearing ring rotatably supports the bearing box with bearings 54, 56. Bearing lubricant 58 is completely enclosed about the bearings by the bearing box and bearing ring, and contained by seals 50, 52.
The bearing box is disposed about an end of the stationary roll shaft, but is spaced from the roll shaft by an annular opening 60 to permit translational movement perpendicular to the longitudinal axis 62 of the roll shaft which coincides with the axis of rotation 63 of the roll shell when the roll shell is centered about the roll shaft. The roll shell is not, therefore, necessarily rotatably supported by bearings 54, 56, but is aligned by the bearings with the bearing ring and bearing box.
Extending axially inwardly from the bearing box, and co-axial with bearings 54, 56, is a hollow, cylindrical seal sleeve 64. Bearings 54, 56 thus maintain alignment of the seal sleeve relative to the roll shell co-axially about the axis of rotation 63 of the roll shell In this discussion, the term "annular" will be used to refer to a hollow, cylindrical body or space, such as seal sleeve 64 and the space defined by the seal sleeve and roll shell 18. The seal sleeve is spaced inwardly from the inner wall 39 of spacer 38 to define an annular space 68 between the seal sleeve and spacer. The distal end 70 of the seal sleeve extends into the cavity 20 and does not bear against any structure or support in the longitudinal direction of the roll. A pair of spaced, circumferential rotary seals 69, 69a are mounted between the spacer and the seal sleeve to seal space 68 at either end of the seal sleeve.
The barrier, generally designated with the numeral 72, comprises an inner spool member 74, which can comprise more than one component part, and which has, in the preferred embodiment, three radially outwardly extending flanges 76a, 76b and 76c. It also comprises a corresponding outer spool member 78 mounted within the annular seal sleeve 64 and includes three corresponding radially inwardly extending flanges 80a, 80b and 80c. The inner and outer spool members are preferably made of metal and the corresponding flange pairs 76a, 80a, 76b, 80b, 76c, 80c are arrayed such that they radially overlap one another such that each flange of each pair is contiguous with its corresponding flange on the other spool. The flange pairs and inner and outer spool body members, therefore, define first and second liquid chambers 82, 84, respectively The overlapping flanges of the corresponding pairs can slide against one another radially inwardly and outwardly to permit chambers 82, 84 to be radially extensible
The outer surface 86 of the outer spool member is made with a large diameter radius to form a spherical surface. A pair of circumferentially extending, axially spaced seals 88, 88a are mounted between the outer spool member spherical surface 86 and the inner wall 90 of the seal sleeve 64. This permits the outer spool member to rotate slightly about an axis perpendicular to the nip plane P through the longitudinal axis 62 of the roll to accommodate misalignment of the roll shaft due to deflection without causing a corresponding movement of the seal sleeve 64. Since the inner spool member moves with the outer spool, this action also prevents relative movement, and loss of sealing engagement, between flanges 76a, 80a, 76b, 80b, 76c, 80c so that chambers 82, 84 remain sealed during roll shaft deflection.
The flanges in the inner and outer spool members define two axially spaced, circumferentially extending chambers 82, 84 within barrier 72. An opening 92 in the outer wall of the outer spool member, and a corresponding opening 94 in the seal sleeve, establish fluid communication between the first chamber 82 and the annular space 68. Similarly, a second opening 96 in the outer wall of the outer spool member axially inwardly of the opening 92, and a corresponding opening 98 in the seal sleeve, permit fluid communication between the annular space 68 and the second chamber 84.
An inlet supply bore 100 extending from the end of the roll shaft to an opening 101 in the first chamber 82 provides access from a pressurized source, such as a pump 102, of cooling liquid 103 to the first chamber 82. Similarly, a return bore 104 extending from outside the roll shaft provides a conduit for the cooling fluid to exit the second chamber 84 from a similar opening 105.
In operation, the center shaft 12 is maintained in a desired stationary position The roll shell is rotationally driven by a means, such as a motor driven gear (not shown) connected to the roll shell in a manner well-known to those skilled in the art. The manner in which the roll shell is rotated does not form part of the invention.
One, or the other, or both, of the roll shell support shoes 22, 24 is actuated by the application of a suitable hydraulic fluid, such as oil, to the appropriate shoe, or shoes, in a manner well-known to those skilled in the art to move the roll shell translationally into, or out of, nipping engagement with a mating roll, which nipping engagement is designated N in FIG. 2.
As the roll shell rotates and is moved into, and out of, nipping engagement with the mating roll, as shown in FIGS. 2 and 2A, barrier 72 is required to accommodate several types of movement of the component parts of the roll. It must accommodate translational movement of the roll shell radially inwardly and outwardly from the longitudinal axis 62; it must accommodate rotational movement of the roll shell and spacer relative to seal sleeve 64; it must accommodate misalignment of the roll shell/spacer relative to the center shaft due to deflection of the center shaft; and axial elongation of the component parts due to thermal expansion.
Since the distal end 70 of the stationary seal sleeve 64 extends into the roll cavity 20, axial elongation of the roll shell and spacer relative to the seal sleeve is accommodated by the spaced rotary seals 69, 69a between the spacer and seal sleeve which bear against the outer cylindrical surface 66 of the seal sleeve which is concentric with the longitudinal axis 63 of the roll shell. There is sufficient space 59 between the roll stand 16 and bearing box 48 to accommodate axial movement of the bearing box. The bearings and bearing box moves axially with the bearing ring.
The radially extending interfaces between corresponding sealing surfaces between flange pairs 76a, 80a; 76b, 80b; 76c, 80c accommodate radial movement of the roll shell as it is moved translationally by the application by pumps 33, 33a, or withdrawal, of hydraulic fluid to shoes 22, 24. This also permits the radially extensible change in shape of the barrier chambers 82, 84 while maintaining the chambers sealed. Thus, pressurized cooling liquid is supplied to the first chamber 82 via conduit 100, which is axially outside of second chamber 84, flows through chamber 82, out into annular space 68, inwardly into chamber 84 and out of the roll via conduit 104. The cooling liquid, thus, is brought into direct engagement with the inner surface 39 of spacer 38 to cool spacer 38, or to cool the inner surface of the end of shell 18 if a spacer is not utilized This inward flow of cooling liquid 103 within both annular space 68 and chambers 82, 84, in conjunction with rotary seals 69, 69a and the cooperating flanges in chambers 82, 84 effectively seals the hot hydraulic fluid 28 from physical contact with the bearings. In addition, the cooling zone, which extends substantially between rotary seals 69, 69a or the axial length of inner and outer spool members 74, 78, effectively shields the bearings from radiant heat from the hot hydraulic fluid and minimizes the conduction of heat through the barrier components themselves due to their relatively thin construction and intimate contact with cooling liquid
Thus, a heat shield between the hot hydraulic fluid within the roll cavity is established and maintained by this invention. Although the invention has been described using separate fluids for the bearing lubricant 58, cooling liquid 103 and hydraulic fluid 28, these fluids do not necessarily have to be different. What is important, and what is intended to be accomplished with this invention, is that the bearing lubricant be maintained separate from the cooling liquid which, in turn, is preferably maintained separate from the hydraulic fluid. This invention accomplishes this concept while accommodating the rotational, translational and misalignment movements of the roll during operation. However, as mentioned previously, it is contemplated, and within the scope of the invention, to pressurize the cooling liquid in the barrier chambers at a greater pressure than the hydraulic fluid applied to the support shoes to thereby maintain any seepage of cooling liquid relative to the hydraulic fluid in the direction inwardly into the roll cavity from where it is removed by means, such as a sump pump (not shown), which is well-known to those skilled in the art. Accordingly, it is contemplated that the cooling liquid and the hydraulic fluid could be the same liquid, if desired. Otherwise, in the preferred embodiment, the bearing lubricant, cooling liquid and hydraulic fluid are maintained separate and the heat shield is established and maintained.
Various modifications are contemplated which are intended to be within the scope of the invention. For example, the concept of providing radial extensibility to the barrier chambers 82, 84 could be provided by other means, such as walls made of flexible material extending between the inner and outer spools. Also, the barrier could comprise one or more chambers with direct contact with the spacer.
Finally, the barrier is intended to be generic to any controlled-deflection type of roll having need to separate the bearing lubricant and hydraulic fluid and where the roll shell can move outwardly, or translationally, relative to the roll shaft, or bow under nip profile control enough to otherwise create a leak for the hydraulic fluid to flow axially outwardly to the bearings. The barrier is, therefore, not limited to use in the so-called self-loading type of controlled deflection roll.
Accordingly, a heat barrier for a controlled-deflection roll has been shown and described which meets the stated objectives and exhibits the features and advantages set forth and others which will be readily apparent to those skilled in the art upon reading the specification, claims and viewing the attached drawings. | A controlld deflection roll has a unique liquid barrier and heat shield which includes a chamber filled with cooling fluid. In a preferred embodiment, the barrier comprises two chambers and a space in fluid communication with both chambers for circulating cooling fluid between the chambers and into and out of the roll. The barrier is interposed between the interior cavity of the roll containing the extremely hot hydraulic fluid which actuates the apparatus for controlling the deflection of the roll, and the bearings which rotatably align the roll shell relative to the space. The barrier, thus, functions to thermally insulate the bearings from heat, whether by radiation or by direct contact with the hydraulic fluid. | 3 |
RELATED APPLICATIONS
[0001] This is a continuation application of U.S. patent application Ser. No. 10/932,413, filed Sep. 2, 2004, which is a divisional application of U.S. Pat. No. 6,809, 960, commonly titled “High Speed Low Voltage Driver” and commonly assigned, the entire contents of which is incorporated herein by reference.
FIELD
[0002] The present invention relates generally to memory devices and in particular the present invention relates to drivers for memory circuits.
BACKGROUND
[0003] Memory devices are available in a variety of styles and sizes. Some memory devices are volatile in nature and cannot retain data without an active power supply. A typical volatile memory is a DRAM which includes memory cells formed as capacitors. A charge, or lack of charge, on the capacitors indicate a binary state of data stored in the memory cell. Dynamic memory devices require more effort to retain data than non-volatile memories, but are typically faster to read and write.
[0004] Non-volatile memory devices are also available in different configurations. For example, floating gate memory devices are non-volatile memories that use floating gate transistors to store data. The data is written to the memory cells by changing a threshold voltage of the transistor and is retained when the power is removed. The transistors can be erased to restore the threshold voltage of the transistor. The memory may be arranged in erase blocks where all of the memory cells in an erase block are erased at one time. These non-volatile memory devices are commonly referred to as flash memories.
[0005] The non-volatile memory cells are fabricated as floating gate memory cells and include a source region and a drain region that is laterally spaced apart from the source region to form an intermediate channel region. The source and drain regions are formed in a common horizontal plane of a silicon substrate. A floating gate, typically made of doped polysilicon, is disposed over the channel region and is electrically isolated from the other cell elements by oxide. For example, gate oxide can be formed between the floating gate and the channel region. A control gate is located over the floating gate and can also made of doped polysilicon. The control gate is electrically separated from the floating gate by another dielectric layer. Thus, the floating gate is “floating” in dielectric so that it is insulated from both the channel and the control gate.
[0006] In high performance flash memories, such as synchronous flash memories, large loads are selected in the memory array during a read or write cycle. These loads must be selected in a very short time. Further, as components continue to shrink, and as operating power continues to decrease, components that consume less power are also needed. In high performance memories, on each bitline of a memory array, there are gates for access transistors. In modem memories, there are on the order of 4000 bitlines. Each bitline has a pass transistor between a global bitline and the local bitline that is turned on for memory access in an active cycle of the memory. Turning on 4000 transistors creates a large capacitance that is turned on and off during each shift from bank to bank of a memory array during a read cycle of the memory. Typically, this row activation occurs every 20 nanoseconds. This can consume on the order of 10 or more milliamps of current.
[0007] A pumped voltage circuit supplies a voltage V pX for the gates of the pass transistors. This pumped voltage uses a supply voltage for the memory as its source. As supply voltages continue to drop, presently to on the order of 1.6 to 1.8 volts, pumping V pX to about 5 volts becomes increasingly less power efficient, especially if there is a current drain due to the large capacitance of 4000 bitline transistors, since V px is a pumped voltage and not a supply voltage. This pumped voltage is quickly drained of an unacceptable amount of current if it is used to supply the current required for loading 4000 bitlines. To supply 10 milliamps from the pumped voltage circuit requires on the order of 30 milliamps from V cC , which yields very low power efficiencies. The current that gets used for V px is very expensive.
[0008] The gates on the pass transistors need to be pulled up to V cc quickly to allow gate selection and activation within the very short time periods used in flash memories. Once a potential at or near V cc is present at the gates, they need to be raised to a voltage slightly above V cc , but time is not as critical for the final increase.
[0009] For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for a driver that does not tax the current of a pumped gate voltage supply.
SUMMARY
[0010] The above-mentioned problems with gate selection and power consumption in flash memories and other problems are addressed by the present invention and will be understood by reading and studying the following specification.
[0011] In one embodiment, a driver for a memory array includes an enable circuit providing an enable signal, a pull down transistor having its gate connected to the enable signal to ground an output node when the enable signal is disabled, and a pass transistor having its gate connected through a first p-type pull-up transistor connected between a pumped voltage and the gate of the pass transistor. An inverter is connected between the enable circuit output and the pass transistor, and a second pull down transistor is connected between ground and the gate of the pass transistor. Two inverters are coupled in series between the output of the first inverter and the gate of the second pull down transistor. A second p-type transistor is connected between the pumped voltage and the output node, the gate of the second p-type transistor connected to the gate of the pass transistor.
[0012] In another embodiment, a driver for a memory array pass transistor block includes a first path for providing a supply voltage to an output node upon initiation of a read cycle, and a second path for providing a pumped voltage to the output node after the output node receives the supply voltage, where the pumped voltage is greater than the supply voltage.
[0013] In yet another embodiment, a memory device includes an array of memory cells, control circuitry to read, write and erase the memory cells, and a driver circuit to control read access. The driver circuit includes a first path for providing a supply voltage to the output upon initiation of a read cycle, and a second path for providing a pumped voltage above the supply voltage after providing the supply voltage.
[0014] In still another embodiment, a flash memory device includes an array of floating gate memory cells, control circuitry to read, write and erase the floating gate memory cells, and a driver circuit to control read access. The driver circuit includes a NAND gate providing a read signal, a pull down transistor having its gate connected to the read signal, to ground an output node when the read signal is disabled, a pass transistor having its gate connected through a first p-type pull-up transistor connected between a pumped voltage and the gate of the pass transistor, an inverter connected between the NAND gate output and the pass transistor, a second pull down transistor connected between ground and the gate of the pass transistor, a series connection of two inverters connected between the output of the first inverter and the gate of the second pull down transistor, and a second p-type transistor connected between the pumped voltage and the output node, the gate of the second p-type transistor connected to the gate of the pass transistor.
[0015] In yet another embodiment, a method of operating a circuit includes holding an output node at a low potential, and maintaining a pass transistor ready to supply the output node with a high potential during a read cycle. A supply voltage is passed to the output node without using a pumped voltage upon initiation of the read cycle, and a pumped voltage is passed to the output node to elevate the output node voltage above the supply voltage once the output node reaches the supply voltage.
[0016] In still yet another embodiment, a method of operating a read cycle in a memory includes supplying an output voltage to the gates of an array of pass transistors of a memory array, the output voltage ramped to a supply voltage without using a pumped voltage, and raised above a supply voltage with a pumped voltage.
[0017] In another embodiment, a method of providing a gate voltage for pass transistors of a memory array includes providing a supply voltage substantially immediately upon initiation of a read cycle, and delaying supplying a pumped voltage to raise the gate voltage above the supply voltage until the gate voltage has reached the supply voltage.
[0018] Other embodiments are described and claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1A is a block diagram of an embodiment of the present invention;
[0020] FIG. 1B is a circuit diagram of an embodiment of the present invention;
[0021] FIG. 2 is a block diagram of a memory according to an embodiment if the present invention; and
[0022] FIG. 3 is a block diagram of a memory according to another embodiment of the present invention.
DETAILED DESCRIPTION
[0023] In the following detailed description of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention.
[0024] In addition, as the structures formed by embodiments in accordance with the present invention are described herein, common semiconductor terminology such as N-type, P-type, N+ and P+ will be employed to describe the type of conductivity doping used for the various structures or regions being described. The specific levels of doping are not believed to be germane to embodiments of the present invention; thus, it will be understood that while specific dopant species and concentrations are not mentioned, an appropriate dopant species with an appropriate concentration to its purpose, is employed.
[0025] The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
[0026] FIG. 1A shows an embodiment of a circuit 100 that is responsive to an enable signal 102 , supplied from an external source. The enable signal activates the output of the circuit 100 . Circuit 100 comprises a first branch 104 and a second branch 106 . In one embodiment, the first branch supplies a supply voltage at an output node 108 , ramping the supply voltage up to a potential at or near the supply voltage for an appropriate circuit to be controlled by the output voltage, and the second branch supplies a pumped voltage above the supply voltage of the first branch.
[0027] First branch 104 , when active, ramps the potential of output node 108 to at or near a supply voltage. When second branch 106 is active, it ramps the potential of the output node from the voltage at or near the supply voltage to a potential above the current output voltage using a pumped voltage supply. In one embodiment, the circuit switches from the first branch as a supply for the output node to the second branch as a supply for the output node once a predetermined threshold potential at the output node is reached. In another embodiment, the circuit switches from the first branch as a supply for the output node to the second branch as a supply for the output node once a predetermined time has elapsed with the first branch actively supplying a voltage to the output node. In one embodiment, the first branch ramps the output potential quickly to at or near the supply voltage.
[0028] In one embodiment, a circuit 150 for providing an output voltage slightly above a supply voltage V cc from an elevated voltage, V px or V h , is shown in FIG. 1B . V px is typically generated using a pump circuit (not shown) and is greater than V cc . For purposes of the present invention, V pX can be generated using any technique including an external supply. Circuit 150 includes a NAND gate 152 that has two inputs. When the inputs to the NAND gate 152 are in a state to provide a high output from the NAND gate, pull down transistor 154 , which is gate connected to the NAND output, is turned on and the output voltage (node 156 ) is pulled to ground. The output node 156 is connected to the gate of p-type transistor 158 , which when NAND output is high, is turned on and passes a high voltage through transistor 158 to the gate of pass transistor 160 , which is therefore turned on.
[0029] The same high voltage at the gate of p-type transistor 162 keeps it off. The output of NAND gate 152 is passed through a series of first, second, and third inverters 164 , 166 , and 168 , respectively. Inverter 164 output is low when NAND gate output is high, keeping a low potential at node 170 connected to pass transistor 160 . The signal is inverted twice, in inverters 166 and 168 , from low to high to low high again at the output from inverter 168 . In a steady state, transistor 171 is off when NAND gate 152 output is high, keeping node 172 high due to the pass through of high potential through transistor 158 .
[0030] Inverter 164 is in one embodiment a very strong PMOS inverter. The strength of the inverter 164 assists in raising the voltage at node 156 to near V cc in as fast a time as possible. The node 170 has an inherent rise time from its ground voltage to near V cc that depends upon the capacitance value seen at the node 156 , that is the capacitance buildup due to the load at node 156 . Node 170 rises with an RC time constant which is the time constant for node 156 to charge to V cc .
[0031] The inputs to NAND gate 152 are provided by a pass transistor control circuit such as circuit 174 shown in FIG. 1B . Pass transistor control circuit determines when the output node voltage is to be supplied to the pass transistors, and is one embodiment dependent upon the control circuitry for a memory. When the pass transistors are to be turned on, the control circuit 174 issues inputs to the NAND gate to force the NAND gate output low. An enable circuit according to one embodiment comprises a control circuit such as circuit 174 coupled to a NAND gate such as gate 152 .
[0032] When the output of NAND gate 152 switches to low, transistor 154 shuts off. Inverter 164 generates a high signal at node 170 which is very quickly passed through pass transistor 160 as pass transistor 160 is already on as discussed above. In one embodiment, the inverter 164 is a large inverter. In this embodiment, the size of inverter 164 creates a strong and fast ramp up of the voltage at the output node 156 to near V cc . As the voltage ramps up to V cc at output node 156 , the increasing voltage begins to and eventually fully shuts off transistor 158 . The output from inverter 164 also passes through time delay inverters 166 and 168 , which in one embodiment are chosen in size to be trip point detectors. The first inverter 166 in one embodiment has a skewed trip point. Inverter 166 does not trip until its input nears V cc , for example, and then it trips the inverter 168 for an additional delay before switching off the pass transistor 160 by operation of the pull down transistor 171 . The delays can therefore be chosen to allow the output node voltage to rise to near Vcc without using current from the pumped voltage V px .
[0033] The delay on inverters 166 and 168 is controlled by the rise time of node 170 . For example, a typical rise time for nodes 156 and 170 to charge to V cc is about two (2) nanoseconds. In one embodiment, the delays for the inverters are about 200 picoseconds each. The trip point of inverter 166 is set high in one embodiment, and the inverter will not trip until about one (1) nanosecond has elapsed. The inverters 166 and 168 are in other words a detector. The line voltage at node 170 has to reach a certain threshold before the inverter 166 trips.
[0034] The trip points of inverters 166 and 168 are chosen in one embodiment to allow the output node to charge to a predetermined potential level at or near V cc before switching off pass transistor 160 and completing a ramp to a potential above V cc using smaller transistor 162 which draws current from the pumped voltage supply (V px ) as opposed to the supply voltage (V cc ).
[0035] Once the output signal from inverter 164 passes through the inverters 166 and 168 , a high signal is presented at the gate of transistor 171 , which turns transistor 171 on, pulling node 172 to ground and shutting off pass transistor 160 . The low potential at node 172 turns on transistor 162 , and transistor 162 passes pumped voltage V px to output node 156 . However, since the output node 156 is already at or near V cc , due to the ramp up from inverter 164 during the time delay for shutting off pass transistor 160 , the pumped voltage only has to provide enough current to pull up node 156 from V cc to a point slightly above V cc , for example a threshold voltage, V t , above V cc , instead of a full potential of on the order of 5 volts.
[0036] The circuit ramps the output node 156 voltage quickly to at or near V cc without relying on the pumped voltage, drawing most of its required current from V cc . The large inverter assists in ramping the output node voltage quickly to at or near V cc . When the output voltage reaches or nears V cc , depending upon the selectable timing from inverters 166 and 168 , the remaining voltage necessary above V cc is supplied by drawing on V px , but the initial ramp in the output node voltage is supplied by V cc .
[0037] A driver for the gates of pass transistors comprises in one embodiment a circuit driven by V px . When the circuit is disabled, that is the memory is not in a read cycle, the output of the driver is a ground voltage so that the gates of the pass transistors it drives are off. The circuit is ready during its disable phase to quickly pass a supply voltage V cc to the output when the circuit is enabled, and to use a pumped voltage to raise the output voltage above V cc once it gets close to V cc , but without requiring a large current draw from the pumped voltage which supplies the driver. The driver of the present embodiments obtains most of its current from the supply voltage, and only relies on the pumped voltage for the extra current to push the output above the supply voltage. It is sufficient to drive the output voltage slightly above V cc , such as to about a threshold voltage V t above V cc . Current usage from the pumped voltage drops to about 1/7 to ⅛ of previous solutions.
[0038] Flash memories using a voltage sensing in order to perform read and write operations are amenable to use with the driver described above. In one embodiment, a driver such as that described above provides the gate voltage for the pass transistors 202 of memory device 200 as is shown in FIG. 2 . The pass transistors connect global bitlines 204 to sense amplifiers 206 of memory device 200 . Memory array 208 is read through the use of the sense amps as is well known in the art. A driver circuit, such as driver circuit 150 described above, provides the gate voltage for the pass transistors. The driver provides a supply voltage nearly immediately upon enabling of the driver circuit. The driver circuit then provides a voltage slightly above the supply voltage, delayed to allow the voltage to rise to at or near V cc , after the gate voltage ramps up to at or near V cc without requiring a drain on the current of the pumped voltage that supplies the driver circuit.
[0039] FIG. 3 is a functional block diagram of a memory device 300 , of one embodiment of the present invention, which is coupled to a processor 310 . The memory device 300 and the processor 310 may form part of an electronic system 320 . The memory device 300 has been simplified to focus on features of the memory that are helpful in understanding the present invention. The memory device includes an array of memory cells 330 . The memory array 330 is arranged in banks of rows and columns.
[0040] An address buffer circuit 340 is provided to latch address signals provided on address input connections A 0 -Ax 342 . Address signals are received and decoded by row decoder 344 and a column decoder 346 to access the memory array 330 . It will be appreciated by those skilled in the art, with the benefit of the present description, that the number of address input connections depends upon the density and architecture of the memory array. That is, the number of addresses increases with both increased memory cell counts and increased bank and block counts.
[0041] The memory device reads data in the array 330 by sensing voltage or current changes in the memory array columns using sense/latch circuitry 350 . The sense/latch circuitry, in one embodiment, is coupled to read and latch a row of data from the memory array. Sense/latch circuitry 350 in one embodiment includes a driver circuit for the pass transistors of the sense/latch circuitry, such as that described above. Data input and output buffer circuitry 360 is included for bi-directional data communication over a plurality of data (DQ) connections 362 with the processor 310 .
[0042] Command control circuit 370 decodes signals provided on control connections 372 from the processor 310 . These signals are used to control the operations on the memory array 330 , including data read, data write, and erase operations. The flash memory device has been simplified to facilitate a basic understanding of the features of the memory. A more detailed understanding of internal circuitry and functions of flash memories are known to those skilled in the art.
[0043] Finally, it will be understood that the number, relative size and spacing of the structures depicted in the accompanying figures are exemplary only, and thus were selected for ease of explanation and understanding. Therefore such representations are not indicative of the actual number or relative size and spacing of an operative embodiment in accordance with the present invention.
CONCLUSION
[0044] A driver for a flash memory has been described that includes a combined voltage obtained mostly from a supply voltage, and only partially from a pumped voltage, so as to not tax the pumped voltage by drawing too much current therefrom.
[0045] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | A high speed high and low voltage driver provides an output voltage without taxing a pumped voltage. The pumped voltage is used only when the output node has risen substantially to a supply voltage without draining the pumped voltage. | 6 |
FIELD OF THE INVENTION
The present invention relates to circular knitting machines and more particularly to a jacquard control mechanism for cylinder needles, sinkers or dial needles.
BACKGROUND OF THE INVENTION
Circular knitting machines are of either the single knit type or the double knit type. Single knit circular knitting machines typically include a rotating needle cylinder with knitting needles slidably mounted in grooves therein and a sinker cap with sinkers slidably mounted in grooves therein mounted on top of the needle cylinder for rotation therewith. Double knit circular knitting machines include a rotating needle cylinder and a rotating dial associated therewith. The needle cylinder has cylinder needles slidably mounted in vertical grooves therein while the dial has dial needles slidably mounted in horizontal, radial grooves therein.
In co-pending U.S. patent application Ser. No. 08/771,519, filed Dec. 23, 1996, now Pat. No. 5,689,977 assigned to the assignee of this application and which is incorporated herein by reference, there is disclosed a jacquard pattern control mechanism for a single knit circular knitting machine for control of cylinder knitting needles and sinkers. While such jacquard pattern control mechanism constitutes a considerable advance over prior jacquard pattern control mechanisms, it still has various limitations and disadvantages. Among such limitations and disadvantages is an inability to be used to control dial needles because of the requirement that the control mechanism must be made smaller so that it will fit in the space available toward the center of the dial. Also, difficulty is frequently encountered with prior such pattern control mechanisms in moving the knitting instrumentalities to the welt, tuck and knit positions.
SUMMARY OF THE INVENTION
With the foregoing in mind, it is the object of the present invention to provide a jacquard pattern control mechanism for controlling all types of knitting instrumentalities and for moving such instrumentalities between all three positions thereof.
This object of the present invention is achieved by a jacquard control mechanism for a circular knitting machine of the single knit type or double knit type in which knitting instrumentalities are slidably movable in grooves between welt, tuck and knit positions and in which a rocker base is installed in each groove with each knitting instrumentality. A selector jack is positioned in each groove between the rocker base and the knitting instrumentality, and at least one rocker is mounted for rocking movement on the rocker base and having attractable portions. At least one pair of attractors or magnetic attracting means is provided in corresponding relation to the attractable portions of the rocker. The rocker base is moved as it engages with and disengages from the selector jack to shorten the stroke, making it possible to select the three positions of the knitting instrumentality. Control cams for controlling the knitting instrumentality, control cams for controlling the selector jack, and intermediate cams for the rocker base are all provided. Additional cams are provided for controlling the rocker.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds when considered in conjunction with the accompanying schematic drawings, in which:
FIG. 1 is a fragmentary, schematic view of a cam block and controlling cams of the jacquard control mechanism of the present invention;
FIG. 2 is a section taken substantially along line 2--2 of FIG. 1;
FIG. 3 is a fragmentary vertical section of a double knit circular knitting machine incorporating the pattern control mechanism of the present invention installed on the dial of the knitting machine;
FIG. 4 is an enlarged, somewhat schematic view of the dial needle, selector jack, rocker base and rocker of the jacquard pattern control mechanism shown in FIG. 3;
FIGS. 5A through 5F, inclusive, are sectional views taken substantially along lines 5A through 5F, inclusive, in FIG. 1;
FIG. 5G is a sectional view similar to FIG. 5F in a different operational position;
FIG. 5H is a sectional view similar to FIG. 5E in a different operational position;
FIG. 6 is a view similar to FIG. 1 of another embodiment of the jacquard pattern control mechanism and particularly a cam block and control cams for a knitting needle;
FIG. 7 is a view similar to FIG. 4 of a knitting needle and associated pattern control instrumentalities for use in the embodiment illustrated in FIG. 6;
FIG. 8 is a view similar to FIG. 6 of a further embodiment of the present invention; and
FIG. 9 is a view similar to FIG. 7 of the knitting needle and pattern control mechanism of the embodiment illustrated in FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more specifically to the drawings and particularly to FIGS. 1-5H, there is illustrated schematically and sectionally the core part of a circular knitting machine, generally indicated at 20, which incorporates the jacquard pattern control mechanism of the present invention. Circular knitting machine 20 includes a rotary needle cylinder 21 having a multiplicity of grooves (not shown) therein. A knitting needle 22 is mounted for vertical sliding movement in each of the grooves in the needle cylinder 21 (FIG. 3).
Circular knitting machine 20 further includes a cam block 23 mounted outside the needle cylinder 21 and mounts a needle cam 24 for raising and lowering the needles 22 between an active (knit) position and an inactive (welt) position. Additional cams may be provided for moving needles 22 to a tuck position.
A rotary dial 25 is mounted on top of the needle cylinder 21 and has a multiplicity of grooves (not shown) extending radially from the outer periphery to the inner periphery thereof. A dial needle 26 is slidably mounted in each of the grooves in dial 25 for movement between welt, tuck and knit positions. Dial needle 26 preferably has at least one butt 26a thereon and a semicircular indentation 26b in the upper surface thereof from which the butt 26a extends (FIG. 4).
A dial cam block 30 is mounted above the dial 25 and mounts on its lower surface dial needle control cams, generally indicated at 31, in facing relation to the grooves in dial 25. Dial needle control cams 31 include outer guard cams 32 and stitch cams 33 which define a cam track T 1 , for the butt 26a of dial needle 26. Stitch cams 33 are mounted for radial adjustment to control the density of the fabric.
A selector jack 34 is disposed in each dial groove in dial 25 outwardly of dial needle 26 (FIGS. 2-4). Selector jack 34 has a butt 34a thereon which has a first vertical edge 34b and a second vertical edge 34c (FIG. 4). Selector jack 34 has an inverse trapezoidal projection 34d from the side thereof opposite butt 34a. A circular projection 34e projects from the end portion of selector jack 34 opposite the end portion having butt 34a thereon, and projection 34e is received in indentation 26b on dial needle 26. Cam block 30 mounts selector jack control cams, generally indicated at 35, including cancelling cams 36, additional cancelling cams 37 and selector jack raising cams 38 defining a cam track T 2 . Cam track T 2 receives butt 34a on selector jack 34 and controls and moves selector jack 34.
A rocker base 40 (FIGS. 2-4) is slidably mounted in each dial groove partially outwardly of selector jack 34. Rocker base 40 includes an outer end section 41, the lower portion of which is received in the dial groove and the upper portion of which includes first and second spaced apart trapezoidal projections 41a and 41b which coact with projection 34d on selector jack 34. Additionally, rocker base 40 includes a butt 42 projecting upwardly therefrom. Butt 42 includes a first vertical edge 42a and a second vertical edge 42b. The outer end section 41 of rocker base 40 has a first indentation 41c between projections 41a and 41b and a second indentation 41d between projection 41b and the first vertical edge 42a of butt 42 to receive therein projection 34d of selector jack 34.
Rocker base 40 includes a medial section 43 having a central portion 43a and opposite end portions 43b and 43c. The lower portion of medial section 43 is received in the dial groove, and the central portion 43a has a recess or socket 43d in the upper portion thereof.
A rocker bar 44 is mounted on the medial section 43 of rocker base 40 for pivotal movement by a circular pivot protrusion 44a which is received in socket 43d. Rocker bar 44 has symmetrical opposite end portions 44b and 44c which are beveled, wedge-shaped at their outer extremities at 44d and 44e. The lower portions of opposite end portions 44b and 44c are bulbous-shaped and serve to engage the upper edges of end portions 43b and 43c of medial section 43 of rocker base 40 to limit the pivotal movement of rocker bar 44. The upper sections 44f and 44g of end portions 44b and 44c are magnetically attractable and are raised above the central portion of rocker bar 44.
Rocker base control cam 46 is carried by cam block 30 adjacent selector jack raising cam 38. Cam 46 has a first side edge 46a which is spaced from side edges 38a of cams 38 to define therewith a cam track T 3 which receives and controls butt 42 on rocker base 40.
Rocker base control cam 46 has a second side edge 46b which is positioned to engage wedge-shaped end 44d of rocker bar 44 when rocker bar 44 is pivoted to have end portion 44b extended. First side edge 46a of rocker base cam 46 has spaced apart indentations 46c and 46d therein which permit rocker base 40 to be moved inwardly a short distance. Second side edge 46b of rocker base cam 46 has protrusions 46e and 46f opposite indentations 46c and 46d to retract rocker bar 44 and thus rocker base 40.
A rocker bar guard cam 48 is mounted on cam block 30 and has a side edge 48a spaced from side edge 46b of rocker base cam 46 a distance equal to the length of rocker bar 44 and defining therewith a cam track T 4 . Side edge 48a engages the wedge-shaped end 44e when rocker bar 44 is pivoted to position end portion 44c in extended position. Cam 48 has spaced apart indentations 48b and 48c opposite and aligned with protrusions 46e and 46f on second side edge 46b of cam 46.
A magnetic attraction selection device, generally indicated at 50, is positioned immediately upstream of protrusions 46e and 46f of cam 46 and indentations 48a and 48b of cam 48 and above the path of travel of rocker bar 44 such that the rocker bar 44 on the rocker base 40 passes closely therebeneath.
Selection device 50 includes two pairs of magnetic attraction means 51 and 52 (FIG. 1) disposed in position to attract magnetically the magnetic attractable sections 44f and 44g, respectively, of rocker bar 44 when rocker bar 44 passes therebeneath. Preferably, the pairs of magnetic attraction means 51, 52 comprises permanent magnets 53, 54 in the center and first and second electromagnets 55, 56 and 57, 58 on opposite sides of permanent magnets 53, 54, respectively. Permanent magnets 53, 54 and electromagnets 55-58 are all supported by a support member 59. For a more complete description of this selection system, reference is made to application Ser. No. 08/771,519, now Pat. No. 5,689,977, incorporated herein by reference.
Referring now to FIGS. 5A-5H, a series of operations of the first embodiment of this invention will now be described. When an individual dial needle 26 and its associated selector jack 34, rocker base 40 and rocker bar 44 approach selection means 50, rocker cancelling cams 60, 61 place the rocker bar 44 in the neutral position shown in FIG. 5A. If it is desired to move dial needle 26 to the knit position, a signal is sent from a controller (not shown) to electromagnet 55 which attracts attractable portion 44f of rocker bar 44.
Rocker bar 44 then moves past electromagnet 55 and the wedge-shaped end 44d of rocker bar 44 engages protrusion 46e of side edge 46b of cam 46. Rocker bar 44 is thus pushed inwardly of the knitting machine 20 along with rocker base 40 (FIG. 5B). Selector jack 34 has the projection 34d thereon riding up on projection 41b of rocker base 40 as rocker base 40 moves to the left as seen in FIG. 5B. This positions butt 34a on selector jack 34 to engage first rising part 38a of selector jack raising cam 38 and selector jack 34 moves to the tuck position along with dial needle 26. Dial needle 26 is pivotally linked to selector jack 34 by portion 34e and recess 26b (FIG. 5C).
Next, signals are sent to electromagnet 57 which attracts attractable portion 44f of rocker bar 44 (FIG. 5D). As rocker bar 44 passes electromagnet 57, the wedge end 44d engages the second protrusion 46f of side edge 46b of cam 46 and rocker bar 44 and rocker base 40 are pushed inward (FIG. 5D). Such inward movement of rocker base 40 causes projection 34d on selector jack 34 to ride up on projection 41a on rocker base 41 (FIG. 5E). Butt 34a on selector jack 34 engages the second rising part 38b on cam 38, and selector jack 34 moves dial needle 26 from the tuck position to the knit position (FIG. 5F).
Once the dial needle 26 is moved to the knit position by the selector jack 34, it is lowered to the welt position by outer guard cam 32 and stitch cam 33 (FIG. 5G). The pattern selection means is then in position for the next needle selection cycle.
If it is desired that dial needle 26 be moved only to the tuck position, the dial needle 26 is moved to the tuck position as described above in connection with FIGS. 5A-5C. However, instead of electromagnet 57 being energized as described previously, electromagnet 58 is energized to attract attractable portion 44g of rocker bar 44 (FIG. 5H). At the same time, cancelling cam 36 in cam track T 2 pushes down butt 34a on selector jack 34 which causes projection 34d on selector jack 34 to remain in the recessed space between projection 41a and 41b. Concurrently, the opposite end of rocker bar 44 passes beneath projection 46f on side edge 46b of cam 46. Therefore, the dial needle 26 remains in the tuck position until dial needle 26 is lowered to the welt position by the stitch cam 33.
If it is desired for the dial needle 26 to maintain the welt position, signals are sent to electromagnet 56 which attracts attractable portion 44g of rocker bar 44. At the same time, cancelling cam 37 in cam track T 2 lowers butt 34a of selector jack 34 and selector jack projection 34d remains to the left of projection 41b on rocker base 41 (FIG. 5G). Concurrently, the opposite end of rocker bar 44 passes beneath projection 46e on side edge 46b of cam 46. The dial needle 26 will not be affected by the rocker base 40 and will not move from the welt position.
In FIG. 1, the lines T 1k , T 1t and T 1w indicate the tracks of butt 26a of dial needle 26 as it moves with dial 25 and as dial needle 26 is moved between these three positions. The lines T 3k , T 3t and T 3w indicate the tracks of butt 42 on rocker base 40 as rocker base 40 moves with dial 25 and is moved by cam projections 46e and 46f and by cam track T 3 to positions corresponding to the knit, tuck and welt positions of dial needle 26.
Referring now to FIGS. 6 and 7 in which another embodiment of the present invention is illustrated, there is shown a jacquard pattern mechanism for a knitting needle 126 which is slidably mounted in a groove in a knitting machine. In this same groove with needle 126 is a rocker base 140 on which is pivotally mounted a rocker bar 144. Rocker base 140 and rocker bar 144 control the needle 126 to be in either the knit position or the welt position.
Needle 126 has a butt 126a thereon which is controlled by needle control cams 131 which include outer guard cams 132, stitch cams 133 and needle raising cams 170 defining a cam track T 11 having a first branch T 11a and a second branch T 11b .
Rocker base control cams 138, 146 and 175 define a branched cam track T 31 having a first branch T 31a between rocker base raising cams 175 and cam 146 and branch T 31b between cams 175 and 138. Cam 146 has a first side edge 146a and a second side edge 146b. Second side edge 146b has a first projection 146c and a second projection 146d. Second side edge 146b and a cam 148 define a cam track T 41 in which the rocker bar 144 travels.
A first electromagnet 155 and a second electromagnet 156 are provided in cam track T 41 immediately upstream of first projection 146c on second side edge 146b of cam 146. Cancelling cams 160 and 161 precede the electromagnets 155 and 156.
If needle 126 is to remain in the welt position, electromagnet 155 is energized to attract attractable portion 144f of rocker bar 144. The wedge end 144d of rocker bar 144 engages first projection 146c of second side edge 146b of cam 146, and rocker bar 144 and rocker base 140 are moved inwardly or downwardly. Needle 126 is not affected by inward or downward movement of rocker base 140 and thus remains in the welt position T 11w by the butt 126a passing along branch T 11a of cam track T 11 .
If needle 126 is to be moved to the knit position, electromagnet 156 is energized to attract attractable portion 144g of rocker bar 144. The other end of rocker bar 144 passes beneath projection 146c on second side edge 146b of cam 146 and control butt 142 on rocker base 140 engages the upward slant 175a of rocker base raising cam 175 and moves upwardly. Butt 126a on needle 126 is moved upwardly and enters branch T 11b of cam track T 11 and engages needle raising cam 170 and moves to the knit position T 11k (FIG. 6). In this way, two positions, i.e. welt and knit positions, can be selected.
Preferably, needle raising cam 170 and rocker base raising cam 175 are supported by springs (not shown). Therefore, when an abnormal force is applied to these cams, they are pulled back, thereby avoiding any significant damage to the butt 142 on rocker base 140 or to butt 126a on needle 126.
If needle raising cam 170 is maintained in its pulled back position and electromagnet 156 is energized, rocker bar 144 will pivot such that the end opposite attractable member 144g will pass beneath projection 146c, and control butt 142 of rocker base 140 will engage rocker base raising cam 175 and raise needle 126 to the tuck position. Therefore, in this mode, the needle 126 can be selected for two positions, i.e. the welt and tuck positions.
Referring now to FIGS. 8 and 9, there is illustrated a further embodiment of this invention. In this embodiment, a knitting needle 226 is provided and has a butt 226a thereon. A selector jack 234 is substantially identical to the previously described selector jack 34 and has a butt 234a thereon. A rocker base 240 is also substantially identical to rocker base 40 and has a butt 242 thereon. A rocker bar 244 is pivotally carried by rocker base 240 and is substantially identical to rocker base 40.
Needle control cams 231 are provided and include outer guard cams 232, stitch cams 233, inner guard cams 280, and tuck cams 281, all of which define a cam track T 111 . Cam track T 111 receives butt 226a on needle 226 and moves needle 226 between the welt and knit positions.
Selector jack control cams 235 are provided on cam block 230 and include selector jack cancelling or deflecting cams 236 and 237 and selector jack raising cams 238. Selector jack raising cam 238 is formed in two parts, the first part 238a being a tuck-raising part and the second part 238b being a knit-raising part near the top of the tuck position.
For support needle selection of needle 226, selector jack 234 is caused to rise up part 238a of cam 238 to the tuck position. Part 238b of cam 238 is withdrawn to a position where it will not be engaged by butt 234a on selector jack 234 such that needle 226 remains in the tuck position. Needle butt 226a moves along tuck cam 281 and outer guard cam 232 until it engages inner guard cam 280 which causes the needle 226 to be lowered toward the welt position. The track of butt 226 of needle 226 along cam track T 111 is represented in FIG. 8 as T 111s while the welt position track is indicated as T 111w . This pattern selection mode permits the selection of two positions, i.e. the support position and the welt position. However, if inner guard cam 280 is withdrawn to a position out of the path of butt 226 of needle 226, then three positions can be selected.
As described herein, the pattern control mechanism of the present invention permits needle or other knitting instrumentality selection for three positions, i.e. welt, tuck and knit (or even support) based upon pattern signals from a controller to produce a jacquard fabric of a variety of different patterns. While principally described herein in association with dial needles, the present invention is not confined thereto, but can be widely applied to guiding selectively any knitting instrumentality, including cylinder needles, transfer needles, jacks, sinkers, etc. through at least two paths and usually three such paths.
The present invention provides numerous advantages not previously available. For example, the depth stroke of the rocker cam 146 can be decreased to the level equivalent to the stroke of projection 134d on selector jack 34 when it moves up projections 41a or 41b. The circumferential stroke of rocker cam 46 or 146 can also be shortened. As a result, the needle selecting parts of the needle selection mechanism necessary for selecting three positions can be made compact. Therefore, three positions of the needles can be selected using the same number of yarn feeds which heretofore could be selected for only two positions.
Additionally, prior needle selection mechanisms placed an inordinate load on the rocker bar during the knitting operation since all of the load on the needles was transferred to the rocker bar. In accordance with the present invention, that load is borne by the rocker base 140 and the rocker base raising cam 175. Therefore, the rocker 144 bears only the load of the weight of the rocker base 140 and of the rocker 144 itself.
In the drawings and specifications, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | A jacquard pattern control mechanism for a circular knitting machine in which knitting instrumentalities are selected in accordance with a jacquard pattern and are moved between three positions, namely, welt, tuck and knit positions, by a selector jack, a rocker base, a rocker bar pivotally mounted on the rocker base and control cams for controlling the knitting instrumentality, selector jack, rocker base and rocker bar and electromagnetic selection mechanisms that attract selected portions of the rocker bar to determine to which position the knitting instrumentality will be moved, and wherein the selection mechanisms are more compact and have shorter strokes to permit selection of all types of knitting instrumentalities and all three positions without reducing the number of yarn feeds. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a method for recovering high-viscosity oil from subsurface formations, and in particular, relates to a method for reducing the viscosity of the oil by the in-situ heating of an underlying salt water formation using heat produced by heat energy radiating nuclear waste materials.
It is well known in the petroleum industry that there are vast reservoirs of petroleum materials in the earth which have not been produced because the petroleum exists in a highly viscous and waxy state such that it cannot be pumped by conventional means. Such petroleum products include those known as tar sands, oil shale and asphalt rock. As a result of this common condition, many methods have been attempted for recovering the petroleum in such deposits. Among such methods is included increasing the temperature of the petroleum in-situ in the earth formation to lower its viscosity, thereby enabling conventional production methods to be used to recover the petroleum.
Prior methods have employed chemical heating means or electrical heaters suspended within the bore holes adjacent the petroleum-bearing strata, and the passage of electric current through the formation by the use of electrodes in the plurality of adjacent wells. Additionally, gases such as CO 2 have been pumped down into a well and into the oil-bearing formation to chemically combine with the oil and lower its viscosity, and in other applications the oil itself has even been ignited to produce heat and gases which would generate pressure to force the oil out of the formation into adjacent well bores while heating the viscous petroleum in the formation.
The above-mentioned prior art systems have met with only limited success for two primary reasons. First, the prior art arrangements have encountered major difficulties in supplying an adequate source of heat within the bore hole itself and ultimately to the formation over extended periods of time. Secondly, the prior art apparatus and methods for removing oil have lacked an efficient means for effectively transferring the heat from a heat source within the bore hole or limited area surrounding the bore hole to the petroleum-bearing strata itself. Such conventional heat sources as heretofore employed for these purposes are, from a thermo-dynamic standpoint, a point source of heat since the actual dimension of the heating source itself is practically negligible as compared to the size and volume of the surrounding formation.
In recent years, attempts to reduce the viscosity of the petroleum contained in subsurface strata have been directed to the use of nuclear reactions in which the greater portion of the energy released by the reactions is liberated as heat. One such method, described in U.S. Pat. No. 3,246,695, utilizes energy-radiating nuclear waste material placed within a bore hole to a point within the subsurface petroleum-bearing strata. As an added benefit, a use is found for radioactive wastes which in recent years has presented a serious disposal problem.
However, implacement of nuclear wastes within the petroleum-bearing strata must be carefully controlled in order to avoid increasing the temperature of the strata arbitrarily, thus charring the crude oil surrounding the implacement point and changing the permeability and flow characteristics of the formation. If such charring does occur, the removal of the petroleum may become even more difficult than prior to the application of the heat.
The disadvantages of the prior art, and especially the invention claimed in the afore-mentioned U.S. patent are overcome with the present invention and a method for reducing the viscosity of subsurface petroleum-bearing deposits is disclosed. More particularly, the method of the present invention permits use of higher concentrations of nuclear waste material without overheating or damaging the subsurface petroleum deposit and any problems related to possible radioactive contamination of the recovered petroleum is avoided, and a safe and convenient means is provided for disposing of spent nuclear waste material.
SUMMARY OF THE INVENTION
This invention is for an improved method of reducing the viscosity of petroleum situated in subsurface strata by utilizing the heat of reaction of nuclear waste material to elevate the temperature of an underlying water strata to cause a corresponding elevation of temperature in the petroleum-bearing strata overlying the water strata. The invention is particularly adaptable for use when the strata comprises a salt water formation underlying the oil-bearing structure.
A brief review of the sources of radioactive nuclear waste materials and their characteristics is necessary here. The use of nuclear energy in this country is progressing at a rapid pace, leading to the construction of numerous facilities which produce energy from nuclear fission. In a typical fission reactor, a neutron is absorbed by a fissionable material, resulting in fission of that material with a resulting release of energy and the production of other neutrons and other elements, both radioactive and inert. The elemental by-products are commonly referred to as fission products and accumulate within the reactor throughout the power generating lifetime of a particular fuel element. A wide variety of fission products are produced, the actual distribution of which depends upon the particular fission process utilized, with both long-lived and short-lived products. The short-lived products generally have half-lives measured in terms of hours whereas the longer-lived products have half-lives measured in terms of years. A further distinction between fission products is the mechanism by which they decay, i.e., the type of radiation which is immanated.
The actual distribution of fission products obtained from a given reactor will depend upon the specific fission process which occurs within the reactor. Hence, no generalization is attempted with respect to a particular mix of fission isotopes which might be available to use in the present invention. In all of the fission processes in use today, the fuel becomes expended at some time and must be removed from the reactor for processing. In all of the processes, the radioactive fission isotopes are separated from the fissionable materials for disposal, while the fissionable materials are recovered and processed into fuel elements for other reactors.
The fission products which remain after processing are generally the long-lived products since there is an appreciable delay between the time a fuel element is removed from a reactor and the time it is actually subjected to processing. The actual residue from the processing operation is voluminous and must be reduced in volume for efficient handling. This volume reduction can be accomplished by any number of conventional distillation techniques whereby the radioactive isotopes are further separated from non-radioactive material and concentrated into a form for disposal. Disposal of such material poses difficult environmental problems to prevent contamination of the atmosphere, or the earth.
The package of these concentrated isotopes requires careful consideration, balancing between the need to shield the environment from harmful radioactivity and the need to provide for removal of the heat generated from the decay processes. The radiation emitted by the fission products may be any of the three prevalent radiations: alpha, beta or gamma ray. Alpha radiation requires only a minor shielding but the capture of these rather "large" particles produces considerable heat generation. Beta radiation (electron emission) requires moderate shielding and again this capture results in significant heat generation. Gamma radiation (X-ray radiation) is the most penetrating of the radiations emitted and requires a heavy lead shielding which typifies most shielding installations. For purposes of the present invention, it would be desirable to prepare an isotope mix in which the beta and alpha radiations are predominant.
A table of radio-isotopic materials that possess the decay characteristics above discussed are provided in the Standard Handbook for Mechanical Engineers (Seventh Edition, 1967). Typically strontium and cesium are some of the more common fission products available in a sufficient quantity.
In a preferred embodiment, a bore hole is provided from the surface to a location within the selected salt water formation for accepting the nuclear waste material container, and, producing bore holes are provided that extend into the petroleum-bearing strata from the surface and in a preselected proximity to the heat producing bore hole.
Nuclear waste material, which has been packaged in a convenient form for shipment to the input bore hole location is positioned therein at a location below the oil bearing formation. Preferably the waste material is positioned within an underlying salt water layer. Alpha, beta and gamma particles given off by the nuclear waste material create heat which elevates the temperature of the salt water, thereby elevating the temperature of the overlying oil stratum by convection from the heated water.
The shielded package of radioactive isotopes must also provide for removal of the heat generated. Accordingly, it is felt that in actual practice, the present invention would probably require that limited quantities of radioactive waste materials be placed in shipping containers which can be adequately cooled by ambient conditions and thereafter assembled at the drill site into a final package for insertion into the selected strata or formation.
Once the nuclear waste material package is implaced in or adjacent to a salt water strata, heating can occur in a variety of ways. Direct heating will occur as a result of gamma ray emission from the relatively unshielded container. Heating of the container will occur due to the absorption of beta and alpha radiation. This heat will be transferred to the surrounding stratum by conduction through the rock and convection of the salt water within the stratum. As the temperature of the salt water elevates, convection elevates the temperature of the overlying petroleum-bearing strata, with the attendant reduction in the viscosity of the petroleum. The petroleum products can then be withdrawn in a conventional manner.
In summary therefore, it is a feature of the present invention to provide a method for thermally reducing the viscosity of hydrocarbon materials contained in a subsurface strata.
It is a further feature of the present invention to reduce the viscosity of hydrocarbon materials by elevating the temperature of the hydrocarbon-bearing strata through heating the underlying strata.
It is still another feature of the present invention to elevate the temperature of the strata underlying a hydrocarbon material strata through the use of reaction heat produced by nuclear waste materials.
Still another feature of the present invention is to elevate the temperature of the hydrocarbon-bearing formation without causing thermal damage to the formation.
These and other features and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited advantages and features of the invention are attained can be understood in detail, a more particular description of the invention may be had by reference to specific embodiments thereof which are illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate only typical embodiments of the invention and therefore are not to be considered limiting of its scope for the invention may admit to further equally effective embodiments.
In the drawings:
FIG. 1 is a cross-section of the earth at a point where a reservoir of entrapped petroleum having an underlying salt water strata lies some distance below the surface and depicts the method of the present invention.
FIG. 2 is a shipment container for radioactive materials intended for insertion into the selected earth strata.
FIG. 3 is a cross-sectional view of the container depicted in FIG. 2.
FIG. 4 is an insertion package assembled by interconnecting a plurality of the shipment containers depicted in FIG. 2.
FIG. 5 is a cross-sectional view of an alternative embodiment of the shipment containers depicted in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a preferred embodiment for heating a selected petroleum-bearing formation in-situ. A conventional bore hole 10 is shown extending from the surface of the earth 12 to a location within the selected salt water strata or formation 14. Bore hole 10 can be completed in a conventional manner by use of steel casing 11. The casing 11 may extend through bore hole 10, or in some applications, the casing 11 may terminate either at or just below the interface between the salt water formation 14 and the petroleum producing formation of interest 18.
A nuclear waste container 21 is assembled (as will be hereinafter described) at the well site and using conventional oil tool equipment, the container 21 will be lowered into bore hole 10 and implaced in the bore hole in the salt water formation 14. Bore hole 10, within formation 14, may be sealed by means of a conventional packer or sealing plate 13, and a cement plug 32 can be positioned above the seal 13 to seal the lower portion of the bore hole, containing nuclear waste container 21, from the remaining portion of the bore hole and to shield the remaining portion of the bore hole 10 from radiation.
A conventional producing bore hole 16 is shown extending from the earth's surface 12 and terminating within the petroleum-bearing formation 18. The producing bore hole 16 will also be conventionally cased or lined by a steel casing 11, and the portion of the bore hole 16 within the formation of interest 18, may also be cased by a suitable casing section 15. Casing section 15 may be conventionally perforated to form perforations 17 and to create cracks or fissures 19 into the formation 18. A tubing string 34 with a conventional pump 23 will be positioned within bore hole 16. Oil from formation 18, its viscosity lowered by the heat generated by nuclear waste container 21, will flow through the fissures 19 and perforation 17 into the interior of well bore 16 and accumulate in the well bore as a standing column of oil 21. The viscosity lowered oil can then be conventionally pumped to the surface of the earth by means of pump 23 cooperating with a conventional tubing string 34 having perforations 23, or other suitable openings for intake of the oil 21 for storage in an appropriate storage facility (not shown).
Once in position, nuclear waste package 21 will begin to heat the salt water formation 14 in a variety of ways. Direct heating of the salt water formation 14 will occur as a result of gamma ray emission from the relatively unshielded package 21. Heating of the package 21 will occur due to the absorption of alpha and beta radiation by the shielding material of package 21, the construction of which will be hereinafter described and by the nuclear waste material itself. Heat generated by alpha and beta radiation absorption within the nuclear waste material will be transferred to the shielding material of package 21 by conduction. The heated package 21 will transfer heat to the surrounding strata 14 by conduction through the rock, sand and clay constituents of formation 14 and by convection to the salt water within the formation. The primary mechanism for heating the salt water strata will be conduction through the surrounding rock structure. Thereafter, convection and vertical conduction of heat will transfer heat to the overlying oil strata 18 and serve to elevate the temperature of the overlying oil strata and thus reduce the viscosity of the oil in formation 18, which can then be removed in a conventional manner as hereinabove discussed.
It is anticipated that the nuclear waste material container 21 will be implanted in the bore hole 10 to remain for an extended period of time before sufficient heat has been supplied to raise the temperature of the surrounding structure sufficiently to significantly reduce the viscosity of the oil. It may also be desirable to include some mechanism for natural convection circulation of salt water from formation 14 through the interior of container 21 to insure proper cooling of the container and also increase the surface area which contacts the salt water in formation 14. It will also be apparent, that by drilling a plurality of bore holes 10 and disposing a plurality of nuclear waste packages 21 in a predetermined design or pattern throughout an oil-bearing reservoir, a comprehensive pattern of heating of the salt water formation 14 will be accomplished for heating a broad area of the petroleum-bearing formation 18. In addition, such heating of the petroleum materials in formation 18 may also release absorbed and trapped gases in the petroleum materials which may act to elevate the formation pressure and help provide a drive for the oil or petroleum substances into producing well bore 16. Further, it is also anticipated that other secondary and tertiary recovery methods could be used in conjunction with the present invention to recover the heated oil.
Referring now to FIGS. 2, 3 and 4, there is shown a suggested cylindrical container 20 designed to be filled with radioactive isotope waste material in any form, either a liquid, solid or gas. Container 20 may conveniently be made from a selected material, such as steel, having sufficient structural integrity to permit insertion of container 20 into the bore hole 10, without damage to the container which may result in release of the nuclear waste material into the bore hole 10. Further, as various nuclear waste materials have different radiation characteristics the density of the material used in forming container 20 and the wall thickness of the formed container 20 may be preselected to provide for the desired absorption of alpha and beta radiation. Container 20 has an interior chamber 22 sized to hold a predetermined amount of nuclear waste material. The amount of waste material carried within each cylinder will be determined by the maximum heat generated by the decay process of the radioactive isotopes, for insuring that each filled container 20 may be transported under ambient conditions without special need for means of cooling the container 20. One way in which to insure such removal of the heat generated by the waste nuclear material within container 20 is to provide sufficient surface area on container 20 that allows the heat to be conducted away by conduction through the container walls and thereafter transferred to the atmosphere by convection. One effective means of providing such increased surface area is by providing ribs or fins 25. If necessary, provisions for circulating a coolant through and around container 20 could be provided during transport, but this would greatly reduce the ability to transport the containers along commercial routes. Accordingly, in the actual practice of the present invention, it would probably require that limited quantities of radioactive isotopes be placed in containers 20 in order that the containers can be adequately cooled by ambient conditions and thereafter assembled and filled with additional isotope material at the bore hole site into a final package 21 for insertion in formation 14.
One extremity of container 20 is formed with a reduced diameter end portion 24 having external threads 26 for mating with the opposite end of another cylinder 20 having a recess 28 and threads 30. After transportation of the desired number of containers 20 to the bore hole site, a nuclear waste package 21 may now be prepared, if such a package was not suitable for shipment assembled as such. A suitable package 21 may be formed by connecting several containers 20 together into a string or column by means of the threaded portions 26 and 30 of each container 20. In this manner, an elongated nuclear waste package 21 may be assembled as shown in FIG. 4. The insertion package must include sufficient shielding (not shown) to protect the workmen at the earth's surface during the insertion of package 21 into bore hole 10, although this shielding probably need not necessarily accompany package 21 into wellbore 10. Subsequent recovery of package 21, if necessary, would be accomplished by withdrawing package 21 back into a suitable shielded structure at the earth's surface. Again, depending upon the final concentration of radioactive isotopes within package 21, an external cooling source may have to be provided for temperature maintenance of package 21 during insertion of the package into wellbore 10 and into the salt water formation 14. If a cement plug 32 is positioned above package 21 to seal the bore hole, as shown in FIG. 1, the package 21 could be recovered at a future time by drilling through plug 32 and grasping the package 21 with conventional downhole recovery tools.
Referring now to FIG. 5, an alternative shape 20' is suggested for the nuclear waste container. As depicted, the container 20' is formed to provide integral ribs or fins 25' and an interior cavity 22' shaped to correspond to the exterior surface of the container 20'. Again, interior chamber 22' is designed to hold a predetermined amount of nuclear waste material with the shape of interior chamber 22' permitting the nuclear waste material to be positioned within the fins 25'. This spreading of the nuclear waste material into the fins 25' reduces its concentrated mass, thereby reducing the absorption heat buildup within the material itself.
Further, container 20' may be formed with mating threads (not shown) at opposing extremities to permit the assembly of a nuclear waste package (not shown) as above-described for container 20. Use of this package will be as above-described for package 21.
It will be apparent from the foregoing description, that many other variations and modifications may be made in the method and apparatus described herein without substantially departing from the essential concept of the present invention. Accordingly, it should be clearly understood that the forms of the invention described herein and depicted in the accompanying drawings are exemplary only, and are not intended as limitations to the scope of the present invention. | A method and apparatus are provided for using heat generated by absorption of radiation from nuclear waste materials to reduce the viscosity of petroleum products contained within a subsurface earth formation. The nuclear waste material is positioned in a salt water formation underlying the subsurface earth formation so that the radiation emitted by the material heats the salt water formation. Conduction and convection transfer the heat to the subsurface earth formation, raising the temperature and thereby reducing the viscosity of the petroleum products. To prevent radioactive contamination within the salt water formation, the nuclear waste material may be encapsulated in a material selected to absorb alpha and beta radiation. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an integral document processing apparatus equipped with an image forming system and a facsimile transmission system and, more specifically, to an integral document processing apparatus equipped with an electrophotographic copying machine incorporating a facsimile transmission unit and having a document feeding unit which serves both as a document feeding unit for the copying machine and the facsimile transmission unit.
In a minor business firm or a small store, only one facsimile equipment is sufficient for transmitting and receiving message. However, in a large enterprise having many offices distributed on many floors in a building, one facsimile equipment is insufficient and hence such a large enterprise needs a plurality of facsimile equipments. It is expected that the use of facsimile equipments at different places in the same building will become more prevalent. When a plurality of facsimile equipments are used in an office building, telephone lines respectively corresponding to the facsimile equipments in number need to be installed in the office building. Recently, private branch telephone exchange system (hereinafter abbreviated to "PBX") have been introduced increasingly into enterprises. However, when a facsimile equipment is connected to PBX, the facsimile equipment is able to transmit message, but the same is unable to receive message, and hence a telephone line exclusively for the facsimile equipment needs to be installed.
On the other hand, distributive installation of electrophotographic copying machines in offices has been prevalent in recent years. Accordingly, the integration of a copying unit, a facsimile transmission unit and a common operating system will facilitate work for facsimile transmission and copying operation and will enable effective use of the copying unit and the facsimile unit.
Although an integral document processing apparatus having an electrophotographic copying unit and a facsimile unit has been known, no integral document processing apparatus having a copying unit and a facsimile transmission unit has been known. Japanese Laid Open Patent Publication No. 60-128859 discloses a copying machine capable of producing a plurality of copies from received facsimile message and collating the copies in accordance with codes included in the facsimile message. However, this known copying machine is not capable of facsimile transmission.
There is also a known document processing apparatus integrally having a digital copying unit which generates digital electric image signals through the pootoelectric conversion of the image of a document and copies the image of the document by driving a thermal printer or a laser beam printer by the electric image signal, and a facsimile unit. However, the copying unit of this known document processing apparatus reads the image of a document electrically, and hence is unable to compete with an electrophotographic copying machine in performance, for example, in resolution of image.
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of the present invention to provide an integral document processing apparatus comprising an image forming system and a facsimile transmission system.
It is another object of the present invention to provide an integral document processing apparatus comprising an image forming system, a facsimile transmission system, and a document feeding system capable of selectively feeding a document from a common document storing means to the image forming system or to the facsimile transmission system.
Foregoing and other objects of the present invention is achieved by an integral document processing apparatus comprising an image forming system and a facsimile transmission system, which comprises a document storing means for storing a plurality of documents; a first document read unit; a second document read unit; a document feed means capable of feeding the documents stored in the document storing means one at a time; a first document conveying means for conveying the document fed by the document feed means to the first document read unit; a second document conveying means for conveying the document fed by the document feed means to the second document read unit; a document passage changeover means for selectively guiding the document to the first document conveying means or to the second document conveying means; an image forming means capable of reading the document delivered to the first document read unit and forming the image of the document on a copying sheet; and a facsimile transmission means capable of reading the document delivered to the second document read unit and providing an electric signal representing the image of the document.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of an integral document processing apparatus, in a preferred embodiment, according to the present invention capable of image forming operation and facsimile transmission;
FIG. 2 is a sectional view of a document feeder employed in the integral document processing apparatus of FIG. 1;
FIG. 3 is a plan view of a control panel incorporated into the integral document processing apparatus of FIG. 1;
FIG. 4 is a block diagram of a controller incorporated into the integral document processing apparatus of FIG. 1;
FIGS. 5 (a), 5 (b), 5 (c) and 5 (d) are flow charts showing the control routines to be executed by a first central processing unit (hereinafter referred to as "first CPU") included in the controller of FIG. 4;
FIGS. 6 (a), 6 (b) and 6 (c) are flow charts showing the control routines to be executed by a second central processing unit (hereinafter referred to as "second CPU") included in the controller of FIG. 4;
FIG. 7 is a flow chart showing the interrupt communication routine; and
FIG. 8 is a timing chart of control signals for controlling document feeding operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A document processing apparatus, in a preferred embodiment, according to the present invention will be described hereinafter with reference to the accompanying drawings.
Referring to FIG. 1 showing a document processing apparatus 50 capable of electrophotographic copying functions and facsimile transmission functions. The document processing apparatus 50 has an analog electrophotographic copying system which includes photosensitive drum 1 rotatably supported for counterclockwise rotation in the substantially central section of the document processing apparatus 50, and a sequential arrangement of a main eraser lamp 2, a subcharger 3, a suberaser lamp 4, a main charger 5, a developing device 6, a transfer charger 7 a separating charger 8 and a cleaning device 9 arranged around the photosensitive drum 1. The circumference of the photosensitive drum 1 is coated with a photosensitive layer. Electric charges remaining over the circumference of the photosensitive drum 1 is erased and the photosensitive drum 1 is charged and sensitized by the main eraser lamp 2, the suberaser lamp 4, the subcharger 3 and the main charger 5 as the same rotates. The circumference of the photosensitive drum 1 is exposed to a light image provided by an optical scanning system 10 to form an electrostatic latent image thereon.
The optical scanning system 10 is disposed for scanning a document below a contact glass 16. The optical scanning system 10 comprises a light source 17, movable mirrors 11, 12 and 13, a lens 14 and a mirror 15. The light source 17 and the movable mirror 11 are driven for movement to the left as viewed in FIG. 1 for scanning operation at a fixed speed v/n, and the movable mirrors 12 and 13 are driven for movement to the left at a speed v/2n, where v is the fixed circumferential speed of the photosensitive drum 1 and n is a copying magnification.
A copying sheet fed by either an automatic copying sheet feed device 20 disposed at the left end, as viewed in FIG. 1, of the document processing apparatus 50 or a manual copying sheet feed device 30 disposed also at the left end of the document processing apparatus 50 is stopped temporarily by a timing roller 21, and then the copying sheet is fed to a transfer section in synchronism with the rotation of the photosensitive drum 1 so that a toner image formed on the circumference of the photosensitive drum 1 is transferred to the copying sheet at an appropriate position. The toner image is transferred from the photosensitive drum 1 to the copying sheet by the transfer charger 7. Then, the copying sheet is separated from the circumference of the photosensitive drum 1 by the separating charger 8, conveyed by a conveyor belt 22 to the fixing device 23 to fix the toner image to the copying sheet, and then is delivered to a sorter 24.
After the toner image has been transferred from the photosensitive drum 1 to the copying sheet, toner and electric charge remaining on the circumference of the photosensitive drum 1 are eliminated by the cleaning device 9 and the main eraser lamp 2 to prepare the photosensitive drum 1 for the next copying cycle.
In feeding copying sheets, either the automatic sheet feed device 20 or the manual copying sheet feed device 30 is used selectively. When a manual-feed tbble serving also as a guide for guiding a manually-fed copying sheet is positioned at an operative position, a manual-feed table open-close detector 36 provides a signal to activate an arrangement for copying operation by manual copying sheet feeding mode.
In an automatic copying sheet feeding mode, upon the start of a copying operation by operating a start key 113 (FIG. 3) for starting copying operation, an electrophotographic image forming unit including the photosensitive drum 1, and the optical scanning system 10 are actuated and a feed roller 25 is actuated by a copying sheet feed signal provided in relation to the scanning operatio of the optical scanning system 10 to feed a copying sheet in synchronism with the image forming operation of the image forming system.
In the manual copying sheet feeding mode, upon the detection of the manual insertion of a copying sheet by a sensor 34, a feed roller 33 for feeding a copying sheet is rotated to feed te copying sheet for copying operation. At the same time with or with a slight delay after the detection of the copying sheet by the sensor 34, the photosensitive drum 1 and the optical system 10 are started. Then, the copying sheet is stopped temporarily by a conveyor roller 35. When the copying sheet feed signal is issured, the conveyor roller 35 is actuated to feed the copying sheet to the image forming unit.
The facsimile transmission system has a facsimile transmission unit 40 disposed in an upper right-hand portion of the document processing apparatus 50. A document to be transmitted is fed by the document feed unit 201 of an automatic document feeder (hereinafter abbreviated to "ADF") 200. A document feed passage changeover finger 213 is operated so as to feed the document to an image read unit 45 in the facsimile transmission system. The document is conveyed by conveyor rollers 43 and 44. Then the document is illuminated by an illuminating unit 46 and is read by the image read unit 45 consisted of an array of photodiodes such as CCD. The operation of the conveyor rollers 43 and 44 is controlled in relation to the functions of document detectors 41 and 42. After the image of the document has been read by the image read unit 45, the document is delivered to a document discharge tray 47.
A single illuminating lamp may be used for both the facsimile transmission system and the electrophotographic copying system to reduce the cost of the document processing apparatus.
The ADF is mounted detachably on the frame of the document processing apparatus 50. As shown in FIG. 2, the ADF 200 comprises the document feed unit (hereinafter referred to "unit A") 201 for storing a plurality of documents and feeding the documents one at a time, and a document conveying unit (hereinafter referred to as "DF unit") 202 for conveying a document along the contact glass, positioning the document at a predetermined position on the contact glass and discharging the document to a document discharge tray 204. The document feed passage changeover finger 213 of the unit A connects the document feed passage selectively to the DF unit 202 or to the facsimile transmission unit 40. The DF unit 202 is able to operate independently for conveying a manually-fed document. Te DF unit 202 is mounted on the upper surface of the document processing apparatus 50 so as to be moved to expose the contact glass 16.
When the electrical connection of the ADF 200 to the document processing apparatus 50 and the correct installation of the same at a predetermined position on the document processing apparatus 50 are detected, the ADF 200 is controlled in relation with the document processing apparatus 50 and the operating mode of the document processing apparatus 50 becomes an automatic document feed mode (hereinafter referred to as "ADF mode"). In the ADF mode, the document processing apparatus 50 is held in a waiting state and the ADF 200 is started, when the start key 113 on the operating panel 101 is operated. Then, a document among those stored on a document feed tray 203 is fed to the facsimile transmission unit 40 or to the DF unit 202 depending on the position of the document feed passage changeover finger 213. Upon the arrival of the document at a predetermined position, the ADF 200 gives a start signal to the document processing apparatus 50, and then the document processing apparatus starts facsimile transmission operation or copying operation. Upon the completion of document scanning operation, the document processing apparatus 50 provides an ADF actuating signal to actuate the ADF 200 for discharging the document to the document discharge tray 47 or 204. If any document to be processed remains on the document feed tray 203, the document is conveyed to the predetermined position simultaneously with the discharge of the preceding document to the document discharge tray 47 or 203.
The manner of operation of the ADF 200 in the ADF mode will be described more specifically hereinafter. When the storage of a document or documents on the document feed tray 203 is detected by a first document detector SE1, the ADF 200 becomes operative. The first document detector SE1 comprises, in combination, for example, a light emitting element and a light receiving element disposed on the opposite sides of the document feed tray 203, respectively. When no document is stored on the document feed tray 203, the light receiving element is able to receive light emitted by the light emitting element.
When a documentor documents are placed on the document feed tray 203 and thereby a start signal is provided, a document feed roller 205 is driven for rotation and is lowered to be pressed against the top document, and thereby the top document is delivered from the document feed tray 203. If a plurality of documents are delivered from the document feed tray 203 by the document feed roller 205, only the top document is advanced further by a feed roller 206 rotating in the normal direction while the rest of the documents are checked by a separating roller 207 rotating in the reverse direction. Upon the detection of the document fed by the feed roller 206 by a second document detector SE2, the document feed roller 205 is raised to be separated from the document.
When the document feed passage changeover finger 213 is positioned so as to deliver the document to the DF unit 202 to copy the the document, the document is delivered to and is advanced further by a pair of feed rollers 208 and 209 of the DF unit 202. Upon the detection of the document fed by the pair of feed rollers 208 and 209 by a third document detector SE3, a pair of pinch rollers 208 and 209 are pressed against each other, the feed roller 206 and the separating roller 207 are stopped, and a conveyor belt 211 is started. Then, with a slight delay after the start of the conveyor belt 211, the pair of pinch rollers 208 and 209 are driven for rotation and a gate 210 is opened to allow the further advancement of the document. Then, the conveyor belt 211 conveys the document along the upper surface of the contact glass 16. A fixed time determined by a timer after the passage of the leading edge of the document by the third document detector SE3, the conveyor belt 211 is stopped, and then the conveyor belt 211 is reversed to bring the trailing edge of the document into abutment with a stopper 212. Thus, the document feed operation is completed.
When the document is stopped in place on the contact glass 16, the ADF 200 gives a signal to the document processing apparatus 50 to start the document processing apparatus 50 for copying operation and, at the same time, the next document is delivered to the gate 210 if any document or documents are stored in the unit A. Upon the completion of the scanning operation of the optical scanning system 10, the document processing apparatus 50 provides a signal to restart the conveyor belt 211 of the ADF 200. Then, the document placed on the contact glas 16 is discharged and, with a predetermined delay determined by a timer after the restart of the conveyor belt 211, the pair of pinch rollers 208 and 209 are pressed against each other to repeat the same document feeding operation. When the document processing apparatus 50 is in a multi copy mode, the document discharging operation is not started until the scanning operation of the optical scanning system 10 for the last copying cycle is completed.
Referring to FIG. 3, arranged on the operating panel 101 of the document processing apparatus 50 are operating keys, namely, a copy mode selection key 111, a transmission mode selection key 112, the copy/transmission start key 113, a telephone number/copy number setting key 114, copying magnification setting key 115, a copying sheet size selection key 116, a copy density up key 117, a copy density down key 118 and a short dial code specifying key 119, a liquid crystal display 102 for displaying modes and conditions specified by pperating keys, and a short dial code indicating section 120 provided in the left section as viewed in FIG. 3. Facsimile transmission may be started simply by pressing the transmission mode selection key 112.
Referring to FIG. 4, the document processing apparatus 50 and the ADF 200 thus constructed are controlled by a controller including a first CPU 301 and a second CPU 302, namely, microcomputers. The first CPU 301 mainly controls the document processing apparatus 50 while the second CPU 302 controls tee ADF 200.
The first CPU 301 is connected to the operating panel 101, a copying operation control system 304 including driving circuits for driving a main motor, a developing device driving motor, clutches and chargers, which are not shown, a facsimile transmission control system 305, a facsimile signal encoding circuit 310 and the ADF 200. The second CPU 302 is connected to the first CPU 301 to give signals relating to the operation of the ADF 200 to the first CPU 301.
The basic electrical constitution of the facsimile transmission unit 40 is the same as that of the conventional facsimile transmission equipment. The image read unit 45 reads the image of a document by an array of photodiodes such as CCD 311 to provide an electric image signal representing the mmage of the document. The electric image signal is amplified and binarized by an image signal amplifier 312. A digital image signal thus produced is stored in a line memory 313. The digital image signal is compressed by an encoder 314. A coded image signal is transferred from the encoder through a transmission controller 315 to a buffer memory 316 and is stored in the same. In transmitting the coded image signal, the coded image signal is modulated by a MODEM 317, and then a network control unit (hereinafter abbreviated to "NCU") 318 applies the modulated image signal automatically to a telephone line.
The first CPU 301 controls the facsimile transmission control system 305 and the conveyor rollers 43 and 44 and processes input data.
TThe second CPU 302 controls a document feed control system 306. A position detecting switch SW1 for detecting the position of the DF unit 202, first to fourth document detectors SE1 to SE4 are connected to the input port of the second CPU 302. A driving circuit, not shown, for driving a motor for driving the document feed roller 205, the feed roller 206, the separating roller 207 and the pair of pinch rollers 208 and 209, and a driving circuit, not shown, for driving a solenoid actuator for pressing the document feed roller 205 against a document, and a solenoid actuator for engaging the pair of pinch rollers 208 and 209 are connected to the output port of the second CPU 302.
The first CPU 301 and the second CPU 302 thus associated with the document processing apparatus 50 and the ADF 200 communicate with each other to execute control routines shown in FIGS. 5 (a) to 5 (d) and 6 (a) to 6 (c).
The control procedure of the first CPU 301 will be described with reference to FIGS. 5 (a) to 5 (d).
Upon the connection of the document processing apparatus 50 to the power source, initialization is executed in step S101 to set the controlled variables of the document processing apparatus 50 for predetermined values including setting the indication of the number of copies to be produced for "1" and to clear the internal RAMs and internal register of the first CPU. In step S102, an internal timer is set for a fixed time regardless of the douument processing mode to determine the process time in the routine and time count is started.
In step S103, input and output signal are processed.
In step S104, a decision is made whether a copy flag is "0" or not. When the copy flag F is "0", the routine goes to step S105. When the copy flag is "1", the routine jumps to step S125 to execute copying operation. The copy flag becomes "1" upon the start of copying operation and becomes "0" upon the completion of the last scanning cycle for copying operation.
In step S105, a decision is made whether a facsimile transmission mode flag is "0" or not. When the facsimile transmission mode flag is "0", the routine goes to step S106. When the facsimile transmission mode flag is "1", the routine jumps to step S141 to execute facsimile transmission operation. The facsimile transmission mode flag becomes "1" upon the start of the facsimile transmission operation and becomes "0" upon the completion of the transmission of each document.
In step S106, a decision is made whether an ADF mode is specified or not. An ADF mode signal becomes "1" upon the start of the ADF 200 for feeding a document and becomes "0" upon the completion of document discharging operation. The second CPU 302 gives the ADF mode signal to the first CPU 301. The routine goes to step S107 when the ADF mode signal is "0", and jumps to step S151 when the ADF mode iignal is "1".
In step S107, a decision is made whether the copy mode is selected by operating the copy mode selection key 111 or whether the facsimile transmission mode is selected by operating the transmission selection key 112. If the copy mode is selected or has previously been selected, a copy mode flag set for "1" and a facsimile transmission mode flag is set for "0" in step S108. In step S109, a copy mode signal "1" and a facsimile transmission mode signal "0" are given to the second CPU 302. The copy mode signal and the facsimile transmission mode signal indicates internally and externally whether the document processing apparatus 50 operates in the copy mode or not and whether the document processing apparatus 50 operates in the facsimile transmission mode or not. When the decision in step S107 is "No", namely, whether the facsimile transmission mode is selected or has previously been selected, the copy mode flag is set for "0" and the facsimile transmission mode flag is set for "1" in step S110, and then a copy mode signal "0" and a facsimile transmission mode signal "1" are given to the second CPU 302 in step S111.
In step S121, a decision is made whether the start key 113 is depressed, namely, whether the start of the copying operation or the facsimile transmission operation is requested or not. When the decision in step S121 is "No", the routine jumps to step S161 and, when "Yes", a decision is made in step S122 whether an ADF ready signal is "0".
When the facsimile transmission mode is selected and the start key 113 is depressed in a state where no document is placed on the document feed tray of the ADF 200, any operation is not started and the absence of any document on the document feed tray is indicated to prevent the failure of facsimile transmission. Accordingly, when a decision is made in step S104, S105 or S106 that the copying operation, the facsimile transmission operation or the automatic document feeding operation is in process, the operation of the start key 113 and the mode selection key 111 is invalidated.
The second CPU 302 gives the ADF ready signal to the first CPU 301. The ADF ready signal is "1" when the ADF 200 is able to feed a document and is "0" when no document is placed on the document feed tray 203 or when the ADF 200 is unable to execute document feeding operation.
When the ADF ready signal is "1", the first CPU 301 gives an ADF start signal "1" to the second CPU 302 in step S130 when the ADF ready signal is "1" to start the ADF 200.
When the ADF ready signal is "0", namely, when documents to be processed are thin sheets or pages of a book which are placed on the contact glass 16 without using the ADF 200, a decision is made in step S123 whether the copy mode flag is "1" or not. When the copy mode flag is "0", namely, when the facsimile transmission mode is selected, since no document is placed in the ADF 200 and the facsimile transmission is impossible, a transmission impossible indication is displayed on the display 102 of the operating panel 101, and then the routine goes to step S161.
When the copy mode flag is "1", the copy flag is set for "1" in step S124 and execute the copying operation in step S125. In step S126, a decision is made whether the copying operation is completed, namely, whether the set number of copies have been producedor not. When the decision in step S126 is "No", the routine goes to step S161 and, when "Yes", the copy flag is set for "0" and the first CPU 301 gives a document change signal "1" to the second CPU 302 in step S128. Then, the ADF 200 executes document changing operation, in which the document placed on the contact glass 16 is discharged and the next document is fed onto the contact glass 16.
In step S161, the first CPU 301 and the second CPU 302 communicate with each other. When the first CPU 301 gives a communication request to the second CPU 302, the second CPU 302 executes an interruption routine to process data. In step S162, a decision is made whether the time counting of the internal timer has completed or not. When the decision in step S162 is "Yes", the routine returns to step S102 to repeat the foregoing steps of the control routine.
When the decision in step S105 is "No", namely, when the facsimile transmission mode flag is "1", the routine jumps to step S141, where processes relating to facsimile transmission including connection of the transmission line, identification of the type of the receiver, identification of sheet size and conveyance of a document are executed. Then, in step S142, a decision is made whether the transmission of the information on one document has been completed or not. When the decision in step S142 is "No", the routine jumps to step S161 and, when "Yes", the facsimile transmission mode flag is set for "0" in step S143 and the document change signal "1" is provided in step S144. Then, in step S145, a decision is made whether the ADF ready signal is "0", namely, whether there is any document to be transmitted or not. When the ADF ready signal is "0", the line is disconnected in step S146 and, when "1", the routine jumps to step S161.
When the decision in step S106 is "No", namely, when the ADF mode signal is "1", the routine jumps to step S151, where a decision is made whether a document position signal given by the second CPU 302 to the first CPU 301 is "1" or not. The document position signal is "1" when a document is set on the contact glass 16 or at the entrance of the facsimile transmission unit 40 by the ADF 200 and is "0" when no document is set on the contact glass or at the entrance of the facsimile transmission unit 40 or when the ADF 200 is in document setting operation. When the document position signal is "0", the document change signal which has been set for "1" in step S128 is set for "0" in step S156, and then the routine goes to step S161. When the document position signal is "1", the ADF start signal which has been set for "1" in step S130 is reset to "0" in step S152, and then the routine goes to step S153.
In step S153, a decision is made whether the copy mode flag is "1" or not. When the copy mode flag is "1", the copy flag is set for "1" in step S154 and, when "0", namely, when the facsimile transmission mode is selected, the facsimile transmission flag is set for "1" in step S155, and then operation in the copy mode or in the facsimile transmission mode depending on the decision in step S153 is started. Then, the routine goes to step S161.
FIGS. 6 (a) to 6 (c) are flow charts showing steps of control routines to be executed by the second CPU 302 for controlling the ADF 200, FIG. 7 is a flow chart of an interruption routine for communication between the first CPU 301 and the second CPU 302, and FIG. 8 is a time chatt of signals for controlling the operation of the ADF 200.
Referring to FIGS. 6 (a) to 6 (c), processes in steps S201, S202 and S203 are initialization, setting of internal timer and input/output processing, respectively, and they are corresponded to processes in steps S101, 102 and 103 of FIG. 5 (a).
In step S204, a decision is made whether the position detecting switch SW1 is closed or not. When the position detecting switch SWl is open, indication that the ADF 200 is not mounted in place is executed and operation for driving the ADF 200 is stopped in step S212, and then the routine jumps to step S213. That is, the ADF 200 is not driven until the DF unit 202 is placed in the operating position.
In step S205, a decision is made on the basis of the output of the first document detector SE1 whether any document or documents are placed on the document feed tray 203 or not. When the decision in step S205 is "Yes", the ADF ready signal is set for "1" in step S206 and, when "No", the ADF ready signal is set for "0" in step S207, and then the routine goes to step S208. In step S208, a decision is made whether the ADF mode flag is "0" or not. Then, the routine goes to step S209 when the ADF mode flag is "0" or goes to step S221 when the ADF mode flag is "1". The ADF mode flag, similarly to the ADF mode signal, is "0" or "1". During the copying operation or the facsimile transmission operation in the ADF mode, the ADF start signal is invalidated.
In step S209, a decision is made whether the ADF start signal provided by the first CPU 301 is "1" or not. The routine jumps to step S213 when the ADF start signal is "0". When the ADF start signal is "1", the ADF mode flag and the ADF mode signal are set for "1" in step S210, and a document feed flag is set for "1" in step S211. After these steps for starting the ADF 200 have been accomplished, the routine goes to step S213.
When the decision in step S208 is "No", namely, when the ADF mode flag is "1", a decision is made in step S221 whether th document feed flag is "1", namely, whether the document setting operation is to be executed or not. When the ADF mode flag is "0", the routine jumps to step S241 without executing document feed operation. When the document feed flag is "1", a decision is made in step S222 whether the copy mode signal provided by the first CPU 301 is "1", namely, whether the document processing apparatus 50 is to be operated in the copy mode or whether the document processing apparatus is to be operated in the facsimile transmission mode. When the copy mode is selected, a solenoid for driving the document feed passage changeover finger 213 is de-energized in step S223, and then document feed operation for setting a document on the contact glass 16 is carried out in step S224.
When the facsimile transmission mode is selected, the solenoid for driving the document feed passage changeover finger 213 is energized in step S225, and then document feed operation for feeding a document at the entrance of the image read unit 45 is carried out in step S226.
A decision is made in step S231 whether the document feed operation has been completed or not. When the decision in step S231 is "No", the routine jumps to step S241 and, when "Yes", the routine goes to step S232 to reset the document feed flag to "0". Then, in step S233, the document position signal is set for "1" and is given to the first CPU 301.
In step S241, a decision is made whether the document change signal provided by the first CPU 301 is "1" or not. The routine goes to step S245 when the document change signal is "0" or step S242 and the following steps are executed when the document change signal is "1".
Steps S242 to S251 are executed in response to the document change request of the first CPU 301.
When the decision in step S243 is "Yes", namely, when the copy mode is selected, steps S244 to S248 are executed to discharge the document to be discharged, and then a decision is made in step S249 whether the next document exists on the document feed tray 203 or not. Document feed operation is requested in step S250 when the decision in step S249 is "Yes" or the operation of the ADF 200 is stopped in step S251 when the decision in step S249 is "No".
When the decision in step S243 is "No", namely, when the facsimile transmission mode is selected, steps S249 and S251 are executed.
A decision is made in step S213 whether the time defining the cycle time of the routine for which the main timer was set in step S202 has elapsed or not. The routine returns to step S202 when the decision in step S213 is "Yes" or step S213 is repeated when the decision in step S213 is "No" until the time elapses.
When an interruption request is provided by the first CPU 301, communications procedure is carried out in step S261 as shown in FIG. 7.
As apparent from what has been described hereinbefore, the integral document processing apparatus in accordance with the present invention has a single document feed unit capable of being used for feeding documents for both copying operation and facsimile transmission operation. When facsimile transmission/reception equipment is connected to a PBX, the receiving function of the facsimile transmission/reception equipment becomes entirely invalid. However, since the integral document processing apparatus of the present invention has only a transmission function, no function becomes invalid even if the integral document processing apparatus is connected to a PBX.
Furthermore, since the integral document processing apparatus comprises a copying machine and a facsimile transmission equipment in an integral unit, the integral document processing apparatus requires less space for installation as compared with an individual copying machine and an individual facsimile transmission equipment.
Still further, since the integral document processing apparatus of the present invention comprises an ordinary analog electrophotographic copying unit and a facsimile transmission unit and does not comprise any receiving unit including memories and a laser optical system, the integral document processing apparatus of the present invention can be manufactured at a less cost than that of an integral document processing apparatus comprising, in combination, a digital copying machine and a facsimile equipment.
Although the invention has been described in its preferred form with a certain degree of particularity, it is to be understood to those skilled in the art that many changes and variations are possible in the invention without departing from the scope and spirit thereof. | An integral document processing apparatus comprising an electrophotographic copying system and a facsimile transmission system. A document fed from a common document storing unit is guided selectively to a first document read unit included in the electrophotographic copying system or to a second document read unit included in the facsimile transmission system by a document feed passage changeover mechanism which is operated selectively by an operator. A document delivered to the first document read unit is copied by the electrophotographic copying system. A document delivered to the second document read unit is converted into a corresponding electric image signal, and then the electric image signal is applied to a communications line. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a geographical globe commonly used for educational purpose, particularly to one that is collapsible for easy stowage.
It is well known that geographical globes are constructed in a collapsible form so as to improve the conventional globes of rigid, heavy and bulk bodies. One of the improvements is disclosed in U.S. Pat. No. 952,119 in which an inflatable globe is rotatably mounted on a bowed arm which is pivoted to a stand so that the globe as well as the bowed arm can be folded in a compact manner.
SUMMARY OF THE INVENTION
A general object of the invention is to provide an improved collapsible globe with a bowed arm which can be disassembled into parts so that the whole assembly can be kept in a more compact manner.
Another object of the invention is to provide an improved collapsible globe rotatable by electrically or mechanically operated driving means.
Further object of the invention is to provide an improved collapsible globe equipped with a musical apparatus to provide an amusing sound during rotation.
According to the invention, a globe assembly is comprised of, a globe-shaped envelope of flexible material having two inflating passages on the wall thereof in diametrically opposite positions, two plug members for obstructing the passages, a bowed support arm formed of releasably connectible curved segments, two pin members fixedly received in the plug members and passing through two ends of the bowed support arm, a driving mechanism provided at one end of the arm for rotating one of the pin members, and a stand for supporting the bowed support arm.
Advantageously, the curved segments are interconnected by interengagements of protrusions and recesses. The driving mechanism may includes an output shaft drivingly connected to the pin member by a pair of interengaging gear members. There may also be provided means for retaining the gear members in a separate position so that the globe shaped envelope can be rotated by hand.
According to an aspect of the invention, the globe is provided with a driving mechanism including a mainspring. Advantageously the driving mechanism can be corporated with a mechanical musical apparatus.
The manner in which the above and related objects is accomplished together with the attending advantages and features of the invention will appear more fully from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a globe constructed according to the invention;
FIG. 2 is a view illustrating a curved segment of the bowed arm; and
FIG. 3 is a portion of the globe assembly viewed in the direction along the arrow A of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1, 2 and 3, there is shown a geographical globe assembly 10 which includes a globe 11 made of a gas impervious flexible sheeting material mounted on a stand 12. The globe 11 is provided with two diametrically opposite inflating passages 13 which can be accomplished by a known manner, such as, by heat-sealing or adhesively bonding semi-rigid molded tube like members, as better shown in FIG. 3, to the wall of the globe 11. Two plug member 15 each of which is fixedly receiving a pin member 16 are further provided for obstructing the inflating passages 13.
As embodied herein, there is further provided a bowed support arm 17 which is formed of a plurality of releasably connectible curved segments 171, 172, 173 and 174. Preferably, these curved segments are made to interconnect by the interengagements of protrusions 18 and recesses 19 as better seen in FIG. 2. One end curved segment 171 is provided with a hole 20 for receiving one of the pin members 16 and another end curved segment 174 is provided with a hole 21 for receiving another pin member 16. To the end curved segment 174 is secured a casing 22, such as, by screwing, which houses a driving mechanism 23 which can be any known device electrically or mechanically operable to rotate the pin member 16. Preferably, the drive mechanism 23 adapted in the embodiment is a mechanical musical apparatus which includes a main spring (not shown) operated by a rotary knob 24 to rotate, through an output shaft 25, a metal reed 26 which can produce a musical sound when engaged with a metal comb 27. The output shaft 25 is parallel with the pin member 16 and is further provided with a gear member 28 which engages a further gear member 29 affixed to the pin member 16, as better seen in FIG. 3. Therefore, when a torque is applied to the main spring through the rotary knob 24, the reversing torque will operate the metal reed 26 as well as the pin member 16 through the output shaft 25.
It can be appreciated from FIG. 3 that there is provided a fixed annular member 30 sleeved onto the pin member 16 and a retaining pin 31 projected from the annular member 30. When the gear members 28 and 29 are interengaged the gear member 29 is engaged with the retaining pin 31 so that the rotary motion can be transmitted to the pin member 16 as well as the globe 11. However, the gear member 29 can be disengaged from the gear 28 by sliding it upward along the pin 16 and turning it to an angle to release from the engagement with the pin 31. At this position, the globe is separated from the driving mechanism 23 and thereby can be rotated by hand.
As embodied herein, the stand 12 is constructed in the form of a hollow body. On the top of the stand 12 is a socket (not shown) which can received a projecting portion 32 of the curved segment 174, thereby enabling the bowed support arm 17 to rest on the stand 12. It can be appreciated that the angle of the axis of the globe 11 can be varied by providing a projecting portion similar to the projecting portion 32 on any chosen curved segment, 171, 172, 173 or 174, for inserting into the socket of the stand 12. The assembly according to the invention has also an advantage that the globe assembly 10 after being disassembled can be stowed in the hollow stand 12. When the globe assembly is set up, the stand 12 can be used as a saving box.
With the invention thus explained, it is apparent that obvious modifications and variations can be made without departing from the scope of the invention. It is therefore intended that the invention be limited only as indicated in the appended claims. | A globe of inflated envelope is supported by a bowed arm formed of releasably connectible curved segments and detachably mounted on a stand. The bowed arm further carries a casing containing a driving mechanism for rotating the globe and producing a musical sound during rotation of the globe. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a material for adsorbing gas molecules. The invention particularly relates to a gas adsorption material comprising a metal organic framework infused with functionalised fullerenes or fullerides, which material has principal applications in gas storage and gas separation.
BACKGROUND OF THE INVENTION
[0002] The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application.
[0003] There is much current interest in the development of materials or systems for adsorbing gas molecules, particularly for the purposes of gas storage or separation.
[0004] Hydrogen and methane are seen as the energy carriers of the future. Hydrogen as a combustion fuel is very environmentally friendly, generating only water as a combustion byproduct. Hydrogen is also an important fuel for fuel cells which generate electricity by the electrochemical oxidation of hydrogen. The use of adsorbed natural gas (ANG) which is primarily methane, as a vehicular fuel is seen as an attractive alternative to compressed natural gas (CNG), which requires operating pressures of 340 atm. so that sufficient gas can be stored on-board, thereby demanding complex multi-stage compression equipment.
[0005] However, the storage of hydrogen and methane in a safe and practical manner presents a formidable engineering challenge. Their efficient use as fuels in vehicular transportation is limited by the current requirement to store them in large, heavy and dangerous high-pressure or cryogenic tanks. Storage of hydrogen and methane for such applications is complicated by the fact that these gases are flammable and in some situations explosive. Alternative methodology for storage of these gases exists, but each of the current alternatives is undesirable for one or more reasons.
[0006] Carbon dioxide capture and storage is another current area of significant interest. Removal of carbon dioxide from the flue exhaust of power plants, currently a major source of anthropogenic carbon dioxide, is commonly accomplished by chilling and pressurizing the exhaust or by passing the fumes through a fluidized bed of aqueous amine solution, both of which are costly and inefficient. Other methods based on chemisorption of carbon dioxide on oxide surfaces or adsorption within porous silicates, carbon, and membranes have been pursued as means for carbon dioxide uptake. However, in order for an effective adsorption medium to have long term viability in carbon dioxide removal it should combine two features: (i) a periodic structure for which carbon dioxide uptake and release is fully reversible, and (ii) a flexibility with which chemical functionalization and molecular level fine-tuning can be achieved for optimized uptake capacities.
[0007] Current research into high volume storage of gases such as hydrogen has largely focussed on physisorption or chemisorption based materials. Metal-organic frameworks have shown great promise as materials with high gas adsorption capacity. They possess intrinsically high surface areas and internal volumes—factors useful for gas storage by physisorption at high pressures and/or low temperatures. However, these operating conditions require heavy and potentially expensive system components for implementation within hydrogen or methane powered vehicles. Consequently, materials that operate at near-to-ambient conditions are highly sought after, as the systemic requirement would be drastically reduced. In order to achieve operation under these conditions, the gas adsorption heat must be drastically increased.
[0008] Whilst increasing the heat of adsorption for physisorption based materials is crucial to their widespread implementation, chemisorption based materials such as magnesium and lithium metal hydrides have adsorption heats well above 15.1 kJ/mol, calculated as the value required for room temperature hydrogen storage. Consequently these materials require several hundred degrees for operation, a substantial energy cost.
[0009] In order for physisorbed methane (ANG) to present a realistic alternative to CNG for powering vehicles, the US Department of Energy has stipulated methane adsorption of 180 v/v at 298 K and 35 atm. as the benchmark for ANG technology, and the optimum adsorption heat has been calculated at 18.8 kJ mol. Most of the effort has been in the development of porous carbons as storage materials, however, even the most sophisticated carbons strain to obtain any significant improvements over the 180 v/v target, largely because of the inherently low adsorption heat of methane within carbons, typically 3-5 kJ/mol.
[0010] It would therefore be desirable to provide an alternative gas absorption material.
SUMMARY OF THE INVENTION
[0011] The present inventors have discovered that a substantial increase both in the gas adsorption heat and in the volume of gas adsorbed by metal-organic frameworks (MOFs), may be achieved by impregnating the MOFs with functionalized fullerenes or fullerides. Fullerenes are particularly attractive candidates as components of hydrogen storage materials due to their ability to store up to 58 hydrogen atoms internally without destroying the fullerene structure, which equates to an uptake of 7.5 wt. %. In addition, decoration of the external fullerenes surface with certain metals drastically enhances their surface adsorption performance, yielding 8 wt. % hydrogen uptake through Kubas interaction in the case of transition metal decoration, or up to 60 H 2 molecules per fullerene in the case of Li decoration. The hydrophobic nature of fullerenes also makes them attractive candidates for methane storage.
[0012] According to a first aspect of the present invention, there is provided a gas adsorption material comprising: (i) a porous metal-organic framework including: (a) a plurality of clusters, and (b) a plurality of charged multidentate bridging ligands connecting adjacent clusters; and (ii) a plurality of functionalized fullerenes or fullerides provided in the pores of the metal-organic framework.
[0013] The present invention also provides in a second aspect, a gas storage system including: a container having a storage cavity and a gas storage material according to the first aspect of the present invention positioned within and filling at least a portion of the container.
[0014] Moreover, the present invention provides a method of manufacturing the gas adsorption material of the invention.
[0015] The metal-organic framework of the present invention includes a plurality of functionalized fullerenes or fullerides in the pores of the metal-organic framework. The presence of functionalized fullerenes/fullerides in the pores of the MOF surprisingly enhances the gas adsorption properties of the metal-organic framework, particularly when compared to the gas adsorption properties of an equivalent metal-organic framework alone or a metal-organic framework with a fullerene (not functionalized) provided in the pores. Typically, the functionalized fullerenes or fullerides are decorated with one or more metals selected from magnesium, aluminium, lithium, sodium, potassium, cesium, calcium and transition metals. Preferably, the functionalized fullerenes or fullerides are magnesium, aluminium and/or lithium decorated fullerenes or fullerides, preferably magnesium decorated fullerenes or fullerides.
[0016] The functionalised fullerene or fulleride is preferably based on a spherical or ellipsoidal fullerene. More preferably, the fullerene or fulleride is in the range of C 20 to C 84 .
[0017] The functionalised fullerenes or fullerides are preferably functionalised C 60 molecules, more preferably, Mg-functionalized C 60 fullerenes or fullerides. More preferably, the functionalized fullerenes or fullerides comprise Mg-functionalised C 60 fullerenes including from about 1 to 10 Mg atoms, preferably ten Mg atoms. Magnesium has the advantageous properties of being a light metal that is known to perform comparatively well within the field of high temperature chemisorption based hydrogen storage.
[0018] As used herein, the term “cluster” means a moiety containing one or more atoms or ions of one or more metals or metalloids. This definition embraces single atoms or ions and groups of atoms or ions that optionally include ligands or covalently bonded groups.
[0019] Preferably, each cluster comprises two or more metal or metalloid ions (hereinafter jointly referred to as “metal ions”) and each ligand of the plurality of multidentate ligand includes two or more carboxylates.
[0020] Typically, the metal ion is selected from the group consisting of Group 1 through 16 metals of the IUPAC Periodic Table of the Elements including actinides, and lanthanides, and combinations thereof. Preferably, the metal ion is selected from the group consisting of Li + , Na + , K + , Rb + , Be 2+ , Mg 2+ , Ca 2+ , Sr 2+ , Ba 2+ , Sc 3+ , Y 3+ , Ti 4+ , Zr 4+ , Hf 4+ , V 4+ , V 3+ , V 2+ , Nb 3+ , Ta 3+ , Cr 3+ , Mo 3+ , W 3+ , Mn 3+ , Mn 2+ , Re 3+ , Re 2+ , Fe 3+ , Fe 2+ , Ru 3+ , Ru 2+ , Os 3+ , Os 2+ , Co 3+ , Co 2+ , Rh 2+ , Rh + , Ir 2+ , Ir + , Ni 2+ , Ni + , Pd 2+ , Pd + , Pt 2+ , Pt + , Cu 2+ , Cu + , Ag + , Au + , Zn 2+ , Cd 2+ , Hg 2+ , B 3+ , B 5+ , Al 3+ , Ga 3+ , In 3+ , TI 3+ , Si 4+ , Si 2+ , Ge 4+ , Ge 2+ , Sn 4+ , Sn 2+ , Pb 4+ , Pb 2+ , As 5+ , As 3+ , As + , Sb 5+ , Sb 3+ , Sb + , Bi 5+ , Bi 3+ , Bi + , and combinations thereof.
[0021] Typically, the cluster has formula M m X n where M is metal ion, X is selected from the group consisting of Group 14 through Group 17 anion, m is an integer from 1 to 10, and n is a number selected to charge balance the cluster so that the cluster has a predetermined electric charge
[0022] Preferably X is selected from the group consisting of O 2− , N 3− and S 2− . Preferably M is selected from the group consisting of Be 2+ , Ti 4+ , B 3+ , Li + , K + , Na + , Cs + , Mg 2+ , Ca 2+ , Sr 2+ , Ba 2+ , V 2+ , V 3+ , V 4+ , V 5+ , Mn 2+ , Re 2+ , Fe 2+ , Fe 3+ , Ru 3+ , Ru 2+ , Os 2+ , Co 2+ , Rh 2+ , Ir 2+ , Ni 2+ , Pd 2+ , Pt 2+ , Cu 2+ , Zn 2+ , Cd 2+ , Hg 2+ , Si 2+ , Ge 2+ , Sn 2+ , and Pb 2+ . More preferably M is Zn 2+ and X is O 2− .
[0023] Typically, the multidentate linking ligand has 6 or more atoms that are incorporated in aromatic rings or non-aromatic rings. Preferably, the multidentate linking ligand has 12 or more atoms that are incorporated in aromatic rings or non-aromatic rings. More preferably, the one or more multidentate linking ligand comprise a ligand selected from the group consisting of ligands having formulae 1 through 27:
[0000]
[0000] wherein X is hydrogen, —NHR, —N(R) 2 , halides, C 1-10 alkyl, C 6-18 aryl, or C 6-18 aralkyl, —NH 2 , alkenyl, alkynyl, —Oalkyl, —NH(aryl), cycloalkyl, cycloalkenyl, cycloalkynyl, —(CO)R, —(SO 2 )R, —(CO 2 )R—SH, —S(alkyl), —SO 3 H, —SO 3− M + , —COOH, —COO − M + , —PO 3 H 2 —, —PO 3 H − M + , —PO 3 2− M 2+ , or —PO 3 2− M 2+ , —NO 2 , —CO 2 H, silyl derivatives; borane derivatives; and ferrocenes and other metallocenes; M is a metal atom, and R is C 1-10 alkyl.
[0024] In one embodiment, the multidentate linking ligand comprises a ligand having formula 3 previously described. In another embodiment, the multidentate linking ligand comprises a ligand having formula 18 (“BTB”). In a further embodiment, the multidentate linking ligand comprises a ligand having formula 14.
[0025] The metal-organic framework may be of any known composition. Examples of metal organic frameworks which may be suitable for use in the present invention include those commonly known in the art as MOF-177, MOF-5, IRMOF-1 or IRMOF-8. In a preferred embodiment, the metal-organic framework is MOF-177.
[0026] Preferably, the gas comprises a component selected from the group consisting of methane, hydrogen, ammonia, argon, carbon dioxide, carbon monoxide, and combinations thereof. More preferably, the gas is one or more of hydrogen, methane or carbon dioxide.
[0027] Typically, the metal-organic framework has pore radii of between 10 and 21 Å, preferably from 13 to 21 Å.
[0028] Where the gas adsorbing material is intended for use in adsorbing methane, the pore radii are preferably from 17 to 21 Å. Where the gas adsorbing material is intended for use in adsorbing hydrogen, the pore radii are preferably from 13 to 16 Å.
[0029] The gas adsorbing materials of the present invention have a number of applications, including gas storage and release, gas separation and gas cleaning.
[0030] In order that the invention can be more readily understood, non-limiting embodiments thereof are now described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will now be described in greater detail with reference to embodiments illustrated in the accompanying drawings. In the drawings, the following abbreviations are used:
[0000] MOF=metal organic framework;
C 60 @MOF=metal organic framework infused with C 60 ; and
Mg—C 60 @MOF=metal organic framework infused with magnesium decorated C 60 .
[0032] FIG. 1 is a schematic representation of a first embodiment of the gas adsorption material of the invention.
[0033] FIGS. 2 ( a ) to ( c ) are graphs showing the potential energy for adsorption (kJ/mol) versus distance from cavity centre (Å) for unfilled and filled MOFs having cavity radii of (a) 10 Å, (b) 12 Å and (c) 18 Å.
[0034] FIG. 3 is a graph showing the average potential energy (kJ/mol) for adsorption versus cavity radius (Å) for MOF, C 60 @MOF and Mg—C 60 @MOF.
[0035] FIGS. 4( a ) and ( b ) are graphs of free volume for adsorption at 298K (lower curves) and 77K (upper curves) for hydrogen (a) and methane (b) adsorption in MOF, C 60 @MOF and Mg—C 60 @MOF.
[0036] FIGS. 5( a ) and ( b ) are graphs of the heat of adsorption (kJ/mol) within IRMOF-8 (in which the ligand has formula 14) vs wt % storage for hydrogen (a) and methane (b).
[0037] FIGS. 6( a ) and ( b ) are graphs of the wt % gas storage vs pressure (atm) for hydrogen at 77K (a) and methane at 298K (b).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] FIG. 1 shows a schematic representation of a first embodiment of the gas adsorption material 10 of the invention.
[0039] The gas adsorption material comprises a porous metal-organic framework 20 having pores 22 infiltrated with functionalized fullerenes 24 .
[0040] The metal-organic framework 20 comprises a plurality of metal clusters 26 , and a plurality of multidentate ligands 28 connecting the metal clusters 26 . Each metal cluster 26 has the formula Zn 4 O 6+ .
[0041] Each multidentate ligand 28 comprises a plurality of aromatic rings 30 and at least two terminal carboxylate groups 32 for coordinating with respective zinc ions in the metal cluster 26 . It is preferred that the multidentate ligand 28 has the formula 18 (“BTB”) illustrated previously. While BTB has three terminal carboxylate groups, only two are shown in FIG. 1 for clarity.
[0042] A number of pores or cavities 22 are defined within the metal-organic framework.
[0043] The geometry of pores 22 can be approximated to a spherical shape having a radius r 1 . The size of r 1 is largely dependent on the size of each ligand 28 and, in particular, the number and configuration of aromatic rings in the ligand 28 .
[0044] Each pore 22 is infiltrated with a functionalized fullerene molecule 24 . The functionalized fullerene 24 comprises a magnesium functionalized C 60 molecule, which is decorated with ten Mg atoms on its outer surface.
[0045] The free volume of the infiltrated pore has a thickness r 2 .
[0046] The inventors conducted modelling studies to predict the adsorption performance of the invented gas adsorption materials, by evaluating the average potential energy for adsorption, volume free for adsorption, heat of adsorption and weight percentage and volumetric hydrogen and methane uptake as a function of pore sizes and fullerene infiltration.
[0047] FIG. 2 shows the potential energy profiles for uninfiltrated MOF (MOF), MOF infiltrated with C 60 (C 60 @MOF) and MOF infiltrated with Mg decorated C 60 (Mg—C 60 @ MOF), for cavity radii of 10, 12 and 18 Å. The vertical dashed lines on FIGS. 2( a ), ( b ) and ( c ) represent the cavity radius r 1 and remaining free volume after infiltration r 2 (labelled only on FIG. 2( a )).
[0048] Without wishing to be constrained by theory, one of the key benefits from the infiltration of MOF structures is believed to be the surface potential energy overlap from the fullerene ‘guest’ with that of the MOF ‘host’ across the remaining free volume. This overlap could both increase adsorption strength, and also the total amount of gas that is adsorbed in a dense fashion, as opposed to simply filling the pores in a low density gaseous form. FIG. 2 demonstrates these effects in three discrete cases, as a function of r 2 , the distance between MOF and fullerene surfaces, by varying r 1 , the MOF pore radius. When r 2 is particularly short, the overlap of potential energies is particularly strong, and under these conditions would engender gas adsorption at high enthalpies ( FIG. 2( a )), but at a cost in the free volume available for adsorption (see discussion of FIG. 4 below). Large r 2 distances reduce potential energy overlap ( FIG. 2( c )), but at intermediate r 2 there exists a region where potential energy enhancement can be achieved whilst maintaining a substantial free volume ( FIG. 2( b )). In all cases it is clear that Mg—C 60 @ MOF has superior performance over C 60 @ MOF and unfilled MOFs. As shown in FIG. 3 , this enhancement is up to 88% for C 60 @ MOF, and extends to 122% for Mg—C 60 @ MOF.
[0049] Fractional free volume for adsorption is another key factor governing gas storage within porous materials. It represents the proportion of volume within the MOF cavity where gases will exist in the dense adsorbed state, as opposed to the bulk gaseous state. FIGS. 4A and 4B demonstrate that up to 50% of the free volume within Mg—C 60 @ MOF is able to house both hydrogen ( FIG. 4A ) and methane ( FIG. 4B ) in the densely adsorbed state, almost twice that for empty MOF structures. The optimal cavity radius r 1 for both adsorbing gases increases at lower temperatures (CH 4 17.0 Å at 298K, and 21 Å at 77K; H 2 13 Å at 298K and 16 Å at 77K). This is believed to be because at lower temperatures it is possible for gas molecules to be in the adsorbed state at larger distances from the adsorbate's surface creating multiple adsorption layers, and thus larger cavities are required to reach the optimal capacity.
[0050] As previously noted, tuning the heat of adsorption within gas storage materials is perhaps the greatest challenge facing those concerned with the viability of hydrogen or methane powered vehicular transport. Most physisorbents operate well below the 15.1 kJ mol-1 considered necessary for room temperature operation. Our modeling of the heats of adsorption of the inventive materials showed that the increase in heat of adsorption observed through fullerene infiltration is stark. FIG. 5 shows the heat of adsorption of hydrogen and methane, respectively, within Mg—C 60 @IRMOF-8. The heat of adsorption for H 2 is around 10-11 kJ mol-1 for Mg—C 60 @ IRMOF-8. To the best of the inventors' knowledge this is the highest value yet reported. The relative increase in adsorption heat for methane uptake is even more marked than for hydrogen, with Mg—C 60 @ MOF improving adsorption heat by 116%. The measured value, 13.5 kJ mol-1, approaches the ideal operating conditions.
[0051] The low pressure gas storage performance of the inventive materials indicate a potential paradigm shift in the future of both hydrogen and methane storage, as shown in FIG. 6 . It is shown that at 77 K Mg—C 60 @ MOF (in this case, IRMOF-8) approaches saturation hydrogen uptake at just 6 atm. By further developing this strategy it is likely that high pressure vessels will not be required to make future hydrogen storage viable.
[0052] In the case of methane storage, the observed results exhibit an even greater breakthrough. At 35 atm./298 K, FIG. 6 ( b ) indicates a 28 wt. % uptake of methane for Mg—C 60 @ MOF. This equates to 265 v/v, which exceeds the US DoE guidelines of 180 v/v by 47%. Whilst some carbonaceous materials have been reported to show methane uptake as high as 200 v/v under identical conditions, to the best of the inventor's knowledge the highest reported methane storage material is a copper-anthracenate coordination polymer, which exhibits a performance of 230 v/v, 28% higher than the DoE target. This material also has an exceptional adsorption heat of 30 kJ mol-1, which surprisingly exceeds the calculated optimum heat of 18.8 kJ mol-1. In this context the modelled results for Mg—C 60 @ MOF are remarkable.
[0053] Accordingly, the present invention provides a gas adsorption material providing a new concept for hydrogen and methane storage materials. The materials exhibit some exceptional properties, which include methane uptake of 265 v/v, the highest reported value for any material, exceeding the US DoE target by a remarkable 47%, and one of the highest reported physisorption hydrogen adsorption heats of 11 kJ/mol, approaching the calculated optimum value of 15.1 kJ/mol concurrent with saturation hydrogen uptake in large amounts at just 6 atm.
[0054] The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the above description. | A gas adsorption material comprising: a porous metal-organic framework and a plurality of functionalized fullerenes or fullerides provided in the pores of the metal-organic framework. The metal-organic framework includes a plurality of metal clusters, each metal cluster including one or more metal ions, and a plurality of charged multidentate linking ligands connecting adjacent metal clusters. | 8 |
TECHNICAL FIELD
[0001] This invention relates generally to medical devices and more specifically to three-dimensional implants that can be administered to injured or otherwise defective tissue within the body.
BACKGROUND
[0002] Soft tissue implants are commonly used to reinforce or replace areas of the human body that have acquired defects. Several soft tissue implants have been developed and are commercially available. For example, Bard Mesh™ is a non-absorbable implant that is made from monofilament polypropylene fibers using a knitting process (C. R. Bard, Inc., Cranston, R.I.; see also U.S. Pat. No. 3,054,406; U.S. Pat. No. 3,124,136; and Chu et al., J. Bio. Mat. Res. 19:903-916, 1985). This same material is used to construct other implants such as the Bard Mesh PerFix™ Plug, discussed further below.
[0003] Soft tissue implants have been used to treat many defects, including those that affect the abdomen and abdominal wall. For example, cylindrical plugs have been suggested for recurrences of inguinal hernia (Lichtenstein et al., Am. J. Surg. 128:439-444, 1974), and an umbrella plug technique was subsequently described (Gilbert, Perspectives in General Surgery 2:113-129, 1991). Yet another technique for mesh plug hernioplasties was described by Rutkow in 1993 (Rutkow et al., Surgery 114:3-8, 1993). Abdominal wall defects can also be addressed with the Bard Mesh PerFix™ Plug, which functions as an implantable and non-absorbable mesh prosthesis that can be used as a compressible and pliable implant (C. R. Bard, Inc., Cranston, R.I.; see also U.S. Pat. Nos. 5,356,432 and 5,716,408; see also U.S. Pat. No. 6,066,776). Implantable prostheses for repairing defects in muscle or other tissues can have a preformed shape that conforms to the shape of the defect. The shaped prosthesis may facilitate placement and minimize shifting (see U.S. Pat. No. 5,954,767). Kits that can be used to repair indirect hernias are described in U.S. Pat. No. 6,166,286, and a prosthetic device having an extension canal made of sheet material for extending through a hernia is described in U.S. Pat. No. 6,241,768. An implantable prosthesis containing a radially-expandable member for placement in and occlusion of a hernia opening is described in U.S. Pat. No. 6,425,924.
[0004] The plugs described above are made using synthetic fiber technology. The implant surface area for the biomaterial used to construct the Bard Mesh™ has been calculated. The following formulas were used to calculate the surface area ratio for Bard Mesh:
[0005] V mat =W mat /D mat where V mat is the material volume, W mat is the material weight, and D mat is the material density which is 0.904 g/cm 3 for polypropylene;
[0006] L fiber =V mat /((II)(R fiber ) 2 ) where R fiber is the radius of the fiber and L fiber is the length of the fiber;
[0007] A surface =(II)(D fiber )(L fiber ) where A surface is the surface area of the fiber used to construct the material and D fiber is the diameter of the fiber; and
[0008] Surface Area Ratio=A surface /F area where F area is the area of the biomaterial fabric used to obtain W mat .
[0000]
Weight
Fiber
Surface
Product
Construction
(g/cm 2 )
Diameter (cm)
Area Ratio
Bard Mesh
Monofilament Knit
0.0096
0.017
2.52
[0009] Bard Mesh™ is used to construct the Bard Mesh PerFix™ Plug. With values for the implant surface area for the Bard Mesh™ and the volume for the Bard Mesh PerFix™ Plug, the implant surface area to volume ratio can be calculated. The following formulas were used to calculate the surface area to volume ratio for the PerFix™ Plug:
[0010] A surface plug =(W plug /W mesh cm2 )*A surface cm2 where A surface plug is the surface area of the fiber used to construct the plug, W plug is the weight of a size large PerFix Plug, W mesh cm2 is the weight of Bard Mesh per cm 2 and A surface cm2 is the area of the fiber used to construct Bard Mesh per cm 2 ;
[0011] V plug =((II)(L plug )(R plug ) 2 )/3 where V plug is the volume of the cone shaped plug, L plug is the plug height, and R plug is the plug radius at the base; and
[0012] Surface Area to Volume Ratio=A surface plug /V plug .
[0000]
Plug Surface
Plug Volume
Surface
Product
Weight (g)
Area (cm 2 )
(cm 3 )
Area:Volume
PerFix Plug
1.01
266
24.68
10.79
(Large)
[0013] These implants are not ideal. Following are some of the disadvantages associated with one or more of the implants presently used. Where their construction results in substantial wall thickness, surface area, density, and/or interstices, there is an increased risk of inflammation and infection; loose or soft plug implants can collapse, leading to shrinkage during the healing process (up to 75%, which can fail to secure the intended repair); excessive scarring and shrinkage can cause plug implants to assume a cartilage-like consistency (which can erode into adjacent tissue such as the bladder, intestines, and blood vessels); in the event of neuralgia, plugs may have to be removed; material content and wall thickness can require large incisions (thus, utility in less invasive surgical procedures may be limited); seromas, caused by the host inflammatory reaction to the implant, and dead space can be created between the prosthesis and host tissue; rough implant surfaces can irritate tissues and lead to the erosion of adjacent tissue structures and adhesion to bowel when the implant comes in direct contact with the intestinal tract; non-absorbable implants may elicit a chronic foreign body response; implants having small pores may not permit adequate tissue ingrowth and incorporation; implants requiring a separate onlay require additional time to implant; and plug implants are prone to migration, even with the use of staples or sutures. Accordingly, there remains a need for devices for repairing soft tissue bodily defects.
SUMMARY OF THE INVENTION
[0014] The present invention features implants (e.g., three-dimensional soft tissue implants) that can be used to treat bodily defects (whether arising congenitally or as a result of a disease, disorder, condition, or surgical procedure) or to remodel tissue (following, for example, a traumatic injury (such as a burn) or for cosmetic purposes). In addition, the invention features methods for making the implants and kits (e.g., sterile kits that include an implant and, optionally, instructions for its application, and which can facilitate the surgical procedure in which the implant is used). In one embodiment, the implants have a low density (i.e., a low weight:volume ratio), a low implant surface area ratio (the fiber or material surface area divided by the material area), and open pores, which may permit tissue ingrowth following implantation into a patient (e.g., a human patient). The surface area ratio can range from about 0.4 to about 4.0. For example, the surface area ratio can be approximately 1.0, 2.0, or 3.0 (e.g., 0.6, 0.8, 1.0, 1.2, 1.4, 1.6, 1.8, 1.9, 2.0, 2.1, 2.2, 2.4, 2.6, 2.8, or 3.0; the implants of the invention can also be described as having a surface area ratio of less than 3.0), the surface area to volume ratio can range from about 2.0 to 4.0. For example, the surface area to volume ratio can be approximately 3.0 (e.g., 2.0, 2.1, 2.2, 2.4, 2.6, 2.8, 3.0, 3.1, 3.2, 3.4, 3.6, 3.8, or 4.0), and the pore size can be approximately 50-2000μ (e.g., 50, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, or 2000μ; preferably, the pore diameter is measured before implantation, when the implant is in a natural, resting position). Thus, and as further described below, the methods of the invention can produce implants that are highly porous and of a low material content, yet strong enough to modify for repair tissue.
[0015] More specifically, the invention features a three-dimensional biocompatible implant, the implant comprising a subassembly that resists compression when implanted in a warm-blooded animal. The subassembly can include woven or braided fibers or can be produced using a circular weft or warp knitting process. In any event, the subassembly can be produced using an internal support (e.g., PEEK). The implant of claim 1 , wherein the subassembly is produced using a circular warp knitting process. The subassembly can also be produced using a nonwoven film and/or a substrate comprising pores as shown in FIG. 9C . The pores can be 50-2000 microns in diameter, and the implant can have a conical form and further include an only or anchor.
[0016] The invention also features a method for producing a three-dimensional biocompatible implant that includes one or more of the following steps:
[0017] a) extruding a biocompatible polymer into a fiber,
[0018] b) transforming the fiber into a compression resistant subassembly,
[0019] c) braiding or weaving the subassembly into a three dimensional structure,
[0020] d) heat setting the structure into the desired shaped article, and, optionally,
[0021] e) attaching the shaped article to a complementary implant article.
[0022] The invention also features a method for repairing a defective tissue in a patient (e.g., a patient with a hernia), the method comprising applying the three-dimensional biocompatible implant to the defect by way of a surgical procedure.
[0023] The invention also features a kit comprising an implant, optionally sterile, as described herein.
[0024] The invention also features a method of delivering the implant of claim 1 to a patient's body, the method comprising exposing a defective tissue on or within the patient's body and placing the implant on or over the tissue. The implant can be compressed, by hand or by a device, prior to being placed on or over the tissue.
[0025] The method for producing a three-dimensional biocompatible implant, the method comprising one or more of the following steps:
[0026] a) extruding a biocompatible polymer into a film,
[0027] b) transforming the film into a subassembly,
[0028] c) shaping the subassembly into a three dimensional structure,
[0029] d) heat setting the structure into the desired shaped article, and, optionally,
[0030] e) attaching the shaped article to a complementary implant article.
[0031] The invention also features a three-dimensional implant comprising two or more layers of two-dimensional biocompatible material with interconnecting supports, said implant constructed to securely fit within a tissue or muscle wall defect.
[0032] The implants of the invention may have one or more of the following advantages. They can be configured to allow or stimulate fibrosis (or fibrotic tissue ingrowth) in an organized pattern (tissue ingrowth under these circumstances may provide additional support to the previously defective tissue); they can have a reduced surface area and/or density (reduced with respect to present implants) that minimizes the inflammatory response and infection risk to the patient; they can have a degree of compression resistance that minimizes shrinkage and erosion of the implant into adjacent tissue structures and reduces the likelihood of collapse after insertion; they can have stress-strain properties that are compatible with the mechanical properties of the tissues they contact in the patient's body and therefore promote healing and minimize discomfort; they can be constrained (e.g., held within a biocompatible (e.g., non-toxic) tube or similar outer structure) and have a profile low enough to facilitate insertion and deployment within a patient in a minimally invasive fashion; they can be biodegradable or bioresorbable; and they can contain an onlay or anchor that can be secured in position in a short period of time. The anchor and three-dimensional soft tissue implant combination create a frictional force with the surrounding tissue to prevent migration. Implants that are less prone to migrate from the site of implantation can be used with fewer, if any, staples or sutures (it is expected that this will reduce complications associated with attachment to the surrounding tissues). Moreover, the implants of the invention can be economical to manufacture and highly reproducible, durable, and efficient.
[0033] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a perspective view of a weft knit subassembly.
[0035] FIG. 2 is a perspective view of a warp knit subassembly.
[0036] FIG. 2A is a perspective view of a weft knit subassembly with an internal support.
[0037] FIG. 3 is a perspective view of an implant.
[0038] FIG. 4 is a perspective view of a shaped implant.
[0039] FIGS. 5A-5C are perspective views of implants in various configurations. FIG. 5A illustrates an implant in a collapsed constrained configuration; FIG. 5B illustrates an implant in a collapsed constrained configuration positioned within a bodily defect; and FIG. 5C illustrates an implant in an unconstrained configuration within a bodily defect.
[0040] FIG. 6A is a perspective view of a three-dimensional implant with connection means to other implants.
[0041] FIG. 6B is a perspective view of the implants connected closely together.
[0042] FIG. 6C is a cross-sectional view of the connected implants positioned within a bodily defect.
[0043] FIG. 7 is a diagram showing the manufacturing steps.
[0044] FIGS. 8A-8C are perspective views of implants in various configurations. FIG. 8A is a perspective view of a non-woven subassembly; FIG. 8B is a non-woven three dimensional implant; and FIG. 8C is a side view of a non-woven three-dimensional implant.
[0045] FIG. 9A is a diagram of non-woven supports using the Mesh3 design.
[0046] FIG. 9B is a diagram of non-woven disks using the Mesh3 design.
[0047] FIG. 9C is a diagram of a unit cell of a non-woven soft tissue implant designated Mesh3
[0048] FIG. 9D is a display of various measured parameters within Mesh3 and the equations used to calculate the surface area ratio and surface area to volume ratio.
DETAILED DESCRIPTION
[0049] The present invention features methods of making and using three-dimensional biocompatible implants, as well as the implants per se. An implant, or a subassembly (or collections of subassemblies) therein (e.g., a weft knit subassembly or warp knit subassembly), can be constructed to resist compression when implanted in a warm-blooded animal (e.g., a mammal such as a human) for a period of time (e.g., one to six months, a year, or more).
[0050] Weft knit subassemblies can include knit materials that are produced by machine or hand knitting with the fibers running crosswise or in a circle. Warp knit subassemblies can include knit materials that are produced by machine or hand knitting with the yarns running in a lengthwise direction. Either or both subassemblies can be used in the three-dimensional implants of the present invention. As illustrated in the figures below, the subassembly can include woven or braided fibers (including those conforming to the weft knit or warp knit patterns just described) of a biocompatible (i.e., not toxic) material such as a non-absorbable polymer (e.g., polypropylene, polyethylene terephthalate, polytetrafluoroethylene, polyaryletherketone, nylon, fluorinated ethylene propylene, polybutester, silicone, and the like), a nonwoven material of a biocompatible (i.e., not toxic) material such as a non-absorbable polymer (e.g., polypropylene, polyethylene terephthalate, polytetrafluoroethylene, polyaryletherketone, nylon, fluorinated ethylene propylene, polybutester, silicone, and the like), an absorbable polymer (polyglycolic acid, polylactic acid, polycaprolactone, polyhydroxyalkanoate, polyglyconate, or copolymers thereof (e.g., a PGA:PLA copolymer (the ratio of PGA to PLA can be about 50:50)), a metal (e.g., stainless steel or nitinol), or a tissue-based material (e.g., collagen or a collagen-based or collagen-containing material).
[0051] Any of the implants described herein can have an internal support material (e.g., an intraluminal support), such as a polymer (e.g., polypropylene, polyethylene terephthalate, polytetrafluoroethylene, nylon, fluorinated ethylene propylene, silicone, polyurethane, rubber) or a metal (e.g., nitinol). The implant can also include polyaryletherketone (PEEK). PEEK polymer has properties that make it useful in implants of the invention that will be used in or around tissues other than soft tissues. For example, a three-dimensional implant of the invention that includes an internal support material such as PEEK can be used in spine cages, bone screws, orthopedic stems, and dental implants (of course, PEEK-containing implants can be made and used to improve defects in soft tissues as well). Invibio Inc., Lancashire, UK, manufactures PEEK. PEEK offers a desirable combination of strength, stiffness, and toughness, together with extensive biocompatibility. Because the PEEK polymer has enhanced mechanical properties, it is well suited for low material content implants. Soft tissue implants can be fabricated from smaller diameter fibers or thin films with lower profiles than commercially available implants.
[0052] The implants (e.g., the subassemblies) can be produced using a circular weft knitting process (with or without an internal support (e.g., with or without an underlying polymer, as described above, mall or a portion of the subassembly)) or a circular warp knitting process. Alternatively, the implants (or subassemblies) can be produced using a braiding process. Alternatively, the implants (or subassemblies) can be produced using a porous biocompatible film with cell patterns having thickness of less than about 0.025 inches (an exemplary cell pattern is shown in FIG. 9C ).
[0053] The implants can be produced by methods that include one or more of the following steps: extruding a biocompatible polymer into a fiber or film; transforming the fiber or film into a compression resistant subassembly; shaping, braiding, or weaving the subassembly into a three dimensional structure; heat setting the structure into the desired shaped article; and, optionally, attaching the shaped article to a complementary implant article (e.g., an anchor). These steps can be performed in the order given. The methods can also include removing shaping mandrels, internal supports, or intraluminal supports (where such are used, at, for example, the completion of the shaping, braiding, or weaving process).
[0054] As noted elsewhere, the subassemblies can include pores of, for example, 50-2000 microns in diameter (when the implant is placed in a resting or non-compressed position). The implant can assume any number of forms, which may be tailored for use in particular parts of the body or in response to certain defects. For example, the implant can have a conical form (as shown, for example, in FIGS. 8A , 8 B, and 8 C).
[0055] The implant subassembly can have a surface area ratio less than 3.0 (e.g., 0.50-3.0 or, for example, about 1.0), and the implant (or one or more of the subassemblies therein) can include an additional component such as an onlay or anchor or other means for stabilizing the implant during placement within a warm-blooded animal. The implants (or one or more of the subassemblies therein) can be connected to one or more implant components (e.g., an onlay and/or anchor) in a manner that permits independent placement and stabilization of the implants.
[0056] The methods of the invention (the methods of generating a three-dimensional implant and the methods for implanting that implant into a patient) can be used to repair essentially any defective tissue. For example, a three-dimensional biocompatible implant described herein can be applied to a tissue defect by way of a surgical procedure (these procedures will be analogous to those carried out in the art using different types of implants). The patient being treated may have, for example, a hernia or other tissue rupture, tear, or defect. The methods can include exposing a defective tissue on or within the patient's body and placing the implant on or over the tissue; before or during placement, the implant can be compressed, by hand or by a device.
[0057] Biocompatible fibers (used in, for example, the subassemblies) can be produced using a melt extrusion process. Luxilon Industries NV (Wijnegem, Belgium) produces medical grade fiber suitable for this application. Luxilon produces polypropylene fiber used for implants. Lamb Knitting Machine Corporation (Chicopee, Mass.) produces knitting equipment suitable for this processing step. The fiber is converted using either a circular weft-knitting machine or a warp knit braider.
[0058] The weft or warp knit subassemblies, with or without an intraluminal support (e.g., a polymer support such as PEEK polymer), can be braided into a three-dimensional implant structure. For example, Wardwell Braiding Machine Company located in Central Falls, R.I. produces braiding equipment suitable for this processing step.
[0059] The braided three-dimensional implant structure can be heat set into a more stable structure by heating the three-dimensional implant structure above its glass transition temperature. A suitable temperature for polypropylene materials is 150° C. Mandrels can be used to support the subassemblies so that a desired shape with predetermined dimensions is produced.
[0060] Biocompatible films (used in, for example, the subassemblies) can be produced using an extrusion and orientation process. Bard Peripheral Vascular (Tempe, Ariz.) produces expanded polytetrafluoroethylene film suitable for this application. The film can be machined into a design with cell patterns to impart a higher degree of porosity with a lower implant surface area ratio. The film can be converted into a three-dimensional object (e.g., a cylinder, cone, sphere, or block (e.g., an essentially square or rectangular block) using a cutting and heat setting process.
[0061] Medical implant applications for the soft tissue implant technology described above may include, but are not limited to, plastic reconstruction, hernia repair, vessel occlusion and other soft tissue reconstruction procedures where biocompatible fillers are required. The soft tissue implant can be produced in a variety of shapes and sizes for the particular indications. The shaped article can also be used for blood filtration applications. Non-medical applications may include diagnostic, biotechnology, automotive, electronics, aerospace, and home and commercial appliances applications.
[0062] Referring now to the figures:
[0063] FIG. 1 is a perspective view of weft knit subassembly 14 . The weft knit subassembly is made from biocompatible fiber 16 and has a known design and fiber count. Fiber count is characterized through needle and stitch densities for the material. The weft knit subassembly 14 is made of a biocompatible material.
[0064] FIG. 2 is a perspective view of a warp knit subassembly 18 . The warp knit subassembly 18 is made from biocompatible fiber 16 and has a known design and fiber count. The warp knit subassembly 18 is made of a biocompatible material.
[0065] FIG. 2A is a perspective view of a weft knit subassembly 14 with intraluminal support 15 . Biocompatible fibers 16 are found external to and, optionally, in physical connection with intraluminal support 15 . Intraluminal support 15 can provide a compression resistant structure during processing, and can be composed of a material that permits post-processing.
[0066] FIG. 3 is a perspective view of three-dimensional implant 20 . Weft knit subassembly 14 has been converted into braided three-dimensional implant 20 using braiding equipment.
[0067] FIG. 4 is a perspective view of shaped three-dimensional implant 22 (a conical implant). The braided three-dimensional structure has been heat set into a shaped three-dimensional implant 22 by placing shaping mandrels in the weft knit subassemblies 14 (composed of biocompatiable fiber 16 ) and applying heat.
[0068] FIG. 5A is a perspective view of a constrained three-dimensional implant 24 . The implant is collapsed and constrained by a hollow tube 26 to prevent expansion of the weft knit subassemblies 14 .
[0069] FIG. 5B is a perspective view of a constrained three-dimensional implant 24 positioned in a bodily defect 28 .
[0070] FIG. 5C is a perspective view of a shaped three-dimensional implant 22 unconstrained and filling the bodily defect 28 .
[0071] FIG. 6A is a perspective view of a shaped three-dimensional implant 22 , implant onlay 30 , and anchor 34 connected together with connecting filament 32 that permits individual placement of separate structures.
[0072] FIG. 6B is a perspective view of a shaped three-dimensional implant 22 , implant onlay 30 , and anchor 34 connected together with connecting filament 32 that prevents migration of the individual components.
[0073] FIG. 6C is a cross sectional view of a shaped three-dimensional implant 22 , implant onlay 30 , and anchor 34 connected together with connecting filament 32 positioned in a bodily defect 28 .
[0074] FIG. 7 is a diagram showing one possible combination of manufacturing steps.
[0075] FIG. 8A is a perspective view of a non-woven subassembly with biocompatible disks 40 and support members 42 . Both disks 40 and support members 42 have openings 43 , which allow the subassembly to slide together.
[0076] FIG. 8B is a perspective view of a non-woven three-dimensional implant with biocompatible disks 40 and support members 42 .
[0077] FIG. 8C is a side view of a non-woven three-dimensional implant with biocompatible disks 40 and support members 42 .
[0078] FIG. 9A is a diagram of non-woven supports 50 machined using the Mesh3 design with openings 43 to permit assembly. Pores 49
[0079] FIG. 9B is a diagram of non-woven disks 40 using the Mesh3 design with openings 43 which accommodate the support members.
[0080] FIG. 9C relates to a non-woven soft tissue implant designated Mesh3.
[0081] FIG. 9D is a display of various measured parameters within Mesh3 and the equations used to calculate the surface area ratio and surface area to volume ratio.
EXAMPLE
Example 1
[0082] A three-dimensional non-woven soft tissue implant was constructed using a biaxially-oriented polymer film. The film is stretched in both the machine and transverse directions (relative to the extrusion direction) to orient the polymer chains. The stretching process can take place simultaneously or sequentially depending on the equipment that is available. The base film was Syncarta™ (AET Films, Peabody, Mass.). The base film was machined into Mesh Design 3 (“Mesh3”) using a 3.0-Watt Avia Q-switched Ultraviolet Laser produced by Coherent, Inc. (Santa Clara, Calif.). The design of a cell for the non-woven soft tissue implant is shown in FIG. 9C . The soft tissue implant was cut into circular disks and triangular supports used to construct a three-dimensional implant. The calculation for the surface area for the components used to construct the three-dimensional implant is shown in FIG. 9D .
[0083] V implant ×((II(L implant )(R implant ) 2 )/3 where V implant is the volume of the cone shaped implant, L implant is the implant height, and R implant is the implant radius at the base; and
[0084] Surface Area to Volume Ratio=A surface implant /V implant .
[0000]
Implant
Implant
Surface
Surface
Volume
Area to
Product
Area (cm 2 )
(cm 3 )
Volume Ratio
Three Dimensional
53.89
21.61
2.49
Implant (Mesh Design 3)
[0085] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the implant can have other subassembly designs, different materials can be utilized, and alternate equipment can be used to produce the structures, etc. | Implants ( 20, 22 ) and methods of making the implants for treating bodily defects or remodeling tissue. The implants have a low density and open pores ( 49 ) which may permit tissue ingrowth. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/230,973 filed by the present inventors on Aug. 3, 2009.
The aforementioned provisional patent application is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a systems and methods for configuring interface systems for automatic test equipment.
2. Brief Description of the Related Art
Interface systems for automatic test equipment are typically composed of many different items potentially from many different manufacturers integrated together into a system. A typical interface system would have one or more card chassis, receivers, test adapters (also known as “ITA's”), instrument connections, terminal block cables, modules, patchcords and pins. The system also could include various external instruments.
In the past, the various component parts or pieces of an interface system commonly were selected and perhaps assembled by a service provider sometimes referred to as an “integrator.” The integrator would perform research to ensure that selected component parts of an interface system were compatible.
In recent years, a new XML-based standard for automatic test equipment, referred to as “Automatic Test Markup Language” or “ATML,” has emerged in the test and measurement industry. See, “ATML—The Standard for Interfacing Test System Components Using XML,” National Instruments (2006); “Draft Trial-Use Standard for Automatic Test Markup Language (ATML) for Exchanging Automatic Test Equipment and Test Information via XML,” IEEE P1671/D2 (December, 2005); and “AML (Automatic Test Markup Language),” The Test Savvy Engineer, (Oct. 1, 2007). ATML is a cooperative effort to define a collection of XML schemes to represent test information such as test programs, test asset interoperability, and unit under test (“UUT”) test data.
SUMMARY OF THE INVENTION
In a preferred embodiment, the present invention is a computer-implemented method for designing an electrical interconnect device. The method comprises the steps of entering an instrument ID into a computer through an input device, entering a slot number corresponding to the instrument ID into the computer through the input device, entering an interface component identifier into the computer through the input device, associating the interface component identifier with the instrument ID and the slot number in a database in the computer, generating and displaying on a computer display a preview of a configuration of an electrical interconnect device, wherein the preview comprises a table showing the instrument ID, the slot number, the interface component identifier and an association between the interface component ID and the instrument ID, and wherein the interface component ID shown in the preview comprises a link to data associated with the interface component; and displaying in a separate window on the computer display the data associated with the interface component. In various embodiments, the displayed data associated with the interface component may be retrieved from a database in a storage or from a website or server of, for example, a manufacturer or distributor of the interface component.
The method may further comprise steps of generating, displaying on the computer, and/or printing a price quotation for the configuration. Still further, the method may have means, such as the generation and sending of an electronic mail message, to provide the generated price quotation for the configuration to a customer.
In another embodiment, the present invention is a computer-implemented method for designing an electrical interconnect device. The method comprises the steps of displaying on a display connected to a computer a request form requesting a plurality of instrument ID's from a user, providing a plurality of instrument ID's entered on the request form to a server, generating on the server a configuration database corresponding to the plurality of instrument ID's entered on the request form, associating a slot number with each of the plurality of instrument ID's in the configuration database, populating the configuration database in the server with a plurality of component identifiers, associating each of the plurality of component identifier with one of the instrument ID's and a slot number in the configuration database and generating and displaying on a computer display a preview of a configuration based upon data in the configuration database. The method may further comprise the step of providing on the preview a link to data associated with a displayed instrument ID. Still further, the method may comprise the step of displaying as an overlay on the preview the data associated with a displayed instrument ID.
Still other aspects, features, and advantages of the present invention are readily apparent from the following detailed description, simply by illustrating a preferable embodiments and implementations. The present invention is also capable of other and different embodiments and its several details can be modified in various obvious respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. Additional objects and advantages of the invention will be set forth in part in the description which follows and in part will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description and the accompanying drawings, in which:
FIG. 1 is a block diagram of an exemplary system of a preferred embodiment of the present invention;
FIG. 2 is a flow chart of the method of an interface system configurator in accordance with a preferred embodiment of the present invention.
FIG. 3 is a diagram of a blank user interface of an interface system configurator in accordance with a preferred embodiment of the present invention.
FIG. 4 is a diagram of an interface configuration preview in accordance with a preferred embodiment of the present invention.
FIG. 5 is a diagram of an interface configuration preview with an instrument data link opened in accordance with a preferred embodiment of the present invention.
FIG. 6 is a diagram of an interface configuration preview with a receiver data link opened in accordance with a preferred embodiment of the present invention.
FIG. 7 is a diagram of a request form open in accordance with a preferred embodiment of the present invention.
FIG. 8 is a diagram of a display provided to a Configuration Administrator during generation of a quotation in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The interface configuration system of the present invention provides for a web-based approach to interface configuration and design in which a configuration request can be configured and displayed in a user-friendly layout for the customer. A preferred embodiment of the present invention provides for a request to be submitted via an on-line form and then configuring a system meeting the request and providing a display showing horizontal and vertical relationships between various components in the configuration. The present invention provides many benefits, including but not limited to, allowing organization of part numbers to assemble and communicate a desired configuration, keyword hinting to assist in developing a configuration request, displaying a product information window to show additional information about a product or component and linking a configuration to other configurations or other software.
A preferred embodiment of the present invention will be discussed with reference to FIGS. 1-6 . FIG. 1 shows the system architecture in which a preferred embodiment of the present invention may be used. The system and method of the present invention may be run on a local system 110 that may, for example, have a server 112 , a storage 114 , a local area network 116 , and one or many terminals or PC's 118 , each of which may be used to access the computer-implemented configurator of the present invention. The local system 112 preferably has access to websites of various other manufacturers 130 , 140 and customers 150 , for example, through the internet 120 . The server 112 and/or the one or many terminals or PC's 118 may access the internet and thereby retrieve data. Additionally, the server 112 and the one or many terminals or PC's may access data, such as in a database, stored in storage 114 or in a memory.
The system and method of the present invention may be implemented in many different ways and may use various levels of security. For example, system configurations may be designed using the present system and method by an individual that may be referred to as “Configuration Administrator,” who may have the right to design and amend a particular configuration and perhaps be given the ability to authorize others, such as customers, to amend a particular configuration.
A method of a preferred embodiment of the present invention will be described with reference to FIG. 2 . Beginning at step 210 , the configurator is opened on a terminal or PC 118 . The user interface of a preferred embodiment is shown in FIG. 3 . In the example shown in FIG. 3 , the user interface includes locations for the configuration administrator to enter identifying information such as a customer name 302 , company name 304 , configuration name 306 , an engineer or other assignee 308 , a sales rep 310 , and an e-mail address 312 . The fields, of course, are merely exemplary as fewer or more fields may be used and different layouts of the fields may be used. The system further may include the ability to customize the user interface. Similarly, the steps for entering various information described below may be performed in various different sequences and do not necessarily need to be entered in the sequence described with respect to the preferred embodiment.
The Configuration Administrator may, for example, begin with a preliminary step of entering a manufacturer and make of a particular card chassis 320 for which the interface is being configured. The Configuration Administrator similarly may enter a recommended receiver 322 and ITA 324 as preliminary steps.
At step 220 , the Configuration Administrator begins by entering an instrument ID 330 . Once the instrument ID 320 is entered, the system finds instrument data regarding the instrument corresponding to that ID. The instrument data may include compatibility data, pictures, or any other data that may be relevant. The data may be retrieved automatically from any of a variety of sources, such as a database stored locally on storage 114 , from a manufacturer's website 130 or from both. For example, a database located on local storage 114 may include website information or links associated with particular manufacturers or particular part numbers such that when an instrument number is entered at step 220 , the system (step 222 ) retrieves a link from the database and then proceeds to the linked website to retrieve specific data. In another embodiment, rather than retrieving a link or web address from the database, the system may automatically search for the manufacturer and/or part number through the internet and, once found, proceed to the manufacturer's website to retrieve the data. If the website is not found, data may be retrieved from a database and perhaps a note would be added to the instrument entry indicating that the data must be verified. To retrieve data from a manufacture's website, one may use, for example, Automated Test Markup Language (“ATML”). See “IEEE P1671/D2 Draft Trial-Use Standard for Automatic Test Markup Language (ATML) for Exchanging Automatic Test Equipment and Test Information via XML,” (2005) and “ATML—The Standard for Interfacing Test System Components Using XML,” National Instruments (2006).
At step 224 , the Configuration Administrator enters a slot number 332 corresponding to the instrument ID entered at step 220 . The method may include error-preventing techniques to prevent a user from entering incorrect or incompatible part numbers. At step 224 , for example, the system may use data retrieved in step 222 for the particular instrument to ensure that the Configuration Administrator enters the correct number of slots for the particular instrument. The error-prevention techniques could include displaying a warning to a user that incorrect data may have been entered, may simply prohibit entry of incorrect data, or may initially prohibit such entry but permit a Configuration Administrator to override the protection. At any of the data retrieval steps, the local system 110 may store or update information regarding manufacturers, parts or websites in a database. In this manner, a local database of information may be compiled. Such a local database may be used, for example, in a situation in which a configuration is being made at a time when a manufacturer's website is unavailable. The system and method could further include means to tag entries pulled from a local database such that the system may access a manufacturer's database at a later time to confirm the accuracy of the data retrieved locally.
Next, at step 230 the Configuration Administrator enters a component ID 334 . The system then retrieves data regarding the component associated with the component ID at step 232 . As with step 222 , the system may retrieve the component data in any of a variety of ways. The system then checks at step 234 whether the component entered at step 230 is compatible with the instrument entered at step 220 . If the component is not compatible, the system may, for example, display an error message to the Configuration Administrator and request correction (step 236 ). The system may or may not provide the Configuration Administrator with the ability to override the error message and continue to step 240 . This may be useful, for example, if the Configuration Administrator is aware the incorrect compatibility data exists for a particular component. If the entered component is compatible with the instrument entered at step 220 , the system then associates the two locally as part of the interface system configuration.
The user then has a choice 250 of entering more components by returning to step 230 or proceeding to save the configuration in storage 114 at step 260 . The user similarly may enter additional instruments and components for such additional instruments. When the configuration is saved, the system may for example assign a configuration number 340 to later identify this particular configuration. The configuration number 340 may be assigned automatically, such as with a random 7-digit number, or may be chosen by the user. Similarly, the date 350 on which the configuration was designed or modified may be entered automatically or manually.
The Configuration Administrator then may preview the configuration or provide access to such a preview to a customer or manufacturer so they may review and possibly amend the configuration (step 270 ). If a preview is selected, at step 280 the system finds links to manufacturer's websites for as many of the instruments, components and cards as possible and at step 282 generates and displays a preview of the configuration, such as is shown in FIG. 4 . The preview includes the links found by the system, which are displayed at step 286 at the selection of the user at step 284 . For example, FIG. 5 shows a preview with an instrument data link 510 . Similarly, FIG. 6 shows a preview with a receiver data link 610 opened. The data may be displayed in a call-out such as is shown in FIGS. 5 and 6 or by other means such as by opening a new window for the data or opening the manufacturer's website directly. If links are not found for particular instruments or components data from a database may or may not be displayed in place of data from a manufacturer's website.
After reviewing the data, the user may be given the option of amending the configuration (step 288 ), in which case the system would return to step 220 . If the user does not wish to amend the system, the preview would be closed and ultimately, at step 290 , the configurator would be closed.
The system and method further include the ability of a user to later access the configuration and if they so desire, amend the configuration. At such a time, the system may include automated methods to re-check or confirm the accuracy and compatibility of the data for various instruments and components in the configuration. The Configuration Administrator may receive a customer's request by any number of means. In one embodiment, a request form may be presented to a user via an electronic display. In FIG. 7 , a request form 710 is shown superimposed over a configuration designer with the standard screen obscured. The request form 710 may include keyword hinting to assist the customer in selecting appropriate instrumentation. Default settings, such as a quantity of 1, may be used. A user's information may appear at the bottom of the request form and may be pre-populated based upon, for example, login data entered by a user. Once a user completes a request form, the user submits the request and a confirmation notice such as an electronic mail message or test message may be sent to the user by the system. The system may further include the ability to display a summary of various configurations submitted, for example, by a particular user or customer. Such summary may be presented in table form or may, for example, be produced on an Excel worksheet. Furthermore, information from a particular request may be downloaded into, for example, an Excel spreadsheet for display.
Once a request is submitted, the local system may generate and display a quote for purchase of the configuration. The generation of the quotations may include steps in which a summary 810 or summaries of the various components in the configuration are displayed to the Configuration Administration, such as is shown in FIG. 8 . During such a display step, the Configuration Administrator may select and deselect various items and modify quantities.
In other embodiments, various pieces of information may be entered automatically by the system. For example, if the system is being run by a particular receiver manufacturer, that manufacturer's receiver product information may be entered automatically by the system once the user enters an instrument identification or part number. Variations in which additional or other information is entered automatically by the system will be apparent to those of skill in the art.
The foregoing description of the preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiment was chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents. The entirety of each of the aforementioned documents is incorporated by reference herein. | A computer-implemented method for designing an electrical interconnect device. The method comprises the steps of entering an instrument ID into a computer through an input device, entering a slot number corresponding to the instrument ID into the computer through the input device, entering an interface component identifier into the computer through the input device, associating the interface component identifier with the instrument ID and the slot number in a database in the computer, generating and displaying on a computer display a preview of a configuration of an electrical interconnect device, wherein the preview comprises a table showing the instrument ID, the slot number, the interface component identifier and an association between the interface component ID and the instrument ID, and wherein the interface component ID shown in the preview comprises a link to data associated with the interface component, and displaying in a separate window on the computer display the data associated with the interface component. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based for priority upon provisional application Serial No. 60/314,879, filed Aug. 24, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to cured epoxy resin and polyglycoside-based cured polymers and to a process and compositions for the preparation of these polymers. In particular, the present invention relates to the curing of epoxy resin precursors with a polyglycoside based polymer. The polymers can contain fillers of various known types, preferably those which are natural. The polyglycoside moiety provides a degree of biogradability to the resulting polymer not usually available in epoxy resin based polymers. The polymers are stable to elevated temperatures up to 300° C., and thus are useful in vehicle engine compartments for sound deadening and the like.
[0004] 2. Description of Related Art
[0005] Recently, there has been increasing interest in the use of biocomposites of natural fibers, particularly cellulosic fibers, especially in the automobile industry. These composites are reported to offer advantages of ˜20% reduction in processing temperature and ˜25% reduction in cycle time in addition to a weight reduction of about ˜30% over conventional glass fiber composites (Saheb, D. N., et al., Advances in Polymer Technology 18 4 351 (1999)). For automotive applications biocomposites have to meet several demanding requirements such as temperature resistance and wet environmental resistance (Reussmann, T., et al., Advanced Engineering Materials 1, 2, 140 (1999)). The incorporation of biobased polymer with natural fibers would be the best combination for development of environmentally friendly composites if the developed biocomposites meet the demanding requirements.
[0006] Glucose maleic acid ester vinyl copolymer (GMAEVC) has been developed to use as a biodegradable adhesive for the paper and packaging industry. GMAEVC contains reactive carboxylic and hydroxyl functional groups in its structure. This leads to cost effective and better performing of biocomposites.
[0007] U.S. Pat. Nos. 5,869,173 and 6,171,688 to Zheng to al show composites which can be formed.
OBJECTS
[0008] It is therefore an object of the present invention to provide novel epoxy resin and polyglycoside based polymers. Further, it is an object of the present invention to provide such polymers which have a degree of biodegradability and high temperature resistance. These and other objects will become increasingly apparent by reference to the following description and the Figures.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a curable polymer composition which comprises:
[0010] (a) an epoxy resin precursor; and
[0011] (b) a co-polymer of a polyglycoside acid or acid ester reacted with an organic anhydride or acid, and optionally with a vinyl monomer, wherein the ratio of (a) to (b) produces a cured polymer composition.
[0012] In particular the present invention relates to a curable polymer composition which comprises:
[0013] (a) an epoxy resin precursor; and
[0014] (b) a copolymer of a polyglycoside acid or acid ester of the formula II or III as follows:
[0015] and mixtures thereof and optionally a vinyl monomer, wherein R and R″ are alkyl containing 1 to 30 carbon atoms and wherein the ratio of (a) to (b) produces a cured polymer composition. X and y are integers between 0 and 4 but x and y are not 0 at the same time.
[0016] The present invention particularly relates to a curable polymer composition which comprises:
[0017] (a) liquid epoxy resin; and
[0018] (b) a copolymer of the formula as follows:
[0019] wherein Glu is a saccharide moiety which is derived from a sugar selected from the group consisting of α-D-glucose, fructose, mannose, galactose, talose, gulose, allose, altrose, idose, arabinose, xylose, lyxosc, ribose, and mixtures thereof, or by hydrolysis of a material selected from the group consisting of starch, corn syrups, maltodextrins, maltose, sucrose, lactose, maltotriose, xylobiose, mellibiose, cellobiose, raffinose, stachiose, levoglucosan, 1,6-anhydroglucofuranose, and mixtures thereof, and wherein the ratio of (a) to (b) produces a cured polymer composition, wherein R 1 and R 2 are substituent groups of a vinyl monomer or mixture of vinyl monomers, wherein said vinyl monomer or mixture of vinyl monomers is selected from the group consisting of vinyl acetate, ethyl hexyl acrylate, butyl acrylate, ethyl acrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, lauryl acrylate, methyl methacrylate, methacryclic acid, acrylic acid, other acrylates, mixtures of different acrylate monomers, ethylene, 1,3-butadiene, styrene, vinyl chloride, vinylpyrrolidinone, other vinyl monomers, and mixtures thereof, R is selected from the group consisting of a C1 to C30 alkyl and mixtures thereof, R is selected from the group consisting of a C1 to C30 alkyl and mixtures thereof, or a hydrogen, n is an integer ranging from 0 to 10; x and y are integers ranging from 0 to 4, but not x and y are 0 at the same time, p and q are integers ranging from 0 to 1000, but not both p and q are zero, and wherein ˜˜˜ indicates continuing polymer chains.
[0020] Preferably Glu is an α-D-glucose moiety. Preferably the molar ratio of (a) to (b) is about 1:1. Preferably an alkyl polyglycoside is reacted with malic anhydride to form the polymer which is reacted with the vinyl monomer to form the copolymer. Preferably R 1 and R 2 and R″ are selected from the group consisting of hydrogen and n-butyl.
[0021] The composition includes a filler. A fiber, particularly a cellulosic fiber, is preferred. Clay can be used as a filler. The compositions are cured to solid resins with or without the fillers.
[0022] The present invention also relates to a process for forming a cured polymer composition which comprises:
[0023] (a) providing a mixture of (1) a liquid mixture of an epoxy resin precursor and (2) a polyglucoside-organic anhydride reaction product which has optionally been polymerized with a vinyl monomer, wherein the ratio of (1) to (2) provides the cured polymer composition; and
[0024] (b) heating the mixture to produce the cured polymer.
[0025] In particular the present invention relates to a process for forming a cured polymer composition which comprises:
[0026] (a) providing (1) a liquid epoxy resin precursor and (2) a liquid copolymer of a polyglycoside acid or acid ester of the formula II or II as follows:
[0027] and mixtures thereof which has optionally been reacted with a vinyl monomer wherein R and R 11 are alkyl contain 1 to 30 carbon atoms, x and y are integers between 0 and 4 but not x and y are o at the same time and wherein the ratio of (1) to (2) produces the cured polymer composition; and
[0028] (b) heating the mixture to produce the cured polymer composition.
[0029] Further, the present invention relates to a process for the preparation of a cured polymer composition which comprises:
[0030] (a) providing a mixture of
[0031] (1) a liquid epoxy resin; and
[0032] (2) a liquid copolymer of the formula I as follows:
[0033] wherein Glu is a saccharide moiety which is derived from a sugar selected from the group consisting of α-D-glucose, fructose, mannose, galactose, talose, gulose, allose, altrose, idose, arabinose, xylose, lyxosc, ribose, and mixtures thereof, or by hydrolysis of a material selected from the group consisting of starch, corn syrups, maltodextrins, maltose, sucrose, lactose, maltotriose, xylobiose, mellibiose, cellobiose, raffinose, stachiose, levoglucosan, 1,6-anhydroglucofuranose, and mixtures thereof, , wherein R 1 and R 2 are substituent groups of a vinyl monomer or mixture of vinyl monomers, wherein said vinyl monomer or mixture of vinyl monomers is selected from the group consisting of vinyl acetate, ethyl hexyl acrylate, butyl acrylate, ethyl acrylate, hydroxyethyl acrylate, hydroxyethyl methacrylate, lauryl acrylate, methyl methacrylate, methacryclic acid, acrylic acid, other acrylates, mixtures of different acrylate monomers, ethylene, 1,3-butadiene, styrene, vinyl chloride, vinylpyrrolidinone, other vinyl monomers, and mixtures thereof, R is selected from the group consisting of a C1 to C30 alkyl and mixtures thereof, R is selected from the group consisting of a C1 to C30 alkyl and mixtures thereof, or a hydrogen, n is an integer ranging from 0 to 10; x and y are integers ranging from 0 to 4, but not x and y are 0 at the same time, p and q are integers ranging from 0 to 1000, but not both p and q are zero, and wherein ˜˜˜ indicates continuing polymer chains, and wherein the ratio of (1) to (2) produces a cured polymer composition; and
[0034] (b) heating the mixture to produce the cured polymer composition.
[0035] Preferably R 1 , R 2 and R″ are selected from the group consisting of hydrogen and n-butyl. The epoxy resin precursor is preferably derived from the diglycidyl ether of bisphenol A. Preferably the epoxy resin precursor is derived from the diglycidyl ether of bisphenol A.
[0036] A “Glycoside” is a compound of a sugar with another substance, wherein sugar hydrolyzes to its constituents: glucosides yield glucose, fructosides yield fructose, galactosides yield galactose, and the like.
[0037] A “polyglycoside” is a polymerized glycoside wherein multiple sugars are joined together and then connected to another organic group.
[0038] The present invention particularly relates to an environmentally friendly biocomposites polymer matrix composed of glucose based copolymer and epoxy resin and to biocomposites with natural fibers, particularly cellulosic fibers, as reinforcements. The primary advantage of this invention over previous approaches are that the polyglycoside polymers are environmentally friendly and cost effective. The polymer matrix for this invention is preferably composed of 50 wt % by weight of glucose based copolymer and 50% by weight of epoxy resin. The glucose based copolymer is a biodegradable. The preferred glucose based copolymer is thus used as a hardener for epoxy resin of the polymer matrix formulation. Hence the polymer matrix formulations do not need any toxic and expensive curing agents that are used to conventional epoxy curing systems.
[0039] The cured polymer matrix shows the relatively constant performances in the wide ranges of curing conditions. The curing process of the polymer matrix depends only on the energy that induces the reaction between glucose based copolymer and epoxy resin. Hence a temperature controlled convection oven can be necessary for the even temperature distributions on curing of the samples for the scale up. The poor heat transfer property of the polymer matrix can cause the sticky property of the less cured polymer matrix or volume shrinkage of the over cured polymer matrix if the curing is not controlled. The lamination of the polymer matrix sheets to fillers can be alternative methods for implementation. Alternatively microwave, RE electron beam and UV processing can be used.
[0040] The matrix formulation is very stable at room temperature so the pot life is long enough for applying it to the fabrication process. The cured polymer matrix shows thermal stability up to 300° C. and maintains the mechanical performance in wet environments. The polymer shows good compatibility with hydrophilic natural fibers, particularly cellulosic fibers, to fabricate biocomposites, making special treatments of hydrophobic polymer matrix or hydrophilic fiber surface to improve the adhesion unnecessary. The markets for this invention can be expected for the transportation, infrastructure and building industries.
[0041] The fillers and their properties are shown in Table 1.
TABLE 1 Comparative properties of some natural fibers with conventional man-made fibers DENSITY DIAMETER TENSILE STRENGTH YOUNG'S MODULUS ELONGATION FIBER (G/CM 3 ) (μM) (MPA) (MPA) AT BREAK (%) Cotton 1.5-1.6 — 287-800 5.5-12.6 7.0-8.0 Jute 1.3-1.45 25-200 393-773 13-26.5 1.16-1.5 Flax 1.50 — 345-1100 27.6 2.7-3.2 Hemp — — 690 — 1.6 Ramie 1.50 — 400-938 61.4-128 1.2-3.8 Sisal 1.45 50-200 468-640 9.4-22.0 3-7 PALF — 20-80 413-1627 34.5-82.51 1.6 Coir 1.15 100-450 131-175 4-6 15-40 E-glass 2.5 — 2000-3500 70 2.5 S-glass 2.5 — 4570 86 2.8 Aramid 1.4 — 3000-3150 63.67 3.3-3.7 Carbon 1.7 — 4000 230-240 1.4-1.8
[0042] The cellulosic fibers are preferred, particularly cellulosic nanofibers (See FIGS. 11 to 13 ). Exfoliated clays and graphites can also be used as fillers.
BRIEF DESCRIPTION OF FIGURES
[0043] [0043]FIG. 1 is a graph of a DSC Scan of DGEBA and GMAEVC Blend.
[0044] [0044]FIG. 2 is a graph of a FTIR spectra of DGEBA and GMAEVC blend.
[0045] [0045]FIG. 3 is a graph of a conversion of epoxy and hydroxyl groups of DGEBA and GMAEVC blend.
[0046] [0046]FIG. 4 is a graph showing a TGA curves of GMAEVC and cured matrix.
[0047] [0047]FIGS. 5A and 5B are graphs of C1s and O1s spectra of the cured matrix of DGEBA and GMAEVC.
[0048] [0048]FIG. 6 is a graph showing water absorption of the cured matrix of DGEBA and GMAEVC versus time.
[0049] [0049]FIGS. 7A and 7B are graphs showing performance changes of the cured matrix after water absorption test.
[0050] [0050]FIGS. 8A and 8B are graphs showing C1s and O1s concentrations with different NaOH concentrations.
[0051] [0051]FIG. 9 is a graph of a TGA of raw and alkali treated henequens.
[0052] [0052]FIGS. 10A and 10B are graphs showing effects of raw and alkali treated fibers on the performances of biocomposite.
[0053] FIGS. 11 to 13 show various cellulosic fibers.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0054] The preferred polyglycoside based polymers are described in U.S. Pat. Nos. 5,872,199 and 6,242,593 to Bloembergen et al which are incorporated herein in their entirety.
[0055] The epoxy resins are well known to those skilled in the art and are described in Kirk-Othmer, John Wiley & Sons, 9 267-290 (1980). They are available from a variety of commercial sources including Shell Co., Ciba, and The Dow Chemical Company.
[0056] Bisphenol A type EPON-828 (Shell Co.), is an epoxy resin precursor with the bisphenol A structure and a molecular weight of 380, and has the formula:
[0057] wherein n=0 (88%); n=1 (10%); n=2 (2%).
[0058] Bisphenol-A type, DER 331 (Dow Chemical Co., Midland, Mich.), is an epoxy polymer precursor and is an analog to Epon-828 having the formula:
[0059] Bisphenol-F type, DER 354 (Dow Chemical Co.) is an epoxy polymer precursor having the formula:
[0060] Novolac type, DER 43, DER 438 and DER 439 (Dow Chemical Co.) are epoxy polymer precursors having the formula:
[0061] wherein n is between about 0.2 and 1.8.
[0062] Epoxy polymer, DER 732 (Dow chemical Co. is an epoxy resin precursor of the general formula:
[0063] There are numerous other types of epoxy polymer precursors which are suitable and which are well known to those skilled in the art.
[0064] Amine curing agents can be used to cure the epoxy resin precursors into a solid epoxy resin along with the polyglycoside-based polymer, although this is not preferred. Curing agents are, for instance, linear polyoxypropylene di- or triamines which are sold as JEFFAMINES, Huntsman Chemical Company, Austin, Tex. The polyoxypropylene diamines (D-series) of the formula:
[0065] wherein x is between about 4 and 40 can be used.
[0066] The linear diamines previously described when used as curing agents for the epoxy resin precursors produce a glass transition temperature of less than ambient temperatures (25° C.) And preferably less than 0° C. As a result, when cured to a pristine epoxy resin without any filler, the resins are flexible when x is between about 4 and 40 in the polyoxypropylene diamine, the cured epoxy resin is also elastic.
[0067] The T series JEFFAMINES can be used. These are
[0068] wherein x+y+z between about 4 and 120.
[0069] Various other epoxy resin curing agents, such as anhydrides and amides, can be used. The amide curing agents are for instance
[0070] where X is between about 5 and 15.
EXAMPLES
[0071] A blend of DGEBA based epoxy resin and glucose maleic acid ester vinyl copolymer (GMAEVC) as a matrix for composites was used in order to develop environmentally friendly biocomposites for high temperature automotive applications. The reaction mechanism of DGEBA and GMAEVC was investigated by DSC and FTIR methods. Three different exothermic reactions were identified upon curing and attributed to etherification and esterification reactions of the hydroxyl and carboxylic functionalities of GMAEVC with the epoxy groups of the DGEBA resin. The cured matrix containing 50 wt % of GMAEVC showed thermal stability up to 300° C. The glass transition temperature and storage modulus of the matrix were as high as 97° C. and 2700 Pa, respectively. A water absorption test was performed to examine the stability of this matrix in wet environments. A slight weight increase and glass temperature decrease of the matrix due to water uptake were observed. However, the matrix did not show any change in mechanical performance and the original glass transition temperature was recovered after heating the matrix up to 150° C. Biocomposites composed of this matrix and henequen fibers with different conditions were manufactured and characterized. This formulated matrix showed good compatibility with henequen fibers. Finally, this study illustrates the possible future developments of biocomposites for high temperature automotive applications based on a blend of DGEBA and GMAEVC as a matrix and natural fibers as reinforcements.
[0072] Epoxy resin Epoxy resin, Tactix 123, based on diglycidyl ether of bisphenol A (DGEBA) was purchased from Ciba Chemical Co. The viscosity of the resin is 5000 cps at 25° C. and the epoxy equivalent weight is 172-176 g/mol. The structure of the monomer is shown in Structure 1.
Structure 1: The DGEBA Molecule
[0073] Glucose maleic acid ester vinyl copolymer GMAEVC was obtained from EcoSynthetix Co. (Lansing, Mich.) and used as received. The average molecular weight of GMAEVC is 420 g/mol. The structure of GMAEVC is shown in Structure 2. Degrees of polymerization of glucose (x) and of substitution of maleate ester group (y) are 1.1-1.3 and 1.4, respectively. The substituents of GMAEVC (R″′, R 1 , R 2 ) are either hydrogen or n-butyl groups (U.S. Pat. No. 5,872,199 (1999), B. Steven). GMAEVC starts to decompose at 165° C. and degrades at temperatures over 110° C. The comparison of FTIR spectra between original GMAEVC and the degraded GMAEVC shows that the —C—O—C— peak characteristic of the glucose and vinyl groups peaks disappeared. A new peak due to the presence of free —C(O)—O− functional group appeared with the GMAEVC degradation. It was also found that the broad peak for the hydroxyl group changed to a sharp peak when the glucose ring opened and formed free hydroxyl groups (S. O. Han, 222 nd American Chemical Society Meeting; Polymer Priprint , (2001)).
Structure 2: Glucose Maleic Acid Ester Vinyl Copolymer Molecule
[0074] Henequen fiber Henequen (Agave fourcroydes) fibers were obtained from Cordemex, S. A. of Merida, Yucatan, Mexico. Henequen fibers were washed with water and dried in air. Dried henequen fibers were vacuum dried at 110° C. for one hour and used as raw henequen fibers. Raw henequen fibers were treated in NaOH solutions of different concentrations to prepare alkali treated henequen fibers. Raw henequen fiber was immersed in 2,5,10 wt % NaOH solutions for one hour, respectively, then washed with running water. The fibers were neutralized with 2 wt % acetic acid solution, washed with water and dried in air. Alkali treated henequen fibers were vacuum dried for one hour prior to composite fabrication. The properties and surface composition of raw and alkali treated henequen fibers were compared with TGA and XPS analysis.
[0075] Experimentation The blend of 50 wt % of DGEBA and GMAEVC was chosen to investigate the curing reaction between DGEBA and GMAEVC and the performance of the cured matrix.
[0076] DSC monitoring of the reaction between DGEBA and GMAEVC A DSC study was performed under a nitrogen atmosphere using a DSC2920 modulated differential scanning calorimeter from TA instruments. High purity indium was used to calibrate the calorimeter. Real time monitoring of the curing of DGEBA and GMAEVC was performed in an aluminum pan in the 30° C. to 350° C. temperature ranges.
[0077] FT-IR monitoring of th reaction between DGEBA and GMAEVC Curing of DGEBA with GMAEVC was quantitatively analyzed by transmission FTIR spectroscopy using a Perkin Elmer FTIR system 2000 model, equipped with a conventional TGS detector. Samples were prepared by casting a thin film of resin onto a sodium chloride plate and placed in a heating cell in the spectrometer to carry out the reaction from 100° C. to 180° C. at a heating rate of 1° C./min. The temperature of the heated cell was monitored with a DigiSense temperature controller from the Cole Parmer Co. The FTIR spectra were collected at different temperatures and compared to the FTIR spectra of fully cured samples prepared in an oven to confirm the polymerization products. The conversion of epoxy and hydroxyl groups in the formulation based on DGEBA and GMAEVC were calculated from the FTIR spectra. The 1509 cm −1 band was unchanged upon curing, and subsequently, was used as an internal standard (B. Defoort, SAMPE International Symposium , (2001)). The decrease of the band at 912 cm −1 assigned to the epoxy function permits accurate measurement of the monomer conversion via the following relation, where Π is the functional conversion and T is temperature. For the hydroxyl function conversion the maximum point of the hydroxyl group peak in the region of 3650-3124 cm −1 was measured at each temperature.
Π ( epoxy ) = 1 - A 912 ( T ) A 1509 ( T ) A 912 ( T = 100 ) A 1509 ( T = 100 ) Π ( hydroxyl ) = 1 - A max ( T ) A 1509 ( T ) A 3512 ( T = 100 ) A 1509 ( T = 100 )
[0078] Thermo-mechanical Analysis The glass transition temperature and the modulus of the cured DGEBA and GMAEVC were measured by dynamic mechanical analysis in the single cantilever mode, at a frequency of 1 Hz. DMA runs were recorded with a DMA 2980 Dynamic Mechanical Analyzer from TA instruments. The glass transition temperature was measured at the maximum of the Tan delta (δ) curve deduced from DMA experiments. Storage modulus of the matrix was determined at 40° C.
[0079] Thermal stability Analysis Thermal stability of the cured matrix was analyzed under a nitrogen atmosphere using a TGA2950 thermal gravimetric analyzer from TA instruments. The thermal stability of raw and alkali treated henequen fibers were also evaluated.
[0080] Surface Analysis X-ray Photoelectron Spectroscopy examination was used to determine the functional groups on the surface of the cured matrix. Perkin Elmer Physical Electronics PHI 5400 ESCA Spectrometer equipped with standard magnesium X-Ray source operated at 300 W (15 kV and 20 mA) was used for surface analysis. Surface analysis of raw henequen and alkali treated henequen fibers were also measure and compared.
[0081] Procedure
[0082] Matrix Preparation DGEBA and GMAEVC were heated to 90° C. separately and mixed by a melt-blending process. This mixture was used to study the curing of DGEBA and GMAEVC by DSC and FTIR in real time. The mixture was degassed for 10 minutes in a vacuum oven at 90° C. and cured in a silicone mold (1.2 cm×7.5 cm×0.03 cm). Curing was completed with heating the matrix at 175° C. for 2 hours and 200° C. for 2 hours, consecutively, in an air-circulating oven at a heating rate of 5° C./min.
[0083] Water Absorption Test on Matrix To investigate the stability of the cured matrix of DGEBA and GMAEVC in wet conditions the water absorption test was performed. The cured matrices were dried in an oven at 110° C. for one hour. Immediately upon cooling, the specimens were weighed. The specimens were immersed in distilled water at ambient temperature and weighed at predetermined times. Every procedure was performed by following ASTM D570-98: Standard test methods for water absorption of plastics (ASTM D570-98; Standard test methods for water absorption of plastics). The specimen size was 1.2 cm×7.5 cm×0.03 cm and the water gain percentage, M %, was determined from the equation:
M % = ( W - W d ) W d × 100
[0084] W is the weight of the water absorbed specimen and W d is the initial weight of the dry specimen. To ensure the removal of excessive surface water, specimens were gently wiped dry using clean, lint-free tissue paper and allowed to stand free at ambient environment for 2 minutes. To examine the reaction between water and the matrix, the specimen that was immersed in the water for 1056 hours was dried in an air-circulating oven at 110° C. for an hour. The weight gain of this specimen was compared to the weights of both dried and water absorbed for 1056 hours specimen.
[0085] Preparation of Biocomposites with the Matrix and
[0086] Henequen fibers Henequen fibers were vacuum dried for one hour prior to composite fabrication. The degassed matrix was poured onto the henequen fibers in silicone molds and degassed. The composite was cured at 175° C. for 2 hour and 200° C. for 2 hours, consecutively, at a heating rate of 5° C./min. The fiber loading was determined by the fibers weight and fiber density. The density of henequen fiber was determined as 0.44 g/cm 3 by the density measurement. The calculated amount of henequen fiber in the matrix was approximately 40 vol %.
Results and Discussion
[0087] Matrix Characterization Characterization of the matrix was performed to examine the possibility of utilizing this matrix for biocomposite applications with henequen fibers.
[0088] DSC monitoring of the reaction A DSC scan of a mixture of DGEBA and GMAEVC during heating from 30° C. to 350° C. is shown in FIG. 1. Three exothermal peaks are observed in the regions of 90-170° C., 180-240° C. and 260-300° C., respectively. These peaks are attributed to the hydroxy-epoxy etherification, carboxylic-hydroxyl esterification and carboxylic-epoxy esterification. The highest peak (D) could be attributed to the decomposition of the DGEBA (S. O. Han, 222 nd American Chemical Society Meeting; Polymer Priprint , (2001)).
[0089] FT-IR monitoring of the reaction between DGEBA and GMAEVC Curing of DGEBA and GMAEVC was monitored in real-time during heating from 100° C. to 180° C. and FTIR spectra obtained at 100° C. and 180° C. are compared in FIG. 2. The peak due to hydroxyl groups (180° C.-1) is shifted toward higher frequency resulting from the ester or ether bond formation near hydroxyl groups. The epoxy peak (100° C.-5) and the vinyl group peaks (100° C.-3, 100° C.-4) disappeared as curing of DGEBA and GMAEVC and degradation of GMAEVC proceeded. A new peak appeared at 1795 cm −1 (180° C.-2) upon heating above 175° C. This peak was also observed in the samples cured at temperatures higher than 175° C. The intensity of the peak increased with increasing curing temperature (G. Socrates, Infrared Characteristic Group Frequencies , pp.45-47, 57-73, (1980)).
[0090] [0090]FIG. 3 shows the epoxy and hydroxyl groups conversions of DGEBA and GMAEVC blend when the blend is heated from 100° C. to 180° C. Epoxy group conversion increases continuously when the temperature increases, but the hydroxyl group conversion starts to increase around 130-150° C. and shows a very slow increase with increasing temperature. The curing reaction between epoxy groups of DGEBA and carboxyl and hydroxyl groups of GMAEVC can be considered as etherification and esterification reactions (H. Lee, Handbook of Epoxy Resin , pp.5:16-5:20, (1982)).
[0091] Thermal Stability and Mechanical Performance of Cured Matrix of DGEBA and GMAEVC FIG. 4 shows the comparison of the thermal stability of GMAEVC alone and the cured matrix of DGEBA and GMAEVC. The cured matrix shows thermal stability up to 300° C. and three products decomposed between 300-400° C. The glass transition temperature and the storage modulus of the cured matrix of DGEBA and GMAEVC are as high as 97° C. and 2700 Pa, respectively. The GMAEVC alone starts to decompose at 140° C. and three products decompose in the 150-300° C.
[0092] Surface analysis of cured matrix of DGEBA and GMAEVC Surface analysis of the cured matrix is shown in Table 1. FIGS. 5A and 5B show the C1s and O1s deconvoluted spectra with the binding energy. The carbon 1s spectrum is deconvoluted to three peaks at 284.6, 286.1 and 287.6 eV, respectively. The peaks are assigned to carbon bind with another carbon or hydrogen (—C—C*—C—, —C*—H), carbon bind with one oxygen atom (—C*—O—H, —C*—O—C—) and carbon bind with two oxygens (—O—C*—O—, —C(O)—O—), respectively. The oxygen is spectra is deconvoluted to two peaks at 530.0 and 532.0 eV that are assigned —O—C—O*— and —C—O*H. These hydrophilic groups on the surface of the cured matrix can be bound to water available from the surroundings. Silicone atom is considered to come from the silicone mold.
TABLE 2 Atomic Ratio of the Cured Matrix Blend [C] % [O] % [O]/[C] [Si] % Cured Matrix 78.4 18.7 0.24 3.0
[0093] Water Absorption Test on the Cured Matrix Blend The cured matrix contains hydrophilic functionalities and can absorb moisture. The absorbed water can lead to dimensional variations in composites and also affect the mechanical properties of the composites. Water absorption tests on this matrix were performed and the performance of samples was compared to the dry, original samples.
[0094] Water Absorption Profile of Cured Matrix The weight increase of the cured matrix due to water uptake is plotted in FIG. 6 versus time. The weight of the matrix increased by 3.2% after 1056 hours of immersion in water. When the sample is heated at 110° C. in an oven for one hour, the weight gain decreases to 1.9%.
[0095] Effects of Water Absorption on Mechanical Performances of the cured matrix Storage modulus and Tan delta (δ) of the cured matrix before and after water absorption are compared in FIGS. 7A and 7B. The maximum peak of Tan (δ) that is related to the glass transition temperature is changed to a convoluted peak for the matrix that immersed in water for 1056 hours. The convoluted peak is changed to the single peak that is the same of the original cured matrix when the water uptake specimen is conditioned using the DMA cycling test. Heating the specimen up to 150° C. and cooling it down to room temperature is one DMA cycle. The glass transition temperature of the cured matrix is changed from 95° C. for the original matrix to 82° C. and 98° C. for the matrix that was immersed in water for 1056 hours. This glass transition temperature shows a constant value as 150° C. after the second DMA cycle. Because the cured matrix of DGEBA and GMAEVC has hydrophilic functional groups on the surface, water can be bound to the surface of the matrix easily. The absorbed water in the matrix can exist as two different types: bound water and free water. Bound water is characterized by strong interactions with hydrophilic groups on the surface of the matrix and free water is present in capillaries and microvoids within the matrix (J. Zhou, Polymer , (1999)). From studies of hygrothermal effects of epoxy resin (L. Barral, Journal of Thermal Analysis , (1996),J. Zhou, Polymer (1999)), the bonding of water molecules with epoxy resin is divided into two types. Type I bonding corresponds to a water molecule that forms a single hydrogen bond within the epoxy resin network. This water molecule possesses lower activation energy and is easier to remove from the resin. Type II bonding is the result of a water molecule forming multiple hydrogen bonds within the resin network. This water molecule possesses higher activation energy and is correspondingly harder to remove. Type I bound water is the dominant form of the total amount sorbed water. Type I bound water acts as a plasticizer and decreases the glass transition temperature. In contrast, Type II bound water contributes to an -increase of the glass transition temperature in water saturated epoxy resin by forming a secondary crosslinked network (L. Barral, Journal of Thermal Analysis , (1996),J. Zhou, Polymer (1999)). Results of this research are coincident with this model. Further research on examination of the different water molecule states in the cured matrix after water absorption is under investigation.
[0096] Biocomposite of the matrix and henequen fibers Biocomposites of the matrix blend and henequen fiber treated with different conditions were manufactured and the performances were investigated. Surface analysis and thermal stability of the henequen fibers were also investigated.
[0097] Surface Analysis of Henequen Fiber Surface analysis of raw and alkali treated fibers in different conditions are compared in Table 3. The atomic ratio of oxygen to carbon on the henequen fiber is generally increased and the nitrogen content is decreased after alkali treatment due to the removal of either impurities or protein from the fiber surface. FIGS. 8A and 8B show the changes of the carbon 1s and oxygen 1s spectra of henequen fibers after alkali treatment. The carbon 1s spectra was deconvoluted to three peaks that are assigned to —C—C*—C— (284.6 eV), —C*—O—H— (286.1 eV) and —O—C*—O— (287.6 eV). The oxygen curve is deconvoluted to two peaks that are assigned —O—C—O*— (530.0 eV) and —C—O*—H (532.0 eV). Generally, carbon 1s concentration due to —C—C*—C— is decreased and carbon 1s and oxygen is concentrations due to —C*—O*H are increased with increasing concentration of NaOH solution. Alkali treatment of henequen fibers increases the oxygen/carbon ratio and the hydroxyl groups on the fiber surface due to removal of impurities or to the formation of new hydroxyl groups. The decrease of the carbon 1s concentration from —C—C*—C— can be explained by the loss of lignin, which leads to the higher crystallinity of the fiber. This can lead to an increased in adhesion of the matrix to henequen fibers. The oxygen/carbon ratio, C 1s and O1s concentration do now show any difference between henequen fibers that are treated with 2 wt % and 5 wt % alkali solution. However the nitrogen concentration does change.
TABLE 3 Atomic Ratio of raw and Alkali treated Henequen Fibers (AT:alkali treated) Henequen [C] % [O] % [O]/[C] [N] % [Ca] % Raw 74.1 22.6 0.31 2.9 0.4 AT-2 wt % 67.7 30.2 0.45 2.0 0 AT-5 wt % 68.4 29.7 0.43 1.5 0.4 AT-10 wt % 65.4 33.7 0.52 0.9 0
[0098] Thermal stability of Henequens Fibers treated with Solutions of Different NaOH Concentrations Henequen fibers are composed of approximately 60 wt % of cellulose, 28 wt % of hemicellulose, and 8 wt % of lignin. Hemicellulose has a very low thermal stability (A. K. Bledzki, Prog. Polym. Sci , (1999)) and can be easily removed from the fiber with an alkali treatment. FIG. 9 shows the thermal decomposition of raw and alkali treated henequen fibers. The decomposition peak of hemicellulose for the raw henequen fibers is shown around 290° C. This peak is not apparent on the TGA results of the alkali treated henequen fibers. A sharp drop in weight at 320° C., the onset of cellulose decomposition is apparent for all the samples. The plateau observed between 380° C. and 600° C. is attributed to oxidation and burning of the high molecular weight charred residues (A. V. Manuel, J. Applied Polymer Science , (1995)).
[0099] Thermo-Mechanical Performances of Biocomposites The effects of henequen fiber loading and alkali treatment on the thermo-mechanical performances of biocomposites are shown in FIGS. 10A and 10B. The storage modulus of biocomposite increased 147% when the raw henequen fibers are added to the matrix. Storage modulus of biocomposites made of alkali treated fibers increased up to 154%, 177% and 150% for fiber treatment with 2, 5, 10 wt % NaOH solutions, respectively. The superior mechanical properties of composites made with alkali treated henequen fibers may be attributed to the fact that alkali treatment improves the adhesive properties of the henequen surface by removing impurities and producing new hydroxyl groups on the surface of the fibers. In addition, the alkali treatment can lead to fiber fibrillation, breaking down of the fiber bundle into smaller fibrillar units. This increases the effective surface area available for contact with the matrix polymer (A. K. Mohanty, SAMPE-ACCE-DOE-SPE, ( 2000)). The storage modulus decrease when the fibers are treated in 10 wt % alkali solution can be explained by the comparative loss of crystallinity of henequen fibers due to the treatment with highly concentrated alkali solution.
[0100] An ecofriendly matrix of DGEBA and GMAEVC has been described in the Examples for biocomposites made with henequen fibers. The curing mechanism of DGEBA and GMAEVC is identified as etherification and esterification reactions of the hydroxyl and carboxylic functionalities of GMAEVC with the epoxy groups of the DGEBA resin. The cured matrix containing 50 wt % of GMAEVC exhibited thermal stability up to 300° C. The glass transition temperature and storage modulus of this cured matrix are as high as 97° C. and 2700 Pa, respectively. Weight increase and glass transition temperature decrease due to water uptake in the matrix were observed in a water absorption test. However, water absorption by the cured matrix did now produce any reduction in storage modulus. The decrease of glass transition temperature was recovered after heating this matrix at a temperature higher than 110° C. This matrix blend showed good compatibility with the henequen fibers and increased the mechanical properties when an alkali treated henequen fiber was used. This example shows the potential for development of cost effective and environmentally friendly biocomposites based on DGEBA and GMAEVC and natural fibers for automotive applications.
[0101] It is intended that the foregoing description be only illustrative of the present invention and that the present invention be limited only by the hereinafter appended claims. | Epoxy resin polyglycoside-based cured polymers and process for the preparation are described. A particular epoxy resin precursor is the diglycidyl ether of bisphenol A. A particular glucose based polymer is a glucose malic acid ester-vinyl copolymer. The polymers have a degree of biodegradability because of the polyglycoside as well as elevated temperature stability and are useful in transportation vehicle settings. Natural source fillers, such as cellulose fibers, which are treated or untreated, exfoliated clays or exfoliated graphite can be used. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to optical fibers, and, more particularly, to the splicing of two lengths of optical fibers to form a single spliced optical fiber.
Optical fibers are strands of glass fiber processed so that light beams transmitted through the glass fiber are subject to total internal reflection. A large fraction of the incident intensity of light directed into the fiber is received at the other end of the fiber, even though the fiber may be hundreds or thousands of meters long. Optical fibers have shown great promise in communications applications, because a high density of information may be carried along the fiber. Also, the quality of the signal is less subject to external interferences of various types than are electrical signals carried on metallic wires. Moreover, the glass fibers are light in weight and made from highly plentiful substances, such as silicon dioxide.
Glass fibers are typically fabricated by preparing a cylindrical preform of glasses of two different optical indices of refraction, with a core of one glass inside a casing of a glass of slightly lower refractive index, and then processing the preform to a fiber by drawing or extruding. The optical fiber is coated with a polymer layer termed a buffer to protect the glass from scratching or other damage. The optical fibers and the buffers may be made with varying dimensions, depending upon their intended use and the manufacturer. As an example of the dimensions, in one configuration the diameter of the glass optical fiber is about 0.002-0.005 inches, and the diameter of the optical fiber plus the buffer layer is about twice the optical fiber diameter.
For some applications the optical fiber must be many kilometers long and must have a high degree of optical perfection and strength over that entire length. Preparation of an optical fiber of that length having no defects is difficult. It is therefore desirable to have the capability to splice two shorter lengths of optical fiber together to form a longer optical fiber. The need to splice optical fibers also arises when it is necessary to use a length longer than can be made from a single preform, when an existing length of fiber breaks, or when apparatus such as an amplifier is to be incorporated into a length of fiber.
The optical fiber splice must be accomplished so that there is no significant increase in loss of light in the vicinity of the splice. The spliced fiber must also have a sufficiently high strength to withstand handling in operations such as winding under tension onto a bobbin, or unwinding from the bobbin at high rates. Additionally, it must be possible to restore the buffer layer initially on the fibers being spliced.
A number of techniques for splicing optical fibers are known in the art. For example, U.S. Pat. No. 4,263,495 depicts the use of a laser to heat and fuse the ends of two opposed optical fibers. In this approach, the laser beam may be directed either perpendicular to the optical fibers, or parallel to the optical fibers and reflected to a focal point by a mirror. As such techniques were applied, they were observed to produce splices that were lacking in strength and reproducibility. As a response, automated optical fiber splicing control systems such as that of U.S. Pat. No. 5,016,971 were developed. The automated approach of U.S. Pat. No. 5,016,971 has significantly improved the ability to splice optical fibers in a reproducible manner. However, there remains the opportunity for improving the strength, optical characteristics, and reproducibility of optical fiber splices.
Therefore, there is a continuing need for an improved method for splicing optical fibers. The improved technique should produce spliced optical fibers of acceptable strength and optical performance, and have the ability to provide a continuous buffer coating over the spliced region. The splicing method should be amenable to accomplishing large numbers of splices in a reproducible manner. The present invention fulfills this need, and further provides related advantages.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for grasping and splicing lengths of optical fiber together to form a single spliced length. High quality splices having little loss of light and little loss of strength due to the presence of the splice are produced. Equally importantly, the splicing method and apparatus are automatically controlled and yield highly reproducible results when applied in a setting where large numbers of splices must be made on a routine basis.
In accordance with the invention, an optical fiber fusion splicer comprises means for supporting two optical fibers with their ends in an aligned facing relation along an axis and means for heating the two optical fibers uniformly around their circumferences at their facing ends. The apparatus further includes means for controlling the power input to the means for heating so as to heat the optical fibers at their facing ends with the minimum power sufficient to fuse the facing ends. The combination of precisely positioning the ends of the optical fibers, circumferentially evenly heating the ends being spliced, and utilizing a minimum required power to fuse the optical fibers produces excellent quality and reproducibility of the optical fiber splices.
In one embodiment, the heating source is a laser power source that includes a laser, a shutter that controllably blocks and passes the laser beam, a parabolic mirror whose axis is parallel to the axis of the optical fibers, and an optical system that expands the diameter of the laser beam before it reaches the parabolic mirror. The laser is preferably a carbon dioxide laser whose output power is monitored and used for control purposes. There is also preferably a sensor that measures the power of the beam reaching the opticaL fiber ends being spliced, such as an optical detector that measures the change in luminescence at the optical fiber ends being spliced. A controller adjusts the beam power responsive to one or both of the sensors. The power level of the laser is determined in a series of calibration tests to be the minimum power required to accomplish the fusion splicing. Once this power level is determined, the same conditions are used in subsequent splices of similar optical fiber lengths.
The means for supporting the optical fibers preferably includes a first optical fiber clamp positioned between the laser and the parabolic mirror, as measured along the beam axis, and a second optical fiber clamp positioned further from the laser than the parabolic mirror, as measured along the laser beam axis. The parabolic mirror includes a bore therethrough coincident with the beam axis. Each of the optical fiber lengths whose ends are to be fused and spliced is supported in one of the optical fiber clamps, coincident with the laser beam axis. The first optical fiber clamp is mounted on a controllable 3-axis manipulator stage that permits the optical fiber end to be spliced to be positioned very precisely relative to the other end, which is held fixed in a location protruding through the bore of the parabolic mirror to the focus of the mirror.
The optical fibers are monitored and positioned responsively using the 3-axis manipulator stage. Two monitoring techniques are used. In one, a video image of the sides of the optical fibers is obtained with a video camera. The image may be viewed on a monitor and the manipulator stage moved responsively. Preferably, the image is processed with pattern recognition techniques to recognize the peripheries of the optical fibers. The stage is automatically moved responsively to align the peripheries prior to splicing. In a second technique, an optical time domain reflectometer is used to measure light reflected from defects and surfaces within the optical fibers. The stage is automatically moved responsively to minimize the reflected light, thus maximizing light transmission.
The present invention also provides a design for the optical fiber clamps that achieves secure clamping and holding of the optical fiber while not stressing the optical fiber. The clamp includes a support base having a slot therein radially dimensioned to conform to the outer buffer surface of the optical fiber, and a retainer that slides into the slot with a lower end dimensioned to conform to the outer buffer surface of the optical fiber. The optical fiber to be held is inserted into the slot, and the retainer is thereafter inserted into the slot to hold the optical fiber securely. The slot is precisely located to the outer surface of the clamp to permit the optical fiber to be positioned exactly and reproducibly. A cooperating clamp holder allows the optical fiber to be moved from place-to-place, and also from apparatus-to-apparatus, while retained within the clamp. Consequently, there is little likelihood that the optical fiber can be damaged while held and moved in the clamp.
After the splicing of the glass optical fibers is complete using the approach of the invention, the spliced optical fibers must be recoated with buffer material. The first important consideration in recoating the now-spliced optical fiber is to move the optical fiber from the laser fusion apparatus to a recoating unit. Experience has shown that the removal of the optical fiber from the clamps and movement to the recoating unit can result in damage to or breakage of the optical fiber in the splice region, inasmuch as it is not protected by a buffer layer at that time. The present invention therefore provides a clamp holder that grasps the two optical fiber clamps and allows them and the spliced optical fiber lengths to be moved as a rigid unit to the recoating apparatus. The result of using this clamp holder, which is also usable in other contexts for moving aligned and/or spliced optical fibers, is substantially improved reliability of the splicing and recoating operation.
The present invention provides an important advance in the art of optical fiber splicing technology. The approach is highly controllable and reproducible, because the pre-fusion alignment and laser fusion operations are controlled responsive to automated measurements of the apparatus. The controller, not an operator, determines the alignment and fusion conditions, and the coaxial design ensures circumferentially even heating of the optical fiber ends as they are fused. Other features and advantages of the invention will be apparent from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an optical fiber;
FIG. 2 is a schematic block diagram of the optical fiber splicing apparatus;
FIG. 3 is a side sectional view of the parabolic mirror with optical fiber lengths in position for splicing;
FIG. 4 is a perspective view of the optical fiber clamp holding an optical fiber;
FIG. 5 is a perspective view of the optical fiber clamp holder;
FIG. 6 is a perspective view of the recoating apparatus; and
FIG. 7 is a perspective view of a split mold for recoating the optical fiber with buffer material, with interior features in phantom lines.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts a generally cylindrical optical fiber 10, having a core 12 of a glass of a selected refractive index and a casing 14 of a glass having a slightly lower refractive index. The glass used in the core 12 and the casing 14 are of slightly different compositions, and are in most cases silicon dioxide-based glasses. A buffer coating 16 of a polymer material such as a UV curable acrylate surrounds the optical fiber 10. By way of illustration and not limitation, for a typical fiber the cylindrical diameter of the optical fiber 10 (that is, the outer diameter of the casing 14) is about 0.002-0.005 inches, and the cylindrical diameter of the buffer coating is about twice that of the optical fiber 10, or about 0.004-0.010 inches. The preferred embodiment of the present invention deals with splicing two of such optical fibers 10 in an end-to-end manner, and not the particular structure or materials of construction of the optical fibers and buffer coating, and is not so limited.
FIG. 2 depicts a laser fusion apparatus 20. A laser 22, preferably a carbon dioxide laser, produces a laser beam 24 directed along a beam axis 26. The laser beam 24 first passes through a controllable shutter 28 and then through a beam expander 30 that produces an output laser beam 32 coaxial with the beam axis 26 but of expanded diameter as compared with the laser beam 24.
A parabolic mirror 34, depicted in greater detail in FIG. 3 and having a reflecting surface 36 which is a parabolic surface of revolution or paraboloid, is positioned so that its parabolic axis is coincident with the beam axis 26. The expanded laser beam 32 is also coincident with the beam axis 26, so that the laser beam 32 reflects from the parabolic reflecting surface 36 through a focal point 38 of the parabolic mirror 34. As depicted by the ray paths of FIG. 3. This arrangement, together with the coaxial alignment and positioning of the ends of the optical fibers during splicing, ensures circumferentially even heating of the ends of the optical fibers during the splicing operation.
A first length of optical fiber 40 to be spliced, from which the buffer layer 16 has been removed, is supported in a first clamp 42. The first clamp 42 positions the first length of optical fiber 40 between the laser 22 and the mirror 34 coincident with the beam axis 26. A second length of optical fiber 44 to be spliced, from which the buffer layer 16 has been removed, is supported in a second clamp 46. The second clamp 46 positions the second length of optical fiber 44 coincident with the beam axis 26 but further from the laser 22 than the mirror 34 along the beam axis 26. The mirror 34 has a bore 48 therethrough, coincident with the beam axis 26, of sufficient diameter so that the second length of optical fiber 44 can pass therethrough. The bore 48 preferably has two diameters, a smaller diameter near the parabolic surface through which the optical fiber 44 (with no buffer coating) slides, and a larger diameter which receives the second clamp 46, as shown in FIG. 3. Alternatively, the second clamp 46 may be supported independently of the mirror 34, as shown in FIG. 2. In the preferred embodiment, the parabolic mirror 34 is hinged along its centerline, to permit the mirror 34 to be assembled over the second length of optical fiber 44 held in the second clamp 46.
The clamps 42 and 46 are designed to firmly but gently grasp the buffer coating around a length of optical fiber in a manner such that the optical fiber can be readily positioned along the beam axis and also moved into the proper splicing position relative to the parabolic mirror. A preferred form of the clamps 42 and 46 is shown in FIG. 4. The clamp 42, 46 includes a elongated base 50 with a cylindrical outer surface 51 and a radial slot 52 extending along the cylindrical axis of the base 50. A lower end 54 of the slot 52 is concavely curved with a radius of curvature of about that of the radius of the buffer layer 16 of the optical fiber 40, 44, and preferably just slightly larger than that of the buffer layer 16 of the optical fiber 40, 44 to be grasped in the clamp. The lower end 54 is generally concentric with the outer surface 51, and is precisely positioned relative to the outer surface 51 of the clamp.
The clamp 42, 46 further includes a retainer 56 with a tongue 58 dimensioned to closely fit within the slot 52 when the retainer 56 is assembled to the base 50 by sliding the tongue 58 into the slot 52. A lower end 60 of the tongue 58 is concavely curved with a radius of curvature about that of the optical fiber 40, 44, and preferably just slightly larger than that of the buffer of the optical fiber 40, 44 to be grasped in the clamp 42, 46. When the clamp is assembled with an optical fiber captured between the lower end 54 of the slot 52 and the lower end 60 of the tongue 58, an outer surface 61 of the retainer 56 is flush with the outer surface 51 of the base 50, so that the outer surfaces 51 and 61 cooperate to form a continuous surface that can be readily grasped. In the preferred form, the outer surfaces 51 and 61 form a generally continuous cylindrical surface when the retainer 56 is assembled to the base 50, with an optical fiber captured between the lower end 54 of the slot 52 and the lower end 60 of the tongue 58.
To grasp an optical fiber 40, 44 in the clamp 42, 46, the retainer 56 is disassembled from the base 50. The optical fiber 40, 44 is placed into the slot 52. The retainer 56 is then assembled to the base 50 by sliding the tongue 58 into the slot 52. The tongue 58 slides downwardly until the lower end 60 of the tongue 58 contacts the buffer of the optical fiber 40, 44, forcing it downwardly to contact the lower end 54 of the slot 52. The optical fiber is thereby held firmly but gently so that it may be positioned as required, in this case along the beam axis. The cooperation between the lower ends 54 and 60 holds the optical fiber at a precisely known position relative to the outer surfaces 51 and 61, permitting the optical fiber to be precisely positioned relative to the outer surfaces 51 and 61. The clamping force may be controlled by adjusting the pressure against the surface 61 of the retainer 56.
The clamp of the present approach offers important advantages over prior clamping techniques for optical fibers such as grooved blocks and magnetic chucks. The optical fiber may be precisely positioned relative to an externally grasped surface. The clamp is compact, easy to use, and does not require external connections such as a vacuum line. The absence of an external support connection is important, because such hook-ups limit the ease of movement of vacuum-type clamps. In the present clamp, the optical fiber is grasped firmly, so that it cannot move either radially or axially in the clamp. This one clamp can therefore be used for a variety of applications and situations, with the optical fiber held securely within the clamp. The optical fiber is inserted into the clamp, and then the clamp is moved from place to place using a clamp holder to be discussed subsequently. There is little likelihood that the optical fiber will be damaged by bending, twisting, or scratching while held in the clamp.
By contrast, in prior approaches the optical fiber was typically held by different clamps at each stage of the process, each clamp being tailored for its particular stage of the process. While each of the clamps might be effective, there was a risk that the optical fiber could be damaged as it was moved from clamp to clamp between operations. This risk is avoided with the present approach, as the optical fiber is not removed from the clamps 42, 46 between splicing operations. Although these clamps 42, 46 were designed for use in the present splicing technique, they have broader use in any application where optical fibers must be grasped firmly but gently.
Returning to FIG. 3, the first length of optical fiber 40 has a first end 62 to be spliced to a second end 64 of the second length of optical fiber 44. These ends 62 and 64 lie coaxial with the beam axis 26, and are placed into a close, and preferably lightly touching, facing relationship at the focal point of the mirror 38.
To effect this positioning, the second end 64 is moved to the proper position at the focal point 38 by manually sliding it along the bore 50. The mirror 34 and the second optical fiber 44 are thereafter held stationary.
The first clamp 42 holding the first optical fiber 40 is mounted on a three-axis remotely programmable and controllable stage 66. The stage 66 permits precisely controllable movement of the first clamp 42 and thence the first end 62 of the first optical fiber 40 in the two dimensions perpendicular to the beam axis 26, so that the first optical fiber 40 can be positioned exactly coincident with the beam axis 26. The stage 66 also permits precisely controllable movement of the first clamp 42 and thence the first end 62 of the first optical fiber 40 toward the mirror 34 or away from the mirror 34 in the direction parallel to the beam axis 26, to bring the first end 62 to the focal point 38 of the mirror 34.
Two monitoring aids are used to precisely position the first end 62 relative to the second end 64. In the first, the region of the focal point 38, with the first end 62 on one side and the second end 64 on the other, is monitored by a TV camera 68. The image is viewed in a television monitor 70. The image is also provided to a microprocessor-based controller 72 operating the stage 66. Using the microprocessor in the controller 72, the image of the two ends 62 and 64 and the peripheries of the optical fibers 40 and 44 may be automatically analyzed using conventional pattern recognition techniques so that the peripheries of the optical fiber are identified. The controller 72 automatically aligns the peripheries so that the outer boundaries of the optical fibers 40 and 44 are precisely aligned along the beam axis 26.
In the second monitoring aid, light transmission through the core 12 of the optical fiber 10 is monitored using an optical time domain reflectometer (OTDR) 74. The OTDR transmits light through one of the optical fibers 40 or 44, and measures the intensity of light reflected from defects that may be present in the optical fiber. The OTDR preferably is used with the shorter of the optical fibers 40 or 44, to maximize the intensity of the reflected light for analysis, but may be used with the longer of the optical fibers or both optical fibers. Other optical monitoring aids may also be used in place of the OTDR, such as a power meter that measures the total light throughput of an optical fiber or a local light injection apparatus that measures the light transmission through a segment of the length of the optical fiber.
The use of the OTDR in characterizing and aligning the optical fibers has several important advantages. First, it permits identification, location, and characterization of the optical defects in the optical fiber, including those at the end to be spliced. Second, it permits the optical fiber cores 12 to be aligned for the splice, as distinct from the peripheries of the optical fibers. In some instances, the cores of optical fibers are not perfectly concentric with the outer peripheries of the casings 14. In those cases, if the visual alignment technique using a television image is used, the optical fiber peripheries will be aligned, but the light-transmitting cores will not be aligned.
The availability of both the visual and OTDR alignment procedures allows the user of the optical fiber considerable flexibility in selection of the result of the splicing operation. The two techniques are first used for screening the optical fibers. The controller determines the position of the stage 66 for the alignment by each of the two monitoring procedures. If the positions are different by more than some preselected amount, it may be concluded that the core is too non-concentric with the cladding. The optical fiber can then be used for some other, less demanding application.
After an acceptable optical fiber is found, one or the other of the alignment procedures is used. If the visual alignment procedure is used, the resulting spliced optical fiber will have maximum physical strength, but may not have maximum optical light transmission because the cores were not perfectly aligned. Conversely, if the OTDR procedure is used, the resulting spliced optical fiber will have maximum light transmission, but may not have maximum strength because the peripheries were not perfectly aligned. The choice of maximum strength, maximum light transmission, or unacceptability of one or both of the optical fibers is achieved automatically according to these procedures and the instructions of the operator.
Once the first end 62 and second end 64 of the optical fiber lengths are positioned in facing contact at the focal point 38 according to these principles, a pulse of laser energy from the laser 22 is directed to the focal point 38 by opening the shutter 28 for a predetermined period of time.
The pulse of laser energy is adjusted to have the minimum power required to successfully melt and fuse the ends 62 and 64 together. The use of a minimum power reduces distortion of the glass optical cores of the optical fibers, and avoids production of melt debris that can distort the optical properties of the optical fibers and also weaken them. In some prior art approaches, gas flame or electric arc heating was used to splice optical fibers. These heating techniques both are inherently difficult to control and also can introduce contaminants into the fused glass. The use of the laser to heat the optical fibers for splicing was an important advance, but too high a laser power level can cause the vaporization and ejection of silica from the optical fibers. These silica particles redeposit onto the optical fiber as flaws that can reduce the strength of the optical fiber. Minimization of the laser power minimizes such damage during splicing. The minimization cannot be reproducibly achieved without evenly heating the optical fibers around their circumference, and positioning the optical fiber ends in a reproducible manner, as provided by the present approach.
To determine the proper laser power required and also the laser power settings and shutter opening duration, calibration tests are performed to splice optical fibers similar to those that will be spliced in production. The power produced by the laser 22 is measured by a meter 80 operating through a port in the laser. Such measurement capability is routinely provided in commercial lasers. The power level measured by the meter 80 is provided to the controller 72.
The power reaching the focal point 38 during the splicing operation is also measured. This measurement is more difficult to obtain. A light intensity sensor 82 is positioned to view the ends 62 and 64 at the focal point 38 during the splicing event. The intensity of the light is detected by the sensor 82, and the output of the sensor 82 is amplified by an amplifier 84 and provided to the controller 72. It will be appreciated that the light intensity is not a direct measure of power, but is a power-dependent parameter that can serve as the basis for the control of the laser source power settings. Thus, during the calibration testing the relative positioning of the optical fiber ends 62 and 64 is determined from the visual image on the monitor 70 and correlated with the position of the stage 66 using the image processing capability of the controller 72. The laser power applied to the ends during splicing is measured both as laser output power and as the emitted light from the region of the splice.
The optical fibers spliced together during calibration are evaluated as to their mechanical and optical properties, and from the correlation with the measured splicing parameters an optimal set of splicing parameters is selected. The splicing parameters include both the positioning and the power information measured during splicing. With the reproducibility afforded by the use of the microcomputer-based controller 72, these conditions can be reproduced by controlling the positioning of the stage 66 and the power applied to the laser 22 through a laser amplifier 86, both of which are established by the controller 72.
After the ends of the optical fibers 40 and 44 are spliced, the bare length of spliced glass must be recoated with buffer material and cured. In the past, it has been common practice to remove the spliced length from the splicing apparatus (of different type than that of the present invention) and to gently move it to a coating apparatus. It has now been found that, no matter how gently this movement is accomplished, the bend or twist stressing of the optical fiber along the bare, uncoated length can lead to imperfections and possible premature later failure in some instances.
To avoid this bending or twisting of the spliced optical fiber during movement from the laser splicing apparatus to the recoating apparatus, a clamp holder 90, shown in FIG. 5, has been designed. The clamp holder 90 includes two grasping arms 92 and 94. These arms 92 and 94 are spaced apart the proper distance to grasp the two clamps 42 and 46, respectively, in their normal position in the apparatus 20. The clamps 42 and 46, with the now-spliced optical fibers 40 and 42 in place within the clamps, are grasped by the arms 92 and 94 and moved as a unit to the recoating apparatus.
Each of the arms 92 and 94 includes a respective facing pair of grasping blocks 96 and 98 that are pivotably mounted to a grasping block base 100. A spring (not shown) biases the two blocks 96 and 98 of each pair toward each other. The grasping blocks 96 and 98 are dimensioned to firmly grasp the sides of the clamps 42 and 44. Respective downwardly extending locating pins 102 and 104 are also mounted from each of the bases 100. The purpose of these locating pins will be discussed subsequently.
The arms 92 and 94 are supported from a handle 106. A movable handle grip 108 operates a linkage extending inside each arm to the grasping blocks 96 and 98. When the handle grip 108 is operated, the grasping blocks 96 and 98 are pivoted apart against the spring biasing force so that the arms can be lowered over the clamps 42 and 46. When the handle grip 108 is released, the grasping blocks again pivot closed, capturing the clamps 42 and 46. The clamps 42 and 46, together with the spliced optical fiber lengths 40 and 44, are then moved as a single rigid unit that does not bend or twist the optical fiber lengths 40 and 44 during transport. On the other hand, in some cases it may be desirable to prestress the optical fibers 40 and 44 in tension during recoating, and the clamps 42 and 46 and clamp holder 90 permit the application of a controllable pretensioning. The clamps 42 and 46 are released by the inverse operation of the handle grip. The clamp holder 90 was developed specifically for use in the splicing operation discussed herein, but can also be used for other operations involving movement of precisely positioned and/or aligned optical fibers and optical fiber devices.
Recoating of the optical fiber is accomplished with an apparatus 112 illustrated in FIG. 6. The clamps 42, 46 rest in cradles 114 and 116, respectively. Positioning of the clamps into the cradles is aided by locating the pins 102 and 104 of the clamp holder 90 into locating slots 118 and 120 of the apparatus 112.
Once the clamps 42 and 46, and thence the optical fiber lengths are positioned, the optical fiber is recoated with a buffer layer in the regions between the previously unstripped coating material, so that the region of the splice is fully protected against scratching. A split mold 130 suitable for casting a flowable polymer around the optical fibers 40, 44 is illustrated in FIG. 7. The mold 130, when assembled around the optical fibers 40, 44, rests on a second set of cradles 122 and 124 around the uncoated portion of the optical fiber.
The mold 130 includes a bottom 132 and a mating top 134, both made of a material transparent to ultraviolet light, such as plexiglass. The bottom 132 and top 134 have semicircular recesses therein along the facing surfaces so that, when the bottom 132 and top 134 are assembled together, a cylindrical central cavity 136 is formed. The bottom 132 and top 134 are assembled over the optical fibers 40, 44 so that the portion of the optical fibers from which the buffer layer 16 has not been removed is positioned at the ends of the mold 130 as seals. The central portion 138, from which the buffer layer 16 has been removed for the laser splicing operation, lies within the interior of the cavity 136. External access to the interior of the cavity 136 is provided through a port 140.
To perform the buffer recoating, a layer of a release agent such as polytetrafluoroethylene (teflon) may be sprayed on the matching faces of the bottom 132 and top 134. The bottom 132 of the mold 130 is placed onto its cradle 122 or 124. The clamps 42 and 46 are placed into their cradles 114 and 116, respectively, so that the central portion 138 lies within the cavity 136 of the as-yet open mold. The remainder of the cavity 136 is filled by injection through a side port 140 with the flowable, ultraviolet curable polymer that polymerizes to become the buffer coating, in this case a UV curable acrylate. The polymer is cured by directing ultraviolet light of wavelength appropriate to the polymer into the previously uncured polymer, through the transparent walls of the plexiglass mold. The preferred ultraviolet light source is a mercury lamp with a strong UV output at about 350 nanometers wavelength, and curing is accomplished in a total of about 10 seconds.
The spliced and recoated optical fiber is removed from the recoating apparatus 112 and the clamps 42 and 46 and inspected. In a typical instance, the spliced region will be indistinguishable from the remainder of the length of the optical fiber, except possible for a slight color difference in the buffer material.
A number of optical fibers have been spliced by this approach and measured both as to optical performance and mechanical strength, after splicing.
In a first series of tests, 12 splices of optical fiber were made. (A thirteenth splice was prepared, but it was found through use of the OTDR that the optical fiber had a serious defect well spaced from the region of the splice, and it was dropped from the study.) The 12 splices were measured to have an optical attenuation to 1.3 micrometer wavelength radiation of 0.089+/-0.089 dB.
In a second series of test, 5 splices of optical fibers were prepared. No attenuation due to the splice was measured at 1.3 micrometer wavelength.
Mechanical data for about 100 spliced optical fibers was taken by loading the spliced optical fibers to tensile failure in an Instron testing machine. The failure strengths were measured in excess of 330,000 pounds per square inch (psi), and many were in excess of 400,000 psi.
In a production test of the approach of the invention, 5 splices were made in a fully automated manner with no operator intervention. The measured attenuations at 1.3 micrometer wavelength were less than 0.3 dB for each splice, and the strengths were in excess of 300,000 psi in each case.
The present invention provides an important advance in the art of splicing optical fibers. It permits good splices to be prepared in an automated, reproducible manner that is well suited for commercial operations that are not dependent upon operator skill and patience. Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. | An optical fiber fusion splicer apparatus (20) comprises a laser power source that produces a laser beam (32) having a laser beam axis (26). The laser power source includes a laser (22), a shutter (28) that controllably blocks and passes the laser beam, and an optical system (30) that expands the diameter of the laser beam. A parabolic mirror (34) has its axis coincident with the laser beam axis (26) and a bore (48) therethrough coincident with the laser beam axis (26). Optical fiber clamps (42, 46) hold the two optical fibers (40, 44) with their axes coincident with the laser beam axis (26) and their ends (62, 64) at the focal point (38) of the parabolic mirror (34). A sensor (82) measures the power reaching the optical fiber ends (62, 64) at the focal point (38) of the parabolic mirror (34), and a controller (72) controls the power level of the laser (22) responsive to the power measured by the sensor. The alignment of the optical fibers (40, 44) is sensed, preferably by a reflective device (74) that measures their internal reflectance or a video camera (68) that images their peripheries, and the optical fiber ends (62, 64) are aligned responsively. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a golfclub, and more particularly to a "wood" type golfclub head structure made of stainless steel.
2. Prior Art
Ever since the beginning of golf history, there have been recognized two types of golfclubs; one is called "iron" clubs which have a relatively short shaft with a small "iron" head designed to hit a golf ball accurately and the other is called "wood" clubs which have a relatively long shaft with a large "wood" head designed to hit a ball for a longer distance.
The head portion of the "wood" clubs is traditionally made of solid wood block. Until recently, persimmon was considered to be the most desirable material because of its high impact resistance and fine sound effect. In addition, golfers favored the well-balanced configuration of the traditional persimmon club heads. Particularly, the smooth tapered line in its neck portion has been highly appreciated. With these and other reasons, persimmon wood clubs substantially predominated the market for a long time.
However, as the demand for good persimmon material grew, the natural source of persimmon became scarce. As a result manufactorers find it rather difficult to satisfy all the market. In an attempt to meet the growing market demand, a number of suggestions and proposals have been made in terms of substitute for natural persimmon.
By way of example, U.S. Pat. No. 3,591,183 discloses a laminated golfclub head which is constructed of wood lamination bonded together and bent to form the angle between striding portion and hosel. U.S. Pat. No. 4,204,684 teaches the use of acrylonitrilebutadiene-styrene (ABS) and other plastic materials. U.S. Pat. No. 4,326,716 discloses a clubhead made of vulcanized polyurethane. In addition, steel made "wood" clubs have been disclosed by U.S. Pat. Nos. 3,761,095, 4,021,047, 4,139,196, 4,214,754, 4,319,752 and many others.
Among these substitute materials, stainless steel has recently acquired a significant part of the marketplace.
In general, a stainless steel "wood" club has a clubhead made of stainless steel having a basic shape similar to the conventional persimmon wood club. Its head portion includes an enclosed hollow body defining a hitting surface, a top wall, a sole member, side walls and a neck.
It has been recognized that stainless steel has certain advantages over natural persimmon, such as lower material cost, durability, and less complex finishing process. However, it has been noticed that stainless steel suffers from some disadvantages.
The most critical problem of stainless steel as a substitute for persimmon exists in its weight balance.
Stainless steel is relatively heavy in nature. Thus, it is necessary to have the walls very thin in order to maintain the same total weight as a persimmon head. On the other hand, it is required to have certain thickness to secure sufficient impact resistance and durability. In particular, since the neck portion has been considered to be weak (see U.S. Pat. No. 4,326,716, col. 2, lines 44 and 45), there is a limit to reduce the thickness of the neck portion. As a consequence, the side adjacent to the neck portion (called "heel") tends to have more weight than the other side ("toe"). This causes the center of gravity (sweet-spot) to shift toward the heel side resulting in more deflection in hitting a ball.
The existing solutions to this problem are to have the whole head portion substantially smaller than the traditional persimmon club and/or to have a straight cylindrical neck portion with its lower portions flared to be connected to the head portion as shown FIG. 1. The above solutions have cured the problem to an extent; nonetheless, those solutions have failed to construct a "wood" club head having the size and the configuration which golfers have been enjoying with the traditional persimmon heads.
Therefore, the existing stainless steel "wood" clubs have not superseded qualified persimmon wood clubs.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of this invention to provide a stainless steel "wood" club which overcomes the disadvantages contained in the prior art stainless steel "wood" clubs.
It is another object of this invention to provide a stainless steel "wood" club which has the sweet-spot in the center of the hitting surface keeping the traditional size and shape in the head portion.
It is still another object of this invention to provide a stainless steel "wood" club which is easy to play and easy to manufacture.
In keeping with the priciples of this invention, the objects are accomplished by a unique structure of the body and the neck portion of the clubhead, wherein the improvement includes the following features:
(a) the neck has a shoulder at its lower end,
(b) the neck has a cylindrical portion extending upwardly from said shoulder,
(c) the cylindrical portion has relatively thin and substantially even thickness in its wall,
(d) a radius is provided between the cylindrical portion and the shoulder,
(e) another radius is provided between the shoulder and the inside of the body,
(f) a shaft is fitted into the cylindrical portion, and
(g) a plastic ferrule is mounted around the cylindrical portion such that the ferrule stands on the shoulder.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features and objects of the present invention will become more apparent by reference to the following description taken in conjunction with the accompanying drawings, wherein like referenced numerals denote like elements, and in which:
FIG. 1 shows a sectional view of a prior art stainless steel "wood" club;
FIG. 2 shows a perspective view of a finished clubhead of this invention;
FIG. 3 shows a sectional view of a clubhead of this invention; and FIG. 4 shows an enlarged partial sectional view of the clubhead shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the figures, shown in FIG. 1 is a sectional view of a prior art "wood" clubhead illustrating the general construction of existing stainless steel "wood" clubheads, shown in FIG. 2 is a perspective view of a finished clubhead in accordance with the teachings of the present invention, shown in FIG. 3 is a sectional view of a basic structure of the clubhead of this invention, and shown in FIG. 4 is a partial sectional view of the clubhead structure of this invention illustrating the interconnection of the clubhead structure of this invention.
First referring to FIG. 1 showing a prior art clubhead structure, a clubhead 1 has a substantially straight neck 2 extending upwardly from its heel side 11. A shaft 6 is fitted into and coupled to the neck 2 by means of adhesive agents such as epoxy resin.
Since the neck portion has been considered to be one of the weakest areas of the clubheads, the lower end 3 of the neck 2 has to be expanded or flared. Accordingly, the flared lower end 3 of the neck 2 has a thicker wall than the upper end 4. It has been believed that the above configuration is essential to absorb the heavy stress created at the impact when striking a golf ball, thereby avoiding cracks at the neck area.
However, according to the prior art configuration, with the addition of a traditional persimmon wood neck structure, the weight at the heel side 11 tends to be heavier than the other side resulting in having the center of gravity (sweet-spot) shifted to the heel side. As a result, golfers have been experiencing difficulty in hitting a ball accurately and farther. In order to compensate for the shift of the sweet-spot, stainless steel "wood" heads have been kept compact as in FIG. 1. In Addition, the prior art structure in the neck area shows a straight neck extending from the flared lower end which looks substantially different from the traditional persimmon clubhead having a smooth tapered line in the neck area. This invention is to provide a practical solution to this problem.
Now referring to FIG. 2 showing a finished clubhead of this invention, the general appearance of the clubhead, is the same as the traditional persimmon wood club, which is substantially larger than the prior art stainless steel "wood" clubs.
The specific configuration of the clubhead of this invention is best shown in FIG. 3. The clubhead 1 has a top wall 8, a sole member 9, a toe side wall 10, and a heel side wall 11 to form a hollow body lA. The clubhead 1 also has a neck 2 which extends upwardly from a shoulder 13 located at the upper end of the heel side wall 11. The diameter of the neck 2 is substantially smaller than that of the shoulder 13. The neck 2 has a cylindrical shape with a relatively thin and even thickness wall from the lower end 3 to the upper end 4.
By thus constructing the clubhead, the weight balance of the clubhead may be kept as desired to have the sweet-spot 12 in the center of the hitting surface 7 (see FIG. 2). This allows golfers to hit a ball straighter and farther.
Experiments have been repeated in terms of the durability particularly at the neck area.
After a number of different types of tests, it has been observed that the thin neck and shoulder structure of this invention would not cause any more cracking or deterioration than the existing stainless steel "wood" clubs, provided that a proper material is used with the proper radiuses at the lower end 3 of the neck 2.
The thin neck and shoulder structure of this invention may properly be embodied as illustrated in FIG. 4.
The clubhead 1 is made of 17-4 Ph. stainless steel and has thickness between 0.03-0.05 inches. The neck 2 has a cylindrical wall slightly thinner than the remainder of the clubhead 1 whereby the weight balance between the heel side 11 and the toe side 10 may be very well kept to maintain the center of gravity (sweet-spot) in the desirable center 12 of the hitting surface 7 (see FIG. 2). The shaft 6 is accommodated in the neck 2 in such a manner that the tip portion 6A of the shaft 6 is in contact with a second shoulder 14 extending inwardly from the first shoulder 13.
In order to ensure a durable structure in the neck area, a radius 19 is provided between the lower end 3 and the shoulder 13 and another radius 20 is provided between the shoulder 13 and the end portion 15 of the clubhead 1. The radiuses 19 and 20 are given a curvature of 1/16"-1/2" and preferrably 1/8"-1/4" to most effectively strengthen the structure and prevent deterioration. In addition a plastic ferrule 16 is placed to cover the neck 2 and a part of the shaft 6. The ferrule 16 is designed to specifically match the size and the shape of the shoulder 13. It is preferable to have a reinforcing string 17 wound around the ferrule 16 such that the diameter of the end portion 15 of the clubhead 1 adjacent to the neck 2 is substantially the same as the diameter of the lower end portion 16A of the ferrule 16. The ferrule 16 has a tapered shape toward its upper end so that the neck area forms a smooth and natural configuration case as the traditional persimmon wood club. Urethane foam 18 or other light materials may be inserted in the head body lA to improve the sound effect.
As is clear from the above description, since the weight balance is well kept between the heel side 11 and the toe side 10, the center of gravity (sweet-spot) may be located in the desirable center 12 of the hitting surface 7. With this advantage and the common advantage for the stainless steel "wood" club such as wider sweet spot by added perimeter weight, the clubhead of this invention enjoys the benefit of more distance and straighter shots even with off center hits.
In all cases, it is understood that the above-described embodiments are merely illustrative of but a few of the many possible specific embodiments which represent the application of the principles of the present invention. Numerous and varied other arrangements can be readily devised by those skilled in the art without departing from the spirit and scope of the invention. | A golf club head for being fitted to a shaft wherein the golf club head is a stainless steel hollow body defining a hitting surface, a top wall, a sole member, a rear wall, a pair of side walls and a neck. The golf club head is further characterized in that the neck has a first shoulder at its lower end, the neck has a cylindrical portion extending upwardly from the first shoulder, the shaft is fitted into the cylindrical portion and a plastic ferrule is mounted around the cylindrical portion such that the plastic ferrule stands on the first shoulder. | 0 |
FIELD OF THE INVENTION
This invention relates to a method for determining cholinesterase activity, characterized by using, as a substrate, a protocatechuoylcholine halide derivative represented by the general formula (I): ##STR2## wherein X is a halogen atom.
DESCRIPTION OF THE PRIOR ART
There have heretofore been reported various methods for determining cholinesterase (hereinafter referred to as ChE) activity in serum using a synthesized substrate, and some of them have been made practicable for daily clinical examinations. However, these determination methods involve various defects and problems, and these disadvantages are responsible for the inaccuracy of the resulting determined value. Examples of the heretofore well-known determination methods include (a) gas analysis method, (b) pH meter method, (c) pH-indicator colorimetry, (d) thiocholine color formation method, (e) enzymatic method, (f) UV method, etc.
(a) The gas analysis method [R. Ammon: Pflugers Arch. Ges Physiol., 233, 487 (1933)] comprises using acetylcholine as a synthesized substrate, bringing acetic acid produced by the enzymatic action of ChE into contact with sodium hydrogen carbonate, and quantitatively determining the carbon dioxide gas produced. This method is disadvantageous, for example, in that since its operations are troublesome, it cannot deal with many samoles.
(b) The pH meter method [H. O. Michel: J. Lab. Clin. Med., 34, 1564 (1949)], like the gas analysis method, comprises measuring a pH change due to acetic acid produced by the enzymatic action of ChE by means of a pH meter. This method involves practical problems of, for example, accuracy of pH meter, inability to deal with many samples, and the like.
(c) The pH-indicator calorimetry, unlike the pH meter method, comprises measuring a pH change due to acetic acid produced by ChE in terms of the molecular absorbance of the indicator. As the indicator, there are used phenol red [Hiroshi Takahashi and Susumu Shibata, IGAGU-TO-SEIBUTSUGAKU (Medicine and Biology), 20, 96, (1959)], bromothymol blue [H. G. Biggs, et al., Amer. J. Clin. Path., 30, 181, (1958)], m-nitrophenol [Tadahide Sasaki, RINSHO-BYORI (Clinical Pathology), 12, 555, (1964)], etc. This method comprises simple operations and can deal with many samples, but it is pointed out that this method is disadvantageous, for example, in that the reaction time is long and in that during the reaction, the pH is not constant and is not sufficiently reproducible at low and high values.
In the case of the above-mentioned methods using acetylcholine as a substrate, the substrate itself also is disadvantageous because acetylcholine tends to undergo nonenzymatic hydrolysis and has no sufficient substrate specificity.
(d) The thiocholine method [P. Garry, J. Clin. Chem., 11 (2), 91 (1965)] uses acetylthiocholine, propylthiocholine, butylthiocholine or the like as a substrate. These substrates yields thiocholine by the enzymatic reaction of ChE, and this thiocholine reacts with,5,5'-dithiobis-2-nitrobenzoic acid (DTNB) to produce a yellow color. Said method comprises measuring this yellow color by means of a colorimeter. This method is advantageous, for example, in that it is excellent in reactivity, has a high sensitivity, comprises simple operations, can deal with many samples, and permits employment of an initial velocity method. However, it is disadvantageous, for example, in that it is seriously affected by bilirubin in serum because of the yellow coloration and unavoidably affected by compounds having a thiol group such as glutathione, and in that the instability of the substrate itself is a problem. These disadvantages are responsible for errors of determined values.
(e) The enzymatic method comprises using benzoylcholine [Hiroaki Okabe et al., RINSHO-BYORI (Clinical Pathology), 25, 751, (1977)], orthotoluoylcholine [Japanese Patent Application Kokai (Laid-Open) No. 138533/79] or the like as a substrate, converting choline produced by the enzymatic action of ChE into betaine by cholineoxidase, and allowing hydrogen peroxide produced at this time to produce color by its oxidative condensation reaction with 4-aminoantipyrine, phenol or the like in the presence of peroxidase. In this method, since the coloration is red, there is not interference by bilirubin in serum, and many samples can be dealt with. However, since phenol or 4-aminoantipyrine used as a reagent for the color-producing system competitively inhibits ChE, the amount of these reagents used is greatly limited, so that sufficient color production is difficult. In general, a determination method via hydrogen peroxide is unavoidably affected not only by bilirubin in serum, reducing substances such as ascorbic acid and the like, etc. but also by choline produced by decomposition of phospholipids or the like. The employment of benzoylcholine as a substrate involves various problems, for example, its nonenzymatic hydrolyzability which causes troubles.
(f) The UV method includes two kinds of methods, and one is a method of W. Kalow using benzoylcholine as a substrate [W. Kalow and K. Genet, Can. J. Biochem. & Physiol., 35, 339 (1957)], while the other is a method using p-hydroxycholine [Japanese Patent Application Kokai (Laid-Open) Nos. 110198/82 and 129999/83] as a substrate. The former comprises following a decrease in amount of the substrate caused by its hydrolysis by the enzymatic action of ChE at a determination wave length of 240 nm. The principle of determination of this method is simple and plain because the decrease of the substrate is directly determined. However, this method is disadvantageous, for example, in that since the determination wave length is 240 nm, interference by serum components tends to occur, that since benzoylcholine, i.e., the substrate causes substrate inhibition, the substrate concentration of the reaction solution is limited, resulting in a narrow range of linearity, and that since nonenzymatic hydrolysis of benzoylcholine tends to occur, the reaction is not carried out at the optimum pH of ChE. The latter comprises using p-hydroxybenzoylcholine as a substrate, allowing p-hydroxybenzoate hydroxylase to act on p-hydroxybenzoic acid produced by the enzymatic action of ChE, in the presence of the coenzyme NADPH [nicotinamide adenine dinucleotide phosphate (reduced form)], and determining and following, at a wave length of 340 nm, a decrease of absorbance at the time of oxidation of NADPH into NADP by the enzymatic action. This method is an excellent method for determining ChE activity which makes it possible to carry out the reaction at an almost optimum pH, permits removal of the defects of the hydrogen peroxide color-producing system, namely, influence of bilirubin, reducing substances such as ascorbic acid and the like, etc. and interference by choline produced by decomposition of phospholipids, is free from the defects of the thiocholine method, and is suitable for an autoanalyzer capable of dealing with many samples. However, since NADPH, the coenzyme used, is an expensive reagent and is poor in stability, it is difficult to control while being kept at a definite quality. Further, in this method, p-hydroxybenzoate hydroxylase, protocatechuate 3,4-dioxygenase or the like is used as a reagent enzyme in the determination, and moreover the principle of determination is considerably complicated as compared with the former determination method; therefore there are many factors which produce an error of the resulting determined value. As to a method for determining ChE activity, determination of pseudo-cholinesterase activity is also important. However, the latter determination method is seriously affected by sodium fluoride and hence is not suitable for determining pseudo-cholinesterase activity.
As described above, the conventional methods for determining the enzymatic activity of ChE involve various problems, which are responsible for errors of measured values. In order to remove the defects of various heretofore well-known determination methods, the present inventors have devoted themselves to research and have consequently invented a novel method for determining serum ChE activity using, as a substrate, protocatechuoylcholine iodide (hereinafter referred to as PCI) which is one of the compounds represented by the general formula (I).
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 shows an IR spectrum of protocatechuoylcholine iodide.
FIG. 2 shows UV spectra [in a 50 mM barbital buffer solution LpH 8.5 )] of (a) protocatechuoylcholine iodide (concentration: 100 μM) and (b) protocatechuic acid (concentration: 100 μM).
FIG. 3 shows a time course observed for diluted serum.
FIG. 4 shows the relationship between serum dilution and ΔO.D.
FIG. 5 shows the optimum pH of ChE.
FIG. 6 shows the stability of a substrate to nonenzymatic hydrolysis.
FIGS. 7 to 14 show the influences of additives.
FIG. 15 shows the relationship between diluted serum and enzymatic activity observed for three kinds of sera.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel method for determining cholinesterase activity.
Another object of the present invention is to provide choline derivative which can be used as the substrate in the method.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
UV spectra of PCI and protocatechuic acid are shown in FIG. 2. On hydrolysis by the action of ChE, PCI gives choline and protocachuic acid. Choline has no UV absorption at a wave length longer than 300 nm. Protocatechuic acid has almost no UV absorption at a wave length longer than 340 nm. Therefore, when PCI is used as a substrate for determining ChE activity and the reaction is followed at a determination wave length of 340 to 360 nm, a decrease in amount of the substrate PCI can accurately be followed. In the above-mentioned UV method of W. Kalow, the determination wave length is 240 nm and hence serious interference by blood components occurs in initial absorptions. On the other hand, no serious interference occurs at the determination wave length of 340 to 360 nm of this invention, so that it is easy to determine the optimum determination conditions. The substrate PCI is very stable to nonenzymatic hydrolysis. For example, hydrolysis hardly occurred under the conditions of 37° C. in a 50 mM barbital buffer solution having a pH of 8.5 for 90 minutes (see FIG. 6). This result indicates that nonenzymatic hydrolysis is negligible in the determination. As a buffer for keeping the pH constant, there can be used barbiturates, phosphates, pyrophosphates, glycine, glycylglycine, tris(hydroxymethyl)aminomethane, etc. Any buffer other than those described above can be used so long as it can retain its buffer capacity in the pH range from 7.5 to 10.0.
The Km value of PCI for ChE is substantially the same as that of benzoylcholine and is 2.6×10 -5 mol/liter in a 50 mM tris-maleic acid buffer solution (pH 8.2) and 5.88×10 -5 mol/liter in a 50 mM barbital buffer solution (pH 8.5). Since the Km value of PCI is sufficiently small, the reaction can be carried out at sufficient substrate concentration in the reaction system of the determination method of this invention, and the range of linearity with the lapse of time is enlarged, so that the determination can sufficiently be carried out for a high unit of the activity.
When PCI is used as a substrate, the optimum pH of ChE was 8.5 to 8.6 in a 50 mM barbital buffer solution (see FIG. 5). As described above, PCI is stable to noenzymatic hydrolysis at pH 8.5, and hence the determination method of this invention makes it possible to carry out the reaction at the optimum pH of ChE.
It is as described above that when the coexisting substances in a sample affect the resulting determined value, they cause an error of the determined value. The determination method of this invention is hardly affected by the coexisting substances also from the viewpoint of its principle. Coexisting substances, for example, up to 20 mg/dl of ascorbic acid, up to 20 mg/dl of uric acid, up to 500 mg/dl of glucose, up to 200 mg/dl of hemoglobin, up to 5 g/dl of albumin, up to 20 mg/dl of bilirubin, and up to 50 mg/dl of glutathione (reduced form) caused no trouble in addition tests (see FIGS. 7 to 13). Further, no trouble was caused also in addition tests on EDTA.2Na (ethylenediamine tetraacetic acid disodium salt), citrate, heparin, oxalate, dihydrogenoxalic acid, and the like as anti-coagulants (see FIG. 14). The determination method of this invention is hardly affected by the coexisting substances and is an excellent method for determining cholinesterase activity in which the causes of error of determined value in the heretofore well-known determination methods are greatly removed.
As cholinesterases, there are known two kinds, namely, pseudo-cholinesterase existing in serum and true-cholinesterase existing in erythrocyte. The one whose activity is usually determined in a clinical examination is pseudo-cholinesterase in serum, but since serum is contaminated with true-cholinesterase in some cases, a subtrate which reacts selectively with pseudo-cholinesterase alone is preferable. PCI used in the method of this invention is a substrate having a very high specificity which reacts well with pseudo-cholinesterase but hardly reacts with true-cholinesterase.
In the fields of surgery and psychiatry, an examination for abnormal pseudo-cholinesterase is important from the viewpoint of the relationship between anesthetics and pseudo-cholinesterase. The determination method of this invention is simple and plain with regard to the reaction mechanism and hence is very suitable as a method of examination for abnormal pseudo-cholinsterase.
The method for determining ChE activity of this invention is, as described above, free from the various problems of the conventional methods. The advantages of this invention are as described below.
(1) The reaction mechanism of the determination system is simple and plain, and there are very few causes of error in the determined value.
(2) Since PCI used as a substrate is stable to nonenzymatic hydrolysis and oxidation, the reproducibility of the determined value is very good.
(3) PCI has a high substrate specificity for pseudo-cholinesterase.
(4) Since none of enzymes and coenzymes for redox systems and reagents for coloration systems are used in addition to the substrate PCI, the method of this invention is inexpensive.
(5) As described above, said method is hardly affected by sample components such as bilirubin, ascorbic acid, glutathione and the like and anti-coagulants.
(6) Since it is unnecessary to employ a sample blank for each sample, the determination can be carried out easily and rapidly, so that many samples can be dealt with.
(7) Examination for abnormal pseudo-cholinesterase is possible.
(8) Since PCI is stable, the reaction can be carried out at the optimum pH (8.5 to 8.6) for ChE.
(9) The determination is possible up to a high unit of the activity.
As described above, the method for determining ChE activity of this invention is free from the defects of the conventional methods, has many advantages and characteristics, permits accurate and simple determination of ChE activity, and can significantly contribute to the determination of ChE activity in daily clinical examinations.
This invention is further explained below in more detail with reference to Referential Examples and Examples, which are not by way of limitation but by way of illustration.
REFERENTIAL EXAMPLE 1
Synthesis Process of Protocatechuoylcholine Iodide
In 71 ml of 2.73 N NaOH was dissolved 10 g of protocatechuic acid, after which the resulting solution was cooled to 0° to 5° C. and 22 ml of carbobenzoxy chloride was added dropwise with vigorous stirring. At the same time, 2.73 N NaOH was also added dropwise so as to maintain the pH at 9 to 10. The pH became constant in about 1 hour. Subsequently, the mixture thus obtained was subjected to reaction with stirring at room temperature for 3 hours. After completion of the reaction, the reaction mixture was adjusted to pH 2 with cold 5 N HCl and extracted with 200 ml of ethyl acetate and then 100 ml thereof, and the ethyl acetate layers were combined, thereafter washed with an aqueous sodium chloride solution, and then dried over anhydrous magnesium sulfate. Then, the solvent was distilled off under reduced pressure to obtain 25 g of an oily substance. The substance was recrystallized from ethyl acetate/n-hexane to obtain 9.2 g of O,O'-dicarbobenzoxyprotocatechuic acid. In 50 ml of ether was suspended 4 g of this product while preventing moistening, after which 2 g of phosphorus pentachloride was added in powder form, and the resulting mixture was subjected to reaction with stirring at room temperature for 5 hours. After completion of the reaction, the solvent was distilled off under reduced pressure to obtain 4.5 g of an oily substance. A solution of this substance dissolved in 20 ml of benzene was added dropwise to a solution of 2 ml of dimethylaminoethanol dissolved in 30 ml of benzene, with cooling to 5° to 10° C. After the addition, the resulting mixture was stirred overnight at room temperature to be subjected to reaction, and subsequently washed with water and then a saturated aqueous sodium chloride solution. The benzene phase was dried over anhydrous magnesium sulfate, and then the solvent was distilled off under reduced pressure to obtain 4.9 g of an oily substance. This substance was dissolved in 260 ml of ethanol, followed by adding thereto 2 g of palladium black, and catalytic reduction was carried out for 5 hours, after which the catalyst was filtered off and the ethanol was distilled off under reduced pressure to obtain 3 g of an oily substance. This substance was dissolved in 90 ml of acetone, followed by adding thereto a solution of 2 g of methyl iodide dissolved in ethyl acetate, and the resulting mixture was allowed to stand overnight at room temperature to deposit crystals. The crystals were collected by filtration, sufficiently washed with acetone, and then dried overnight over phosphorus pentaoxide under reduced pressure to obtain 2.5 g of protocatechuoylcholine iodide, a novel compound of this invention, m.p. 205°-209° C. These crystals gave a single spot (Rf=0.31) in a silica gel thin layer chromatography (n-butanol:acetic acid:water=4:1:2).
Elementary analysis values: for C 12 H 18 NO 4 I (M.W. 367.166): Found (%): C: 39.34; H: 5.07; N: 3.90. Calculated (%): C : 39.25 ; H: 4.94; N: 3.81.
Their IR spectrum and UV spectrum are shown in FIG. 1 and FIG. 2, respectively.
EXAMPLE 1
Method for Determining Serum ChE Activity
(1) a 50 mM barbital buffer solution (pH 8.5, 25° C.)
(2) a sample
(3) a 6.3 mM substrate (PCI) solution
To the 2.0 ml of the buffer solution of (1) was added 0.1 ml of the sample, and preheating was conducted at 37° C. for about 2 to 10 minutes. Thereto was added 0.1 ml of the substrate solution of (3) and the resulting mixture was quickly stirred and then subjected to determination by means of a spectroscope. The optical absorbance at 340 nm of the substrate was determined and followed with the lapse of time. FIG. 3 shows the results of measuring twice each of time courses for serum and diluted serum. The pH of the barbital buffer solution was adjusted at 25° C. As the serum, CONSERA I (manufactured by Nissui Pharmaceutical Co., Ltd.), and the serum was diluted with a 0.877% aqueous sodium chloride solution. As can be seen from FIG. 3, linearity was observed up to 8 minutes for each serum. The relationship between dilution of serum and ΔO.D. is shown in FIG. 4. The results obtained showed a perfectly straight line passing through the origin. This fact indicates that the ChE activity and ΔO.D. are proportional to each other, and that said novel method for determining ChE activity is practical and useful.
EXAMPLE 2
The pH of the buffer solution of (1) in Example 1 was varied from 7.4 to 9.2 and the optimum pH for ChE in said method was determined. This determination was carried out entirely according to Example 1 except for the pH of the buffer. The result obtained is shown in FIG. 5. Under these conditions, the optimum pH was 8.5 to 8.6.
EXAMPLE 3
To 2.0 ml of the buffer of (1) in Example 1 was added 0.1 ml of the substrate solution of (3), and the resulting solution was placed in a heat insulating cuvette having a temperature of 37° C. The change of optical absorbance at a wave length of 340 nm was followed with the lapse of time, whereby the stability of the substrate to nonenzymatic hydrolysis was examined. As a result, the substrate was almost stable up to 90 minutes as shown in FIG. 6. Since the substrate PCI is stable at the optimum pH of 8.5, it is unnecessary to measure a reagent blank value for each sample.
EXAMPLE 4
The influence of the following additives in the reacation system was examined according to the determination method in Example 1.
______________________________________Additive Added amount______________________________________(1) Ascorbic acid 0-20 mg/dl(2) Glucose 0-500 mg/dl(3) Uric acid 0-20 mg/dl(4) Hemoglobin 0-500 mg/dl(5) Albumin 0-5 g/dl(6) Bilirubin 0-20 mg/dl(7) Glutathione 0-50 mg/dl(8) Anti-coagulant Heller paul (a mixture of 200 mg/dl potassium oxalate with ammonium oxalate) Sodium oxalate 200 mg/dl Heparin 2 mg/dl Sodium citrate 500 mg/dl EDTA.2Na 200 mg/dl NaF 500 mg/dl______________________________________
The determination results are shown in terms of relative activity (%) in FIGS. 7 to 14. As to hemoglobin, the relative activity was 97.3% in the case of its addition in an amount of 300 mg/dl, and hence the determination is possible up to about this amount. Since NaF is an inhibitor of pseudochloinesterase, determination of ChE activity by any method generally gives no accurate determined value in the presence of NaF. Therefore, from the result for NaF in FIG. 14, NaF cannot be used as an anti-coagulant in determining pseudo-cholinesterase activity.
EXAMPLE 5
Method for Determining Inhibitory Activity of Serum ChE
(1) a 50 mM barbital buffer solution (pH 8.5, 25° C.)
(2) a sample
(3) a 6.3 mM substrate (PCI) solution
(4) a solution of 6.3 mM substrate (PCI) and 0.44 mM of dibucaine
(5) a solution of 6.3 mM substrate (PCI) and 220 mM NaF
(1), (2) and (3) are the same as in Example 1. (4) and (5) are mixed solutions of the specified concentrations of the substrate and each inhibitor. The determination method is the same as the method is Example 1. That is to say, the solution of (4) or (5) was added in place of the solution of (3), and the reaction was followed at a determination wave length of 340 nm. The results obtained were that the serum ChE was inhibited by 80% by the addition of dibucaine and by 57.9% by the addition of NaF.
EXAMPLE 6
Method for Determining Serum ChE Activity
______________________________________(1) a 250 mM substrate (PCI) solution 2.0 ml [prepared by dissolving in a 50 mM tris-maleic acid buffer solution (pH 8.2, 25° C.)](2) serum or diluted serum(i) serum I: CONSERA I 0.1 ml(ii) serum I: CONSERA I 0.2 ml(iii) serum II: PRECIPATH E 0.1 ml______________________________________
At 37° C., 2.0 ml of (1) was preheated for 2 to 10 minutes, and 0.1 ml or 0.2 ml of the serum or the diluted serum of (2) was added. Each of the mixtures thus obtained was quickly stirred and then placed in a cuvette maintained at 37° C. of a spectroscope, and the decrease of optical absorbance was determined and followed at a determination wave length of 340 nm. The pH of the buffer solution of (1) was adjusted at 25° C. As the sera, CONSERA I (manufactured by Nissui Pharmaceutical Co., Ltd.) and PRECIPATH E (manufactured by Bohringer Mannheim, GmbH.) were used, and the sera were diluted with a 0.877% aqueous sodium chloride solution.
The ChE activity value is calculated from the following equation. ##EQU1## (1) ΔO.D. is a change per minute of optical absorbance at a determination wave length of 340 nm.
(2) The molecular absorption at 340 nm is 2960.
As shown in FIG. 15, for all of the three sera, the serum dilution and the enzyme activity are proportional to each other in the manner of a straight chain passing through the origin very sufficiently. | In a method for determining cholinesterase (hereinafter referred to as ChE) activity, the improvement comprising by using, as a substrate, a protocatechuoylcholine derivative represented by the general formula (I), ##STR1## (wherein X is a halogen atom). The method for determining ChE activity according to the present invention is free from defects of the conventional methods, has many advantages and characteristics, permits accurate and simple determination of ChE activity, and can sufficiently contribute to determination of ChE activity in daily clinical examinations. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a movement detector for composite color television signals and in particular to a circuit for extracting information concerning movement of objects contained in composite color television signals, where the subcarrier modulated by color difference signals is combined with luminance signals.
2. Description of the Prior Art
For the processing of composite color television signals according to the NTSC system, in the case where the signal processing utilizing a frame memory is effected for the purpose of improving the picture quality, it is important to detect movement of images in the television signals.
In the composite color television signals the polarity of the modulated chrominance signal is inverted for every scanning line and it is inverted also between the scanning line of the present frame and that preceding frame. A simple frame difference motion detector is not convenient for composite color television signals, since the modulated chrominance signal component appears in the frame difference signal in a still picture. Therefore it was not possible to extract correct information concerning movement of objects.
As a movement detector in composite color television signals known heretofore, there is known a circuit, by which the difference between the signal of the present frame and that of the frame preceding it by two frames is formed and the movement detection output signal is made by forming the absolute value of the difference signal.
This is because, in the color television signals according to the NTSC system, the polarity of the modulated chrominance signal in the scanning line of the present frame and that preceding it by two frames are equal.
There is known also another movement detector, by which a component in the frequency band of the modulated chrominance signal is extracted from the difference signal between the present frame and that preceding by two frames, the magnitude of the difference signal represents as information concerning movement in the frequency band of the modulated chrominance signal; at the same time the difference signal between the present frame and that preceding by one frame is made pass through a low pass filter in order to extract its low frequency components; movement of the low frequency components of the luminance signal is extracted by forming their absolute value and finally a movement detection signal is made by combining these two information signals concerning movement of images.
By the movement detector described above by which movement information is obtained from the difference signal between the present frame and that preceding frame by two frames to be "no movement" when the television image is still one, it is correctly judged. However, when an object moves with a high speed, there is a problem that its movement is sometimes not detected because of the fact that signals of the frame preceding present one by two frames are used.
On the other hand, by the movement detector, by which a movement detection signal is formed by combining information concerning movement of objects in the frequency band of the modulated chrominance signal with movement in the low frequency components of the luminance signal, since information of the difference between the present frame and that preceding it by one frame is also utilized, the lost motion problem described above occurs more rarely. However the lost motion occurs as well for an object, whose luminance signal level is identical to that of the background and only whose chrominance phase differs therefrom.
SUMMARY OF THE INVENTION
The object of this invention is to provide a movement detector for composite color television signals permitting to remove the problems described above and to detect correctly movement of objects, even if they move with a high speed, so that no lost motion is produced.
In order to achieve, the above object the movement detector in composite color television signal according to this invention is so constructed that detection signal for movement of objects is obtained by temporally integrating a signal, containing movement information obtained from the difference signal between the present frame and that preceding it by two frames over a period of time corresponding to a finite number of past frames.
For a part of an object moving even with a high speed, which cannot be detected by using the two frame difference signal, its movement is detected in past fields or frames of the same pixel or surrounding pixels. If the movement is detected in a finite number of past frame periods by obtaining a two-frame difference signal, the movement signal is always obtained by inputting the difference signal in a motion information converting circuit, which converts it into motion information and integrating its output with respect to temporal axis. And thus, it is possible to prevent occurrence of lost motion problem that a motion of an object cannot be detected.
The above-mentioned and other features and objects of this invention will become more apparent by reference to the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2 and 3 are block diagrams indicating three different embodiments of the movement detector in composite color television signals according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinbelow an embodiment of this invention will be explained, referring to FIG. 1. In the figure, a composite color television signal according to NTSC system presented on an input terminal 1 is inputted in a frame memory 2 having a two-frame capacity (1050 H). In a subtractor 3 the difference between the input and the output of the frame memory 2, i.e. the difference between the present frame and that preceding it by two frames, is calculated. Then, it is possible to output desired exact motion information at an output terminal 6 by integrating motion information of the same pixel or surrounding pixels over a finite number of past frame periods by means of a temporally integrating circuit with respect to temporal axis after having transformed the two frame difference signal into a signal representing the movement of the object by means of a motion information converting circuit 4.
FIG. 2 illustrates the construction of another embodiment of this invention. In the figure, the frame difference signal between adjacent frames and the two frame difference signal between the present frame and that preceding it by two frames are obtained in the subtractors 10 and 3, respectively, by means of two frame memories with one frame capacity (525 H) 8 and 9 connected in cascade. After the modulated chrominance signal has been removed from the frame difference signal by a low pass filter 11, the absolute value of the difference signal is formed by an absolute value forming circuit 12 and transformed into a motion information M 1 of the low frequency component in the luminance signal corresponding to the degree of the movement by a read only memory (ROM) 17. On the other hand, the two frame difference signal obtained by the subtractor 3 is transformed into motion information M 2 based on the two frame difference, which is the output of an ROM 20, by a motion information converting circuit 4 consisting of an absolute value forming circuit 18, a low pass filter 19, the ROM 20 and an adder 21. The adder 21 combines motion information M 1 and M 2 . Desired motion information is obtained at the output terminal 6 by integrating the sum thus obtained for every field period by means of the integrating circuit 5 with respect to temporal axis, which consists of adders 22 and 25, a field memory (having a capacity of 262 H) 23, a line memory (1 H) and a coefficient circuit 26.
FIG. 3 illustrates the construction of still another embodiment of the movement detecting circuit according to this invention. In the figure, for the luminance signal component in the NTSC signal inputted in the input terminal 1, the motion information M 1 is extracted from the low frequency component of the frame difference signal by utilizing a frame memory 27, a subtractor 28, a low pass filter 29, an absolute value forming circuit 30 and an ROM 31, just as for the embodiment indicated in FIG. 2. On the other hand, for the chrominance difference signal, a two frame difference signal is obtained by the frame memory 2 with a two frame capacity and the subtractor 3 after having been demodulated to base band chrominance difference signals by means of a band pass filter (BPF) 32 and a demodulating circuit 33. Then the motion information M 2 for the chrominance difference signals is extracted by an absolute value forming circuit 34 and an ROM 35. Signal combining M 1 and M 2 is done by a maximum value selector (MAX) 36 selecting which is greater between M 1 and M 2 . The selected motion information is integrated by the integrating circuit 5 with respect to temporal axis, which consists of a maximum value selector 37, a coefficient circuit 38, a field memory (having a capacity of 262 H) 39 and a line memory 40. The maximum value of the motion information between the present scanning line and the scanning lines above and below it in the preceding field is outputted at the output terminal 6. The maximum value thus obtained is multiplied by α (0<α<1) in the coefficient circuit 38 and fed into the field memory 39, where the integration with respect to temporal axis over a finite number of field periods.
In the embodiment indicated in FIG. 2, it is also possible to input the two frame difference signal obtained by the subtracting circuit 3 in the absolute value forming circuit 18 after having extracted its modulated chrominance signal band therefrom by the BPF. Further it is possible to reduce the necessary number of ROMs by using the ROMs 17 and 20 in common, adding the output of the absolute value forming circuit 12 and the output of the LPF 19 and transforming the summing output into the motion information by means of the ROM.
In the embodiment indicated in FIG. 3 it may be also possible to realize the temporally integrating circuit 5 with respect to temporal axis over a finite number of field periods by disposing a substrating circuit instead of carrying out a multiplication with the coefficient α and subtracting a certain number from the output of the maximum value selecting circuit 37.
In the embodiments indicated in FIGS. 2 and 3 the integrating circuit 5 with respect to temporal axis carries out the integration for every field period, which has a certain extent not only in the direction of the temporal axis but also in the direction of the vertical axis of a displayed picture. It is possible to realize the integration purely with respect to temporal axis for every frame period by replacing the field memories 23 and 39 and the line memories 24 and 40 by frame memories. The spatial integration effect also is efficient for remedying deficient motion information of the two frame difference signal and the circuit used in the embodiments shows excellent characteristics. Furthermore, although the integrating circuit 5 in the embodiments has an extent in the vertical direction, it is easy to realize an integrating circuit with respect to temporal and spatial axis having an extent in both the vertical and horizontal directions.
According to this invention, effects can be obtained that, in the movement detection using the difference between the present frame and that preceding it by two frames in the color television signal according to the NTSC system, since lost motion can be prevented, it is possible to extract exact motion information and that, when it is applied to various kinds of signal processing circuits adapted to movement of objects, their characteristics are remarkably improved. | A movement detector necessary for processing composite color television signals, which detects movement in image signals, wherein the detecting circuit is so constructed that no deficient motion is produced. A difference signal between the present frame and that preceding by two frames of the television signals is converted into a motion information signal and a movement detection signal is made by integrating the signal obtained by the conversion with respect to temporal axis. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a vapor lock preventing mechanism in a motor-driven fuel pump.
Conventionally, there is disclosed in Japanese Patent Laid-open Publication No. 62-214294 a motor-driven fuel pump provided with a vapor jet in a pump chamber for eliminating a fuel vapor generated in the pump chamber at high temperatures or drawn with a fuel upon sucking of the fuel into the pump chamber and thereby preventing vapor lock.
Such a vapor jet is normally provided at a high-pressure position in the pump chamber. In the case of a multi-stage motor-driven pump, the vapor jet is provided at a high-pressure position in a first-stage pump chamber on a suction side of the pump section, so as to efficiently eliminate the fuel vapor under the high fuel pressure. However, if a large amount of fuel vapor is generated in the case of using a light gasoline as the fuel, for example, the fuel vapor resides widely in the pump chamber to pass the position of the vapor jet or generate vapor lock in the worst case.
Such a problem is considered to be eliminated by enlarging a diameter of the vapor jet or forming the vapor jet at a higher-pressure position to thereby improve a vapor discharging ability. However, the fuel is largely leaked with the fuel vapor through the vapor jet to cause a reduction in fuel discharge quantity of the pump and a reduction in pump ability at an ordinary temperature.
In another type two-stage motor-driven fuel pump disclosed in Japanese Utility Model Publication No. 63-100686, a first impeller has a thickness and a vane depth greater than a second impeller to thereby increase a gradient of fuel pressure increase in a first pump chamber, thereby early diminishing the fuel vapor generated in the first pump chamber or efficiently eliminating the fuel vapor from the vapor jet.
However, in the latter case, since the first impeller and the second impeller have different shapes and sizes as mentioned above, a common member for each pump stage cannot be utilized, and an overall size of the pump section is increased.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a multi-stage motor-driven pump which may efficiently prevent vapor lock with use of a common member for each pump stage.
According to one aspect of the present invention, there is provided a multi-stage motor-driven fuel pump comprising a motor section provided with an electric motor and a pump section to be driven by said electric motor, said pump section having a plurality of pump chambers partitioned by intermediate plates and communicated with each other by a fuel communication hole formed through each of said intermediate plates; wherein a ratio of a sectional area of said fuel communication hole of any one of said intermediate plates between adjacent ones of said pump chambers to a sectional area of said pump chamber on a lower pressure side is set in a predetermined range such that a gradient of fuel pressure increase in said pump section is increased to early prevent vapor lock.
With this construction, as the ratio of the sectional area of the fuel communication hole formed through the intermediate plate between the adjacent pump chambers to the sectional area of the pump chamber on a lower pressure side is set in the predetermined range, the gradient of fuel pressure increase in the pump section is increased to thereby efficiently diminish fuel vapor generated in the pump chambers and early prevent vapor lock.
According to a second aspect of the present invention, there is provided a multi-stage motor-driven fuel pump comprising a motor section provided with an electric motor and a pump section to be driven by said electric motor, said pump section having a plurality of pump chambers, a fuel inlet communicated with a first one of said pump chambers, and a fuel outlet communicated with a final one of said pump chambers; wherein a ratio of a sectional area of said fuel outlet to a sectional area of a final one of said pump chambers is set in a predetermined range such that a gradient of fuel pressure increase in said pump section is increased to early prevent vapor lock.
With this construction, as the ratio of the sectional area of the fuel outlet of the pump section to the sectional area of the final pump chamber is set in the predetermined range, the gradient of fuel pressure increase in the pump section is increased to thereby early reach a predetermined fuel pressure and efficiently diminish fuel vapor generated in the pump chambers, thereby early preventing vapor lock.
In summary, the fuel pressure in the pump section can be increased early by suitably setting the sectional area of the fuel outlet of any one of the pump chambers. Thus, it is only necessary to simply work the fuel outlet, and a common member can be used for each pump stage. Accordingly, a manufacturing cost can be reduced, and an overall size of the motor-driven pump can be maintained compact.
Especially, in the case that the above-mentioned predetermined range is set to 0.5-1.4, and that a normal gasoline is used as the fuel, the generation of vortex due to separation of fuel stream and cavitation can be prevented to effect desirable vapor lock prevention with desired amount of fuel flow and fuel pressure maintained.
The invention will be more fully understood from the following detailed description and appended claims when taken with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cutaway elevational view of a first preferred embodiment of the motor-driven pump according to the present invention;
FIG. 2 is a bottom plan view of an intermediate plate shown in FIG. 1;
FIG. 3 is a cross section taken along the line III--III in FIG. 2;
FIG. 4 is a plan view of an inlet body shown in FIG. 1;
FIG. 5 is an enlarged sectional view of a part of a first pump stage shown in FIG. 1;
FIG. 6 is a view similar to FIG. 5, showing a sectional area of a first pump chamber shown in FIG. 4;
FIG. 7 is a characteristic graph of a fuel pressure in the pump section with respect to a rotational angle of the pump section, according to the first preferred embodiment and the prior art;
FIG. 8 is a view similar to FIG. 2, showing a modification of the first preferred embodiment;
FIG. 9 is a cross section taken along the line IX--IX in FIG. 8;
FIG. 10 is a characteristic graph of a pump discharge amount with respect to a ratio of a sectional area of a fuel outlet of a first pump chamber to a sectional area of the first pump chamber in the case of using gasoline as the fuel;
FIG. 11 is a characteristic graph of a pressure at a position just upstream of the fuel outlet of the first pump chamber with respect to the ratio of the sectional area of the fuel outlet of the first pump chamber to the sectional area of the first pump chamber in the case of using gasoline as the fuel;
FIG. 12 is a view similar to FIG. 1, showing a second preferred embodiment of the present invention;
FIG. 13 is a bottom plan view of an outlet body shown in FIG. 12;
FIG. 14 is an enlarged sectional view of a part of a second pump stage shown in FIG. 12;
FIG. 15 is a view similar to FIG. 14, showing a sectional area of a second pump chamber shown in FIG. 14;
FIG. 16 is a view similar to FIG. 7, according to the second preferred embodiment and the prior art;
FIG. 17 is a view similar to FIG. 2, showing the prior art; and
FIG. 18 is a cross section taken along the line XVIII--XVIII in FIG. 17.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There will now be described a first preferred embodiment of the present invention with reference to FIGS. 1 to 8.
Referring to FIG. 1 which is a partially cutaway elevational view of the motor-driven fuel pump of a so-called in-tank type such that the fuel pump is so mounted as to be submerged in a fuel tank (not shown) for storing a fuel. The fuel pump is generally constructed of a cylindrical casing 1, a motor section disposed in the casing 1 and including an electric motor 2 having a motor shaft 3, and a pump section 4 of a cascade type disposed below the casing 1 and operatively connected to the motor section so as to be driven by the motor shaft 3. A filter 5 is connected to a fuel inlet 6 of the pump section 4, so that the fuel is sucked by the pump section 4 to be fed through the filter 5 through the pump section 4 into the casing 1. Then, the fuel is fed through an annular space around the electric motor 2 and through a check valve (not shown) to a fuel outlet 7 formed at an upper end of the casing 1. Then, the fuel is discharged from the fuel outlet 7.
The pump section 4 is constructed of a pair of first impeller 8 and second impeller 9 having the same shape and size which are centrally fixed to the motor shaft 3 of the electric motor 2, an outlet body 10 fixed by bonding to a lower end of the casing 1, an inlet body 11 fixed by screws (not shown) to the outlet body 10, a first annular spacer 12, an intermediate annular plate 13 and a second annular spacer 14 which spacers and plate are fixedly interposed between the outlet body 10 and the inlet body 11. Under the assembled condition of these elements of the pump section 4, a first pump chamber 15 is defined among the inlet body 11, the first spacer 12, the intermediate plate 13 and the first impeller 8, while a second pump chamber 16 is defined among the intermediate plate 13, the second spacer 14, the outlet body 10 and the second impeller 9. Thus, the pump section 4 is constructed as a two-stage pump. That is, a first fuel flow groove 17 is formed on the upper surface of the inlet body 10 and on the lower surface of the intermediate plate 13 along an outer circumferential vane 8a of the first impeller 8, and an annular space is defined between the outer circumferential vane 8a of the first impeller 8 and the inner circumference of the first spacer 12, thus forming the first pump chamber 15. Similarly, a second fuel flow groove 18 is formed on the upper surface of the intermediate plate 13 and the lower surface of the outlet body 10 along an outer circumferential vane 9a of the second impeller 9, and an annular space is defined between the outer circumferential vane 9a of the second impeller 9 and the inner circumference of the second spacer 14, thus forming the second pump chamber 16.
The fuel inlet 6 is formed through the inlet body 11 to communicate with the first pump chamber 15, and a first outlet 19 (see FIGS. 2 and 3) is formed through the intermediate plate 13 to communicate with the first pump chamber 15 and the second pump chamber 16. Further, a second outlet 20 is formed through the outlet body 10 to communicate with the second pump chamber 16 and the motor section. Thus, the fuel is sucked from the fuel inlet 6 into the first pump chamber 15, and a pressure of the fuel is gradually increased by the rotation of the first impeller 8. Then, the fuel is discharged from the first outlet 19, and is fed into the second pump chamber 16, wherein a pressure of the fuel is further increased by the rotation of the second impeller 9. Thereafter, the fuel having a high pressure is discharged from the second outlet 20 to the motor section.
The vapor lock preventing means in the first preferred embodiment is constructed in such a manner that a sectional area of the first outlet 19 formed through the intermediate plate 13 is substantially equal to a sectional area S of the first pump chamber 15 (which sectional area S is represented by a hatched portion surrounded by a-b-c-d-e-f-a shown in FIG. 6).
Further, as shown in FIG. 4, the inlet body 11 is formed with a vapor jet 21 having a small diameter, which communicates the fuel flow groove 17 with the outside of the fuel pump. The vapor jet 21 is located at an angular position θ as measured from the position of the fuel inlet 6 in a direction of fuel flow as shown by an arrow.
On the other hand, a sectional area of the fuel inlet 6 is larger than the sectional area S of the first pump chamber 15 in the same manner as the prior art (a ratio of the former to the latter is set to about 5). Further, a sectional area of the second outlet 20 is larger than a sectional area of the second pump chamber 16 (which sectional area is equal to the sectional area S of the first pump chamber 15) in the same manner as the prior art (a ratio of the former to the latter is also set to about 5).
FIGS. 17 and 18 show the prior art construction of the intermediate plate 13, wherein a first outlet 19A is different in sectional area from the first outlet 19 shown in FIGS. 2 and 3, and the other parts are identical with each other. That is, as apparent from FIGS. 17 and 18 in comparison with FIGS. 2 and 3, the sectional area of the first outlet 19A in the prior art is larger than that of the first outlet 19 of the first preferred embodiment of the present invention. Specifically, the sectional area of the first outlet 19A is set in such a manner that a fuel pressure at the first outlet 19A is substantially half a fuel pressure at the second outlet 20, and it is increased substantially linearly until the fuel is discharged from the second outlet 20 as shown in FIG. 7.
To the contrary, the sectional area of the first outlet 19 in the first preferred embodiment is substantially the same as that of the sectional area of the first pump chamber 15. In other words, the sectional area of the first outlet 19 is smaller than that of the first outlet 19A in the prior art. Accordingly, as shown in FIG. 7, a gradient of fuel pressure increase in the first pump chamber 15 from the fuel inlet 6 to the first outlet 19 is greater than that in the prior art. In the second pump chamber 16, the gradient of fuel pressure increase is reduced to reach a predetermined pressure at the second outlet 20 to be adjusted by a pressure regulator (not shown) provided in a fuel pipe leading from the fuel outlet 7 to a fuel injector (not shown).
As mentioned above, the gradient of fuel pressure increase in the first pump chamber 15 is made higher than that in the prior art by reducing the sectional area of the first outlet 19 to be substantially equal to the sectional area of the first pump chamber 15. Accordingly, fuel vapor generated in the first pump chamber 15 can be early deminished by the high fuel pressure even when a light fuel is used. Further, as the vapor jet 21 for eliminating the fuel vapor is provided at a high-pressure position in the first pump chamber 15 to be communicated with the atmosphere, the fuel vapor can be effectively eliminated from the vapor jet 21. For example, the high-pressure position where the vapor jet 21 is formed is shown by a dotted line in FIG. 7. Accordingly, as apparent from FIG. 7, the fuel pressure at the vapor jet 21 can be higher than that in the prior art to thereby efficiently eliminate the fuel vapor from the vapor jet 21.
Thus, in the first preferred embodiment, the sectional area of the first outlet 19 of the first pump chamber 15 is reduced to thereby make the gradient of fuel pressure increase greater than that in the prior art, with the result that the fuel pressure at the first outlet 19 is made greater than that in the prior art to suppress the generation of the fuel vapor and prevent the vapor lock in the first pump chamber 15.
FIGS. 8 and 9 show a modification of the first preferred embodiment shown in FIGS. 2 and 3, wherein a ratio of the sectional area of a first outlet 29 to the sectional area S of the first pump chamber 15 is set to about 0.5.
The selection of the first outlet 19 of the first preferred embodiment or the first outlet 29 of this modification is dependent upon a kind of fuel to be used. Further, a degree of reduction in sectional area of the first outlet is also dependent upon a kind of fuel to be used. That is, the lighter the fuel, the smaller the sectional area of the first outlet is made to more increase the gradient of fuel pressure increase. Especially in the case of using a normal gasoline as the fuel, the ratio of the sectional area of the first outlet 19 to the sectional area S of the first pump chamber is preferably set to a range of 0.5-1.4 for the following reasons.
FIG. 10 shows the relationship between the ratio of the sectional area of the first outlet 19 to the sectional area S of the first pump chamber and the discharge amount of the fuel pump, and FIG. 11 shows the relationship between the above-mentioned ratio and the pressure at a position just upstream of the first outlet 19. In the graphs of FIGS. 10 and 11, a pump discharge pressure is controlled to 2.55 kg/cm 2 , and a normal gasoline (leadless regular gasoline; Reid vapor pressure: 0.75 kg/cm 2 at 37.8° C.) was used in the test. It has been realized in the test that the vapor lock prevention is remarkably effective when the pressure at the position just upstream of the first outlet 19 is 1.7 kg/cm 2 or more at a fuel temperature of 25° C. (or 1.3 kg/cm 2 or more at a fuel temperature of 40° C.). The specification of the fuel pump used in the test is as follows:
Diameter of the first impeller 8=Diameter of the second impeller 9=35 mm
Sectional area S of the first pump chamber 15=Sectional area S of the second pump chamber 16=9.24 mm 2
Inner diameter of the vapor jet 21=0.9 mm
Angular position θ of the vapor jet 21=210°
(Angle from the fuel inlet 6 to the first outlet 19=300°)
As apparent from FIG. 10, the pump discharge amount becomes almost constant near the ratio of 1.4. Further, as apparent from FIG. 11, when the ratio exceeds 1.4, the pressure at the position just upstream of the first outlet 19 becomes less than 1.7 kg/cm 2 . Accordingly, the ratio must be set to equal to or less than 1.4. If the ratio is set to be greater than 1.4, there will be generated separation of fuel stream at the fuel outlet to cause a turbulent flow and the generation of fuel vapor.
On the other hand, if the ratio is set to be less than 0.5, a difference between a flow rate of the fuel in the fuel flow groove 17 and a velocity of the vanes of the first impeller 8 becomes large to cause the generation of cavitation. Further, the flow rate at the first outlet 19 is increased by the suction from the second pump chamber 16 to cause a reduction in pressure at the postion just upstream of the first outlet 19. Consequently, it is necessary to set the ratio to the range of 0.5-1.4.
Although the predetermined range of 0.5-1.4 is applied to the case that the diameter of the first impeller 8 and the second impeller 9 is set to 35 mm in the above preferred embodiment, the same range of the ratio may be applied to the cases where the diameter ranges from 25 mm to 50 mm, which cases may exhibit the similar vapor lock prevention effect. Such a range of the diameter is desirable in respect of a pump size suitable for mounting into an automotive fuel tank.
Referring next to FIGS. 12 to 16 which show a second preferred embodiment of the present invention, wherein the same reference numerals as in the first preferred embodiment denote the same parts, an orifice 31 is provided in a second outlet 30, and an opening area of the orifice 31 is set to be substantially equal to the sectional area S of the second pump chamber 16 as shown by a hatched portion surrounded by a-b-c-d-e-f-a in FIG. 15. Accordingly, the sectional area of the second outlet 30 is restricted by the opening area of the orifice 31. On the other hand, the sectional area of the first outlet (not shown in FIGS. 12 to 16) is the same as that of the first outlet 19A in the prior art.
Accordingly, the fuel pressure is increased substantially linearly from the fuel inlet 6 to the second outlet 30 in the same manner as the prior art. However, as the sectional area of the second outlet 30 is restricted by the restriction 31, a gradient of fuel pressure increase can be made greater than that in the prior art as shown in FIG. 16, and a predetermined fuel pressure to be adjusted by the pressure regulator can be reached earlier than the prior art. As apparent from FIG. 16, the fuel pressure in the first pump chamber 15 can be made greater than that in the prior art. Accordingly, the fuel vapor generated in the first pump chamber 15 can be diminished earlier than the prior art, and the fuel vapor can be more efficiently eliminated from the vapor jet 21 owing to the high fuel pressure.
The opening area of the orifice 31 is dependent upon a kind of fuel to be used. That is, the lighter the fuel, the smaller the opening area of the orifice 31 is made.
Further, although the above-mentioned preferred embodiments are applied to a two-stage motor-driven fuel pump, the present invention may be applied to a multi-stage motor-driven fuel pump having three or more pump chambers.
Having thus described the preferred embodiments of the invention, it should be understood that numerous structural modifications and adaptations may be made without departing from the spirit of the invention. | A multi-stage motor-driven fuel pump including a motor section provided with an electric motor and a pump section to be driven by the electric motor, the pump section having a plurality of pump chambers partitioned by intermediate plates and communicated with each other by a fuel communication hole formed through each of the intermediate plates. A ratio of a sectional area of the fuel communication hole of any one of the intermediate plates between adjacent ones of the pump chambers to a sectional area of the pump chamber on a lower pressure side is set in a predetermined range such that a gradient of fuel pressure increase in the pump section is increased to early prevent vapor lock. | 5 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to seal clearances in rotary machines. More particularly, the invention relates to a method to modify the stationary casing in a manner to compensate for circumferentially non-uniform rotor movements.
[0002] Rotary machines include, but are not limited to, gas turbines and steam turbines. The moving part of the turbine is called a rotor and the fixed, non-moving part i. e. housings, casings etc. a stator. Usually, the rotor rotates within a stator assembly at very high speeds, powering a generator which in turn produces electricity or power. A steam turbine has a steam path that typically includes, in serial-flow relationship, a steam inlet, a turbine, and a steam outlet. A gas turbine has a gas path, which typically includes, in serial-flow relationship, an air intake (or inlet), a compressor, a combustor, a turbine, and a gas outlet (or exhaust nozzle). Gas or steam leakage, either out of the gas or steam path or into the gas or steam path, from an area of higher pressure to an area of lower pressure, is generally undesirable. For example, gas path leakage in the turbine or compressor area of a gas turbine, between the rotor of the turbine or compressor and the circumferentially surrounding turbine or compressor casing, will lower the efficiency of the gas turbine leading to increased fuel costs.
[0003] In practice, clearances between the rotating and stationary parts are often designed to be sufficiently large so that minimal contact occurs during the operation of the engine. However, overly generous clearances tend to promote undesirable leakages and decreased performance. In some machine designs, where reduced clearances have been designed for better efficiency, contact between rotor and stator is anticipated and accommodated by disposing a seal, such as a brush seal or an abradable seal, between these components. Abradable seals applied on the stationary parts of the gas or steam turbines have been used in order to allow the components from the rotating part (e.g. bucket tips, shaft teeth, etc.) to come into contact with the stator without suffering significant damage or wear. Contact between rotating elements and the abradable seal results in trenches worn into the abradable seal, creating a tight clearance between the two.
[0004] Effects such as thermal distortion of the casing and vibrations due to rotor dynamics often cause the path of relative rotor motion to become circumferentially non-uniform with respect to the stator. This non-uniformity of motion can lead to substantial contact in preferential, localized areas of the stator, resulting in undesirable amounts of component wear. A number of approaches have been tried to compensate for this non-uniform motion and resultant prevention of contact. Conventionally, machine parts have been machined circular and assembled with generous uniform clearances to prevent contact. The large clearances allow for more gas or steam to escape, however, which degrades system performance. In certain cases, parts are machined off-center to provide non-uniform clearances, but this complicates their fabrication and significantly boosts costs. In some steam turbines, seals are segmented into 4, 6, 8, or more segments, and the segments are each machined to a different diameter. This greatly complicates turbine assembly because individual parts must be tracked and assembled insitu in their specific circumferential locations. Therefore, what is needed is a cost-effective stator component that is capable of producing non-uniform rotor clearances. A further need is for efficient methods for making such components.
BRIEF SUMMARY OF THE INVENTION
[0005] Embodiments of the present invention meet these and other needs.
[0006] One embodiment of the invention is a stator component for a turbine assembly. The stator component comprises an annular base component having an inner surface that is substantially circular in axial cross-section and a coating disposed on the inner surface of the base component. The coating has an interfacial surface in contact with the inner surface of the base component and an outer surface opposite the interfacial surface. The coating also has a thickness that varies as a function of circumferential position along the inner surface of the base component.
[0007] A second embodiment of the invention is a method for making a stator component for a turbine assembly. The method comprises providing an annular base component having an inner surface that is substantially circular in axial cross-section and disposing a coating on the inner surface of the base component. The coating has an interfacial surface in contact with the inner surface of the base component and an outer surface opposite the interfacial surface. The coating has a thickness that varies as a function of circumferential position along the inner surface of the base component.
[0008] These and other aspects, advantages, and salient features of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Referring now to the figures wherein like elements are numbered alike:
[0010] FIG. 1 is a schematic view illustrating one embodiment of non-uniform spray coating disposed on stator base component;
[0011] FIG. 2 is a schematic view illustrating another embodiment of non-uniform spray coating disposed on stator base component.
DETAILED DESCRIPTION OF THE INVENTION
[0012] In the following description, like reference characters designate like or corresponding parts throughout the several views shown in the figures. It is also understood that terms such as “top,” “bottom,” “outward,” “inward,” and the like are words of convenience and are not to be construed as limiting terms. Moreover, it will be understood that the illustrations are for the purpose of describing a particular exemplary embodiment of the invention and are not intended to limit the invention thereto.
[0013] Referring generally to FIGS. 1 and 2 , embodiments of the invention address the needs described above by providing a stator component 20 for a turbine assembly 40 . The stator component 20 comprises an annular base component 60 which, in certain embodiments, comprises at least one of a shroud, a turbine casing, and an annular assembly of turbine nozzles. The base component has an inner surface 80 that is substantially circular 90 in axial cross-section 100 ; and a coating 120 disposed on the inner surface 80 of base component 60 . The coating 120 has an interfacial surface 140 in contact with the inner surface 80 of the base component 60 and an outer surface 160 opposite the interfacial surface 140 . Coating 120 has a thickness 180 that varies as a function of circumferential position along the inner surface 80 of the base component 60 , and as a result the shape of the outer surface 160 of coating 120 departs from the circular shape of the base component 60 to more closely conform to eccentricities in the motion of the rotor, thereby providing the tightest possible clearances during service. Embodiments of the invention allow parts to be machined round and on-center, and it is the coating 120 that provides the desired non-uniform rotor-stator clearance during assembly and operation.
[0014] Experience with certain types of turbomachinery has revealed that in many cases the rotor tends to follow an elliptical path of travel. Accordingly, to better conform clearances to this condition, in some embodiments of the present invention the outer surface 160 of the coating 120 is substantially an ellipse 220 in axial cross-section 100 . The elliptical shape of the coating outer surface 160 is achieved by disposing a coating having a maximum thickness at the peripheral position where clearances are desired to be smallest (i.e., regions on opposite sides of the minor axis 260 of the ellipse) and a minimum thickness in areas needing the maximum clearance (i.e., regions on opposite sides of major axis 280 ). In certain embodiments, the base component 60 comprises a top portion 300 and a bottom portion 320 that are joined together by a horizontal joint 260 , and the ellipse formed by the outer surface 160 of the coating has a major axis 280 running between the top portion 300 and bottom portion 320 . Although conventional approaches as described above often machine a circular stator to the desirable elliptical shape, or assemble a complex, multi-segmented stator to achieve an elliptical shape, the application of a coating as described herein offers significant advantages in cost and simplicity.
[0015] The thickness 180 of the coating 120 is up to about 3 mm and in particular embodiments up to about 1.75 mm. In one embodiment of the invention, coating 120 comprises an abradable material 130 . Abradable coatings are widely known in the art and are used for their ability to provide seals between parts with relative motion. An abradable material is defined as one that selectively and sacrificially wears away under rotor-stator contact leaving behind a profile matching that of the eccentric motion of the rotor. Extremely tight seal clearances are obtained as a result. Exemplary abradable coatings are described in U.S. Pat. No. 6,547,522. In one embodiment, the abradable material comprises a metal matrix phase and at least one secondary phase. In one embodiment, the metal matrix phase comprises at least one alloy selected from the group consisting of cobalt-nickel-chromium-aluminum (CoNiCrAlY), nickel-chromium-iron-aluminum (NiCrFeAl), and nickel-chromium-aluminum (NiCrAl). In one embodiment, the secondary phase comprises graphite. In other embodiments, the at least one secondary phase comprises at least one of a ceramic, a polymer, and a salt. In one embodiment, the ceramic comprises at least one of hexagonal BN, aluminosilicates, and calcined bentonite clay. In other embodiments, the polymer comprises at least one of polyester, polyimide, polymethyl methacrylate, silicone, siloxane, and rubber. In still further embodiments, the salt comprises at least one of aluminum phosphate and aluminum hydroxide.
[0016] In one embodiment of the invention, the coating 120 comprises a spray coating. Many different spray techniques suitable to produce coating 120 are known in the art. In certain embodiments the spray coating comprises at least one of a plasma-sprayed coating, a flame-sprayed coating, a high velocity oxygen fuel (HVOF)-sprayed coating, a thermal-sprayed coating, and a wire-arc sprayed coating.
[0017] In order to take full advantage of the features described above, a further embodiment of the present invention is a stator component 20 for a turbine assembly 40 . The stator component 20 comprises an annular base component 60 having an inner surface 80 that is substantially circular 90 in axial cross-section 100 ; and a coating 120 comprising an abradable material. Coating 120 is disposed on the inner surface 80 of the base component 60 and has an interfacial surface 140 in contact with the inner surface 80 of the base component 60 and an outer surface 160 opposite the interfacial surface 140 . The outer surface 160 of the coating 120 is substantially an ellipse 220 in axial cross-section 100 having a major axis 280 running between top 300 and bottom 320 portions of the base component 60 .
[0018] Other embodiments of the present invention include a method for making a stator component 20 for a turbine assembly 40 . The method comprises providing an annular base component 60 having an inner surface 80 that is substantially circular 90 in axial cross-section 100 , and disposing a coating 120 in the inner surface 80 of base component 60 . The coating 120 has an interfacial surface 140 in contact with the inner surface 80 of base component 60 and an outer surface 160 opposite the interfacial surface 140 . Coating 120 has a thickness 180 that varies as a function of circumferential position along the inner surface 80 of base component 60 .
[0019] In one embodiment of the invention, coatings are deposited using a spray coating technique as described above. To achieve non-uniformity in thickness, the spray coating is, in some embodiments, applied using a robot that is programmed to vary the number of times the spray gun passes over specific arc lengths of the circumference. Each of these so-called “passes” typically deposits a coating layer ranging from about 20 μm to about 80 μm thick. For instance, the clearance is varied by roughly 200 μm by applying about 5 more coating layers over certain areas of the casing than over other areas. Also, the arc length of each coating layer is varied from layer to layer, to provide a relatively smooth transition between the areas of thick coating and the areas of thin coating
[0020] While typical embodiments have been set forth for the purpose of illustration, the foregoing description should not be deemed to be a limitation on the scope of the invention. Accordingly, various modifications, adaptations, and alternatives may occur to one skilled in the art without departing from the spirit and scope of the present invention. | The invention provides spray coatings to achieve circumferentially non-uniform seal clearances in turbomachines. In steam and gas turbines it is desirable to assemble the machines with elliptical seal clearances to compensate for expected casing distortion, rotordynamics or phenomena that cause circumferentially non-uniform rotor-stator rubs. The claimed invention allows the casing hardware to be fabricated round, and a spray coating is applied to the radially inner surface such that the coating thickness varies circumferentially, providing the desired non-uniform rotor-stator clearance during assembly. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns an intermediary channel or chamber for a fuel and combustive agent feeding device for a pulsatory combustion chamber, i.e. a chamber formed by a channel which is located between the chamber where injection occurs and the combustion chamber where the pulsatory combustion takes place.
2. Background of the Invention
P.C.T. patent application No. 81 01454 for "Starting Method and Device for Combustion Apparatus" describes a device comprising a combustion chamber topped by a feeding device between which parts is located an intermediary channel substantially at the level of a second conical part of a tube that surrounds the injection head. According to this P.C.T. patent application, the intermediary channel is provided with an inner tube, also called heat tube. The inner wall of the intermediary channel and the heat tube define an annular space which is open at its lower portion, but is closed at its upper portion.
This heat tube principally allows the fuel to be vaporized before entering the combustion chamber. For this purpose said heat tube must be maintained at a relatively elevated temperature. One possible drawback of such a device is that if soot, might become deposited therein, particularly at the level of the injection head. Generally, such deposit is due to excessively high temperatures.
The present invention is aimed at providing an intermediary channel provided with a heat tube which, while being maintained at a high temperature, yet which prevents soot from being deposited in the chamber wherein injection takes place.
SUMMARY OF THE INVENTION
To this end, the invention provides an intermediary channel located between a combustion chamber for pulsatory combustion of a mixture of a combustive agent and fuel and an injection chamber for injection of said mixture, said intermediary channel being provided with a heat tube, wherein the inner wall of said intermediate channel and said heat tube delimit a recirculation zone for recirculating the burned gases issuing from said combustion chamber, said recirculation zone being at least partially open at its upper end. Due to this novel arrangement according to the invention, the recirculation of the hot gases allows the heat tube to be maintained at a temperature high enough for the fuel to be vaporized, while yet limiting the heat transfer toward the injection chamber, since the recirculation zone is partially open at its upper end.
Preferably, the intermediary channel comprises a lower portion located in the vicinity of said combustion chamber and an upper portion located in the vicinity of said injection chamber, said heat tube being located in said lower channel portion. Preferably, these two channel portions are cylindrical, the lower portion having a larger diameter than the upper portion and said two portions being connected to each other by a flange in front of which is located the upper end of said heat tube.
The flange can be flat or rounded and preferably comprises, in its peripherical zone of smallest diameter, a circular projection or protrusion the maximum diameter of which is smaller than the inner diameter of said heat tube. Said circular projection can be vertical and can be inclined either towards the outside of the intermediary channel or chamber or towards the inside thereof.
In its lower portion, the intermediary channel can be provided with an insulating sleeve coaxial to the heat tube, which is made of a thermally insulating material.
In another embodiment the upper portion of said intermediary channel is provided with a cylindrical sleeve, the inner diameter of which is smaller than that of said heat tube, and the lower edge of which forms the protrusion of the flange.
The cylindrical sleeve of the upper portion can be maintained in place by a series of rings which are located inside of an external cylindrical jacket and which bear on an annular flat surface of said jacket.
Preferably, some of these rings are made of thermally insulating material and/or define insulating at least one annular isolating space or interval.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed decription when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a partial sectional view of a first embodiment of the invention;
FIG. 2 is a detailed view of a variant of the device of FIG. 1;
FIG. 2a shows a modification of the detail of FIG. 2;
FIG. 3 is a sectional view of a second embodiment of the invention;
FIGS. 4a and 4b show details of the structure of FIG. 3;
FIG. 5 is a partial view of a modified embodiment of the invention;
FIG. 6 shows a detail of the lower channel portion; and
FIG. 7 shows a modification of the structure of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The device 1 represented in FIG. 1 comprises a body 2 fitted on the neck 3 of a pulsatory combustion chamber 4. Body 2 includes a fuel/combustive agent mixture injection chamber 150 in which is located an injection head 115. Injection chamber 150 is delimited at its lower portion by a circular surface 5, an annular surface 6 and a wall 10, which define a cylindrical bore 39 adapted to receive a disc 7.
Said disc 7 comprises two coaxial cylindrical parts 43 and 44, a central bore 45, a second central bore 46 and a circular groove 48. Lower cylindrical part 44 has a diameter greater than that of upper cylindrical part 43 and is fitted in the bore 30 of a sleeve 55. Thus disc 7 is maintained in position between sleeve 55 and the lower end of injection chamber 150. A combustion chamber is indicated by reference number 4.
The upper part 43 of disc 7 and its central bore 45 constitute the upper portion of the intermediary channel, which upper channel portion is connected to the lower portion by groove 48 defining a connecting flange between said two channel portions.
Central bore 45 is conical, and its upper end diameter is equal to the small diameter of the injection chamber.
The walls of groove 48 and central bore 45 are connected to each other by a flat annular surface, so as to define a circular protrusion 162.
Cylindrical sleeve 55 is mounted within neck 3 and comprises an upper bore 56 and a flange 57 which is fitted in a complementary bore 58 of neck 3. The outer diameter of sleeve 55 is equal to the inner diameter of neck 3, fitting clearance or tolerances being taken into account.
Located in cylindrical sleeve 55 is a heat tube 165 shown in FIG. 2a in the form of a cylindrical jacket 70, which is maintained in position by four fixing pads 71 crimped in a bearing crown 52 interposed between bore 56 and a circular groove 72 of disc 7.
In the device shown in FIG. 1 disc 7 is made of graphite, sleeve 55 is made of an isolating ceramic material, the remaining elements being made essentially of metallic material.
Under normal service conditions--i.e. disregarding the combustion initiation phase--the device operates as follows:
Fuel is injected in a manner known per se into the injection chamber by means of an injector, with a sprinkling cone so selected that the impact of the fuel droplets takes place mostly below the upper level of jacket 70.
The lower portion thereof then constitutes the fuel/combustive agent mixing zone, although part of the mixing may already have taken place in the lower collector or injection chamber zone, or may take place, on the contrary, within combustion chamber 4.
As is well known by those skilled in the art, the explosion phase of a pulsatory combustion process includes a pressure increase in the combustion chamber, followed by the expulsion of the burnt gases toward the exhaust system. However, part of the burnt gases will be forced back toward the top of the device, in the direction of injection chamber 150. In accordance with the invention this part of the burnt gases can be used to heat the heat tube to a sufficiently elevated temperature. Indeed the outer surface 123 of jacket 70, the inner wall 125 of sleeve 55 and groove 48 define an annular gas recirculation channel.
This channel has a shape converging toward the inside portion of groove 48. During recompression the burnt gases thus are accelerated upwardly, then deviated downwardly. Acceleration of the gases in the downward direction is enhanced by the provision of circular protrusion 162 which allows to generate a tromp effect at the outlet of bore 45.
Due to this recirculation of the hot burnt gases the heat tube 165 is heated to a temperature which enables it to support the evaporation of the fuel droplets impinging on said heat tube. Indeed, in the absence of such evaporation effect these droplets would agglomerate as they move downwardly toward the combustion chamber 4 which they would then enter in shape unsuitable for complete combustion. Thus the vaporization effect obtained due to the elevated temperature of the tube will combine with that obtained by the recirculation of the gases which sweep the inner wall 20 jacket 70 so as to limit the impact of the liquid fuel droplets onto the wall.
Furthermore, as shown in FIG. 1, the upper portion of the heat tube is flared so that at the outlet of circular groove 48 the direction changing zone of the recirculated gases substantially constitutes a convergent conduit tapering toward the inner wall 120 of heat tube 165.
FIG. 2 shows a detail of a variant of the device of FIG. 1. In this embodiment central bore 45 of disc 7 is cylindrical and terminates by a protrusion 170 the outer surface 171 and inner surface 172 are conical and directed toward the inside of heat tube 165. Disc 7 has an annular recess 175 of rectangular section. The lower portion of injection chamber 150 is provided, too, with an annular recess 176 having the same width. Annular recesses 175 and 176 are facing each other so as to define any empty closed annular chamber 178. Said chamber 178 constituutes a heat isolating cushion which limits the heat transfer from heat tube 165 toward the upper portion of the device. As shown in FIG. 2, neck 3 is not provided with a sleeve, whereby the gas recirculation channel is defined directly by the inner wall of neck 3. The bearing or supporting crown 52 to which are affixed fixing pads 71 is maintained in position in groove 72 by an intermediary disc 183 which, in turn bears on an annular surface 184 of neck 3.
This figure furthermore shows that the annular surface 185 itself of jacket 70 is cylindrical, at least as far as its lower portion is concerned.
On the device shown in FIG. 2, as already set forth herein-above, ring 7 is made of graphite or ceramic material. Due to the nature of said ring and the small size of fixing pads 71, heat transfer from the sleeve upwardly is limited. Thus said sleeve is maintained at an elevated temperature.
However, another embodiment may be envisaged, which allows the upper portion of the recirculation channel to be maintained at an elevated temperature, so that the recirculated gases are not cooled. Such embodiment is illustrated by FIG. 2a. In front of sheath or jacket a 70 ring 7 made of graphite or ceramic material is provided with a ring member 173 made of heat conductive material, such as stainless steel. Sheath or jacket 70 constituting the heat tube is fixed directly to ring member 173 by fixing pads made of stainless steel, as shown at 375.
FIG. 3 shows another embodiment of the invention, which is particularly adapted to be used when air is injected in a vertical direction. Similar components used in the embodiments of FIGS. 1, 2 and 3, respectively, are designated by identical reference numerals.
The lower portion of injection chamber 150 in which an injector 115 is located is delimited by a first ring 200 having a substantially triangular profile and the lower surface 201 of which is planar and comprises an annular protrusion 202. An O-ring 203 is placed in a groove 204 and engages neck 3.
A cylindrical sleeve 205 is mounted below ring 200 and comprises an upper annular flange 206 the outer diameter of which is equal to that of ring 200, and an annular notch 207 the profile of which corresponds to that of protrusion 202. Sleeve 205 is mounted in a second sleeve 210 the inner diameter of which is slightly greater than the outer diameter of sleeve 205, and which comprises an annular flange 211. A flat ring 220 is interposed between this annular flange 211 and flange 206 of sleeve 205. The lower end 221 of second sleeve 210 is rounded toward the first sleeve 205 and engages the same. Thus sleeve 205 is surrounded by an air jacket 225. Its outer diameter is smaller than the inner diameter of the heat tube.
The lower end 222 of sleeve 205 is located at a level slightly below that of the lower end of 221 of second sleeve 210. This end 222 is narrowed so as to define a inwardly converging rim portion.
Sleeve 210 is maintained in position in neck 3 by a disc 226 which is blocked between annular flange 211 and annular surface 184 by means of rings 230 and 231 and washers 232, 233 and 234 that define annular isolating spaces or intervals 300.
Sheath or jacket 7 which is cylindrical over its entire height, comprises a flange 235 that engages washer 234.
Washer 234 is shown in detail in FIGS. 4a and 4b. Its outer diameter is substantially equal to the inner diameter of neck 3, while its inner diameter is greater than the outer diameter of tube or jacket 70, while being smaller than the maximum diameter of flange 235. Washer 234 is provided with a plurality of elongated apertures 240 extending radially from its inner periphery Said apertures define between them tongues 242 which engage flange 235 (cf. FIG. 4b).
In the present embodiment as shown in FIG. 3 the following materials are selected for manufacturing the various elements: Sleeves 205 and 210, the two rings 230 and 231 and disc 226 are made of graphite, whereas flat ring 220 and washer 232 are made of asbestos. This allows to limit efficiently the heat transfer by conduction toward the upper portion of the device, i.e. toward the injection chamber.
Referring to FIG. 3, it will be noted that the lower end of sleeve 205 is located below the inlet face of the heat tube, and that the minimum inner diameter of said sleeve is smaller than the inner diameter of said heat tube, whereby the assembly formed by these components defines, in combination with lower disc 226, the upper portion of the recirculation zone of the hot gases issuing from the combustion chamber.
FIG. 5 shows another variant of the device according to the invention, and more particularly of the device represented in FIG. 1. In this variant, jacket or sheath 70 of the heat tube 165 is extended at its lower end by a series of four pads 350 extending inwardly of combustion chamber 4. Said pads facilitate the temperature rise of jacket 70 during combustion initiation, since they allow heat transfer to take place between the central portion of chamber 4 and jacket or sheath 70.
FIG. 6 shows another embodiment of the lower portion of the intermediary channel. As shown in this figure, neck 3 is welded onto combustion chamber 4. Sheath or jacket 70 and sleeve 55 extend within the neck, up to a higher level of combustion chamber 4, in such a manner that the lower faces of the sleeve and the jacket are located in the plane 60 containing the intersection of chamber 4 and the inner space of the neck.
FIG. 7 shows another embodiment of disc 7. Central bore 45 of said disc is cylindrical. The disc is mounted in ring 200 and directly engages the inner surface of neck 3; said disc comprises an annular recess 250 constituting a sealed heat insulation chamber. In this variant, as in the one shown in FIG. 3, the flange connecting the upper portion of the intermediary channel to the lower portion thereof does not define a rounded groove, but a groove having a prism-shaped section the upper surface 260 of which is horizontal. Said groove may have any other convenient profile; more particularly it may, for example, have an inclined upper surface so as to define a downwardly diverging space.
The invention is not limited to the embodiments shown and described herein; many variants and modifications may be envisaged by those skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims. | An intermediary chamber associated to a device for feeding a pulsatory combustion chamber with fuel and comburent includes a heat tube l65 defining with the inner channel wall 125 a recirculation zone for the burnt gases issuing from the combustion chamber. The intermediary channel located between the combustion chamber for pulsatory combustion of a mixture of fuel and a combustive agent and an injection chamber includes the heat tube being directly communicated with the combustion chamber, wherein an internal wall of the intermediary channel and an outer surface of the heat tube define a recirculation zone for the recirculaton of burn gases issuing from the combustion chamber, the recirculation zone being at least partially open at an upper end thereof. | 5 |
This application is a continuation-in-part of U.S. patent application Ser. No. 10/429,668, filed on May 1, 2003, which claims priority to Canadian Application No. 2,380,662 filed on May 1, 2002 and Canadian Application No. 2,391,438 filed on Jun. 25, 2002 the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to diagnostic assays, methods, and kits for detecting a free form of PSP94, and reagents such as antibodies able to bind to a free form of PSP94.
BACKGROUND OF THE INVENTION
The prostate gland, which is found exclusively in male mammals, produces several components of semen and blood and several regulatory peptides. The prostate gland comprises stromal and epithelial cells, the latter group consisting of columnar secretory cells and basal nonsecretory cells. A proliferation of these basal cells as well as stromal cells gives rise to benign prostatic hyperplasia (BPH), which is one common prostate disease. Another common prostate disease is prostatic adenocarcinoma (CaP), which is the most common of the fatal pathophysiological prostate cancers, and involves a malignant transformation of epithelial cells in the peripheral region of the prostate gland. Prostatic adenocarcinoma and benign prostatic hyperplasia are two common prostate diseases, which have a high rate of incidence in the aging human male population.
Approximately one out of every four males above the age of 55 suffers from a prostate disease of some form or another. Prostate cancer is the second most common cause of cancer related death in elderly men, with approximately 185,000 cases diagnosed and about 39,000 deaths reported annually in the United States.
Studies of the various substances synthesized and secreted by normal, benign and cancerous prostates carried out in order to gain an understanding of the pathogenesis of the various prostate diseases reveal that certain of these substances may be used as immunohistochemical tumor markers in the diagnosis of prostate disease. The three predominant proteins or polypeptides secreted by a normal prostate gland are: (1) Prostatic Acid Phosphatase (PAP); (2) Prostate Specific Antigen (PSA); and, (3) Prostate Secretory Protein of 94 amino acids (PSP94), which is also known as Prostatic Inhibin Peptide (PIP), Human Seminal Plasma Inhibin (HSPI), or β-microseminoprotein (β-MSP), and which is hereinafter referred to as PSP94.
PSP94 is a simple non-glycosylated cysteine-rich protein, and constitutes one of three predominant proteins found in human seminal fluid along with Prostate Specific Antigen (PSA) and Prostate Acid Phosphatase (PAP). PSP94 has a molecular weight of 10.7 kDa, and the complete amino acid sequence of this protein has already been determined. The cDNA and gene for PSP94 have been cloned and characterized (Ulvsback, et al., Biochem. Biophys. Res. Comm., 164:1310, 1989; Green, et al., Biochem. Biophys. Res. Comm., 167:1184, 1990). Immunochemical and in situ hybridization techniques have shown that PSP94 is located predominantly in prostate epithelial cells. It is also present, however, in a variety of other secretory epithelial cells (Weiber, et al., Am. J. Pathol., 137:593, 1990). PSP94 has been shown to be expressed in prostate adenocarcinoma cell line, LNCap (Yang, et al., J. Urol., 160:2240, 1998). As well, an inhibitory effect of exogenous PSP94 on tumor cell growth has been observed both in vivo and in vitro (Garde, et al., Prostate, 22:225, 1993; Lokeshwar, et al., Cancer Res., 53:4855, 1993), suggesting that PSP94 could be a negative regulator for prostate carcinoma growth via interaction with cognate receptors on tumor cells.
Native PSP94 has been shown to have a therapeutic effect in the treatment of hormone refractory prostate cancer (and potentially other prostate indications). For example, PSP94 expression within prostate cancer is known to decrease as tumor grade and agressivity increases. Tumor PSP94 expression is stimulated upon anti-androgen treatment, particularly in high grade tumors. U.S. Pat. No. 5,428,011 (Sheth A. R. et al., issued 1995-06-27), incorporated herein by reference, describes pharmaceutical preparations comprising native PSP94 used in the in-vitro and in-vivo inhibition of prostate, gastrointestinal and breast tumor growth. These pharmaceutical preparations include either native PSP94 alone or a mixture of native PSP94 and an anticancer drug such as, for example, mitomycin, idalubicin, cisplatin, 5-fluorouracil, methotrexate, adriamycin and daunomycin. In addition, the therapeutic effect of recombinant human PSP94 (rhuPSP94) and polypeptide analogues such as PCK3145 has been described in Canadian Patent Application No.: 2,359,650 (incorporated herein by reference).
Immunohistochemical studies and investigations at the level of mRNA have shown that the prostate is a major source of PSP94. PSP94 is involved in the feedback control of, and acts to suppress secretion of, circulating follicle-stimulating hormone (FSH) both in-vitro and in-vivo in adult male rats. PSP94 acts both at the pituitary as well as at the prostate site since both are provided with receptor sites for PSP94. PSP94 has been demonstrated to suppress the biosynthesis and release of FSH from the rat pituitary as well as to possibly affect the synthesis/secretion of an FSH-like peptide by the prostate. These findings suggest that the effects of PSP94 on tumor growth in vivo, could be attributed to the reduction in serum FSH levels.
Recently, it has been shown that PSP94 concentrations in serum of patients with BPH or CaP are significantly higher than normal. The highest serum concentration of PSP94 observed in normal men is approximatly 40 ng/ml, while in men with either BPH or CaP, serum concentrations of PSP94 have been observed up to 400 ng/ml.
In the serum, PSP94 occurs as a free (unbound) form or bound form associated with a carrier protein(s) of unknown identity. PSP94 in its bound form (state) has been quantified in the blood of prostate cancer patients and these measurements have been analyzed for their utility as prognostic evaluation (Bauman, G. S., et al., The Prostate J. 2:94-101, 2000; Xuan, J. W. U.S. Pat. No. 6,107,103; Wu, D. et al., J. Cell. Biochem. 76:71-83, 1999). It was suggested that measurements of the free and bound forms of PSP94 are likely to have a greater clinical relevance in several areas of prostate cancer than measurements of the free form alone. In addition, it was demonstrated that measurements of both forms of PSP94 allows an accurate prediction of relapse free interval in post-radiotherapy prostate cancer. However current assay for PSP94 measurement, such as the one described in U.S. Pat. No. 6,107,103 rely on a purification step for separating bound and free forms of the protein and therefore lack the simplicity necessary for a useful and efficient commercial assay.
SUMMARY OF THE INVENTION
Methods for evaluating (quantifying) levels of PSP94 (free or bound forms of PSP94 as well as total PSP94) are described herein. The present invention relates to antibodies having specificity for PSP94 or a PSP94-binding protein and improved diagnostic and prognostic assays, hybridomas, kits and reagents thereof.
In addition, the carrier protein(s) to which PSP94 is bound is described, identified and characterized in the present application.
Due to its ability to be associated with PSP94, a PSP94-binding protein(s) and related antibodies may have an impact on the biological activity of PSP94 and may therefore be used herein as a diagnostic and prognostic marker of (PSP94-related) disease.
More particularly, the present invention relates to an (isolated) antibody able to bind to an epitope of PSP94 which may be available when PSP94 is in a free form. For example, an (isolated) antibody of the present invention may bind to a free form of PSP94 (SEQ ID NO.:1) without being able to bind to a PSP94/PSP94-binding protein complex.
In accordance with the present invention, the antibody may be, for example, an antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 or antigen binding fragments thereof. Also in accordance with the present invention, the antibody may be, for example, the antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599 or antigen binding fragments thereof.
Also more particularly, the present invention relates to a hybridoma cell line producing an antibody that may bind to an epitope of PSP94 which may be available when PSP94 is in a free form. Examples of hybridoma cell line which may be used for the present invention may include the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 or the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599. Hybridomas designated PTA-4240, PTA-4241, PTA-4242 and PTA-4243 were deposited on Apr. 23, 2002 at the American Type Culture Collection (ATCC), 10801 University Blyd, Manassas, Va., 20110-2209 according to the provisions of the Budapest Treaty. The hybridoma designated PTA-6599 was deposited on Feb. 23, 2005 at the American Type Culture Collection (ATCC), 10801 University Blvd, Manassas, Va., 20110-2209, U.S.A. according to the provisions of the Budapest Treaty.
This invention also relates to polypeptides (SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9) identified herein as PSP94-binding protein(s), purification process, nucleic acid and amino acid sequence and the use of these sequences in the diagnosis, and prognosis of diseases (e.g., prostate cancer or diseases characterized by abnormal or elevated levels of PSP94 and/or follicle stimulating hormone (FSH) and/or abnormal or elevated levels of a PSP94-binding protein).
In a first aspect, the present invention provides a (e.g., isolated) polynucleotide (e.g., encoding a PSP94-binding protein), which may comprise a member selected from the group consisting of
a) a polynucleotide as set forth in SEQ ID NO.: 1, b) a polynucleotide as set forth in SEQ ID NO.: 6, c) a polynucleotide having sequence 1 to 1392 of SEQ ID NO.:6, d) a polynucleotide having sequence 1 to 1653 of SEQ ID NO.:6, e) a polynucleotide of a size between 10 and 2005 (or 2004) bases in length identical in sequence to a contiguous portion of at least 10 bases of the polynucleotide as set forth in SEQ ID NO.: 1, and f) a polynucleotide of a size between 10 and 1876 (or 1875) bases in length identical in sequence to a contiguous portion of at least 10 bases of the polynucleotide as set forth in SEQ ID NO.: 6.
The polynucleotide may preferably be the polynucleotide as set forth in SEQ ID NO.:1 or the polynucleotide as set forth in SEQ ID NO.:6 or the polynucleotide having sequence 1 to 1392 of SEQ ID NO.:6 or a polynucleotide having sequence 1 to 1653 of SEQ ID NO.:6. The polynucleotide of the present invention may particularly be chosen based on the ability of the encoded protein to bind PSP94. It is to be understood herein that SEQ ID NO.:1 may be considered an analogue of SEQ ID NO.: 6.
In a second aspect, the present invention provides polypeptides and polypeptides analogues such as for example,
a polypeptide as set forth in SEQ ID NO.: 2, a polypeptide as set forth in SEQ ID NO.: 3, a polypeptide as set forth in SEQ ID NO.: 7, a polypeptide as set forth in SEQ ID NO.: 8, a polypeptide as set forth in SEQ ID NO.: 9, a polypeptide of a size between 10 and 505 amino acids in length identical to a contiguous portion of the same size of SEQ ID NO.:2, a polypeptide of a size between 10 and 592 amino acids in length identical to a contiguous portion of the same size of SEQ ID NO.:3, a polypeptide of a size between 10 and 624 amino acids in length identical to a contiguous portion of the same size of SEQ ID NO.:7, a polypeptide analogue having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 2, in SEQ ID NO.:3, in SEQ ID NO.:7, in SEQ ID NO: 8 or in SEQ ID NO.:9, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 2, in SEQ ID NO.:3, in SEQ ID NO.:7, in SEQ ID NO: 8 or in SEQ ID NO.:9, a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 2 in SEQ ID NO.:3, in SEQ ID NO.:7, in SEQ ID NO: 8 or in SEQ ID NO.:9, a polypeptide analogue having at least 90% of its amino acid sequence identical to the amino acid sequence of
a polypeptide of a length from between 10 and 505 contiguous amino acids of SEQ ID NO.:2, a polypeptide of a length from between 10 and 592 contiguous amino acids of SEQ ID NO.:3 or, a polypeptide of a length from between 10 and 624 contiguous amino acids of SEQ ID NO.:7,
a polypeptide analogue having at least 70% of its amino acid sequence identical to the amino acid sequence of
a polypeptide of a length from between 10 and 505 contiguous amino acids of SEQ ID NO.:2, a polypeptide of a length from between 10 and 592 contiguous amino acids of SEQ ID NO.:3 or, a polypeptide of a length from between 10 and 624 contiguous amino acids of SEQ ID NO.:7,
a polypeptide analogue having at least 50% of its amino acid sequence identical to the amino acid sequence of
a polypeptide of a length from between 10 and 505 contiguous amino acids of SEQ ID NO.:2, a polypeptide of a length from between 10 and 592 contiguous amino acids of SEQ ID NO.:3 or, a polypeptide of a length from between 10 and 624 contiguous amino acids of SEQ ID NO.:7.
In accordance with the present invention, the polypeptide may preferably be the polypeptide as set forth SEQ ID NO.: 2, the polypeptide as set forth SEQ ID NO.: 3, the polypeptide as set forth SEQ ID NO.:7, the polypeptide as set forth SEQ ID NO.:8 or the polypeptide as set forth SEQ ID NO.:9. The polypeptide of the present invention may particularly be chosen based on its ability to bind PSP94. It is to be understood herein that SEQ ID NO.: 2 and SEQ ID NO.: 3 may be considered analogues of SEQ ID NO.: 7. SEQ ID NO.: 8 and SEQ ID NO.:9 may also be considered analogues of SEQ ID NO.:7.
In an additional aspect, the present invention provides an immunizing composition including, for example, a vector comprising a polynucleotide as defined herein. It is sometimes preferable to have a polynucleotide of at least 21 bases in length of a desired sequence since a polypeptide of 7 amino acids (encoded by a 21 base pair polynucleotide sequence) is often associated with the major histocompatibility complex (MHC) during antigen presentation. The vector may comprise, for example, a polynucleotide selected from the group consisting of a polynucleotide as set forth in SEQ ID NO.: 1, a polynucleotide as set forth in SEQ ID NO.: 6, a polynucleotide having sequence 1 to 1392 of SEQ ID NO.:6, a polynucleotide having sequence 1 to 1653 of SEQ ID NO.:6, a polynucleotide of a size between 21 and 2005 bases in length identical in sequence to a contiguous portion of the same size of the polynucleotide set forth in SEQ ID NO.: 1 or a polynucleotide of a size between 21 and 1876, bases in length, identical in sequence to a contiguous portion of the same size of the polynucleotide set forth in SEQ ID NO.: 6, and a diluent or buffer. It is to be understood herein that the vector may enable the expression of a polypeptide encoded from the polynucleotide. The vector may be linear or circular and may contain minimal sequences in addition to the polynucleotide itself (e.g., sequence for integration into the genome, promoter, CpG sequences). Administration of a polynucleotide of the present invention (without any additional sequence, i.e, without a vector) may sometimes be sufficient to initiate a desired immune response.
In a further aspect, the present invention relates to an immunizing composition comprising a polypeptide as defined herein (e.g., SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9), a polypeptide analogue, variant, fragment or combination thereof and a diluent or a buffer. Immunization with a combination of any of the immunizing composition described herein is also encompassed by the present invention.
The immunizing composition(s) may further comprise an adjuvant. In an additional embodiment, the immunizing composition may also comprise PSP94 (native and/or recombinant), PSP94 variant, PSP94 fragment, a vector comprising a polynucleotide encoding PSP94, a polynucleotide encoding a PSP94 variant, a polynucleotide encoding a PSP94 fragment and combination thereof. Again, the vector may enable the expression of a polypeptide encoded from the polynucleotide. For reference on native PSP94, recombinant PSP94 (e.g., rHuPSP94), PSP94 variants, analogues and fragments, please see Canadian patent application No.: 2,359,650 or international patent application, published under No. WO 02/33090.
In a further aspect, the present invention relates to a method of (for) generating an antibody (monoclonal or polyclonal) to a polypeptide (e.g., PSP94, PSP94-binding protein and/or PSP94/PSP94-binding protein complex), the method comprising administering to a mammal an immunizing composition (comprising a polypeptide, polypeptide analogue, a polynucleotide and combination thereof etc.) as defined herein.
In accordance with the present invention, mammals that may be immunized using the present method include, for example, a human, a mouse, a rabbit, a sheep, a horse, a cow, a rat, a pig, and other mammals having a functional immune system. A “mammal having a functional immune system” is to be understood herein as a mammal able to produce antibodies (immunoglobulins) when immunized with an antigen (i.e., having a humoral immune response and/or a cellular immune response to the antigen).
Further aspects of the present invention relate to a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and antigen binding fragments thereof, to a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243 and antigen binding fragments thereof, to an hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and to a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243.
In an additional aspect, the present invention relates to a cell that has incorporated (has been transformed, transduced, transfected, etc.) with any of the polynucleotide of the present invention e.g., SEQ ID NO.: 1, SEQ ID NO.:6, antisenses, fragments, variants, mRNA, etc.
In yet an additional aspect, the present invention relates to a (isolated) cell that has incorporated and/or that is expressing at least one of the polypeptides of the present invention, e.g., SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9, variants, fragments, analogues or combination thereof.
In another aspect, the present invention comprises the use of a polynucleotide as defined herein (SEQ ID NO.:1, SEQ ID NO.:6, fragments, antisense, analogues, mRNA), in the diagnosis or prognosis, (or treatment) of a condition linked with abnormal (e.g., high, elevated) levels of PSP94, or with abnormal (e.g., high, elevated) levels of a PSP94-binding protein.
In yet another aspect, the present invention provides the use of the polypeptide as defined herein (e.g., SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9, analogue, variant, fragments) in the diagnosis or prognosis, (or treatment) of a condition linked with abnormal (e.g., high, elevated) levels of PSP94 or with abnormal (e.g., high, elevated) levels of a PSP94-binding protein.
In accordance with the present invention the polynucleotide defined herein or the polypeptide defined herein may be used in the diagnosis, or prognosis of a condition such as, for example, prostate cancer, stomach cancer, breast cancer, endometrial cancer, ovarian cancer, other cancers of epithelial secretion and benign prostate hyperplasia (BPH) or a disease characterized with an elevated level of FSH.
In an additional aspect, the present invention relates to a method for measuring, in a sample, the amount of a polypeptide as defined herein, for example, a polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.: 3, SEQ ID NO.:7, SEQ ID NO.:8 and SEQ ID NO.:9 (as well variants, analogues and fragments thereof) or combination thereof. In accordance with the present invention, the method may comprise contacting the sample with a molecule (an antibody or a polypeptide) able to recognize the polypeptide. The method contemplated herein may be applied to polypeptides that are immobilized to a blot membrane, a plate, a matrix or not (in solution).
It is to be understood herein that in order to develop a quantitative assay to assess the level of a polypeptide, a preferred molecule may have sufficient affinity and specificity for the desired polypeptide. Affinity and specificity may be determined, for example, by comparing binding of the molecule to irrelevant polypeptides, by competition assays for the polypeptide of interest, etc.
In one embodiment of the present invention, the molecule used for the above described method may include, for example, the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243. In another embodiment of the present invention, the molecule may be, for example PSP94 and analogues thereof.
The method for measuring the amount of a polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.: 3, SEQ ID NO.:7, SEQ ID NO.:8 and SEQ ID NO.:9 contemplated herein may further comprise, for example, the following steps:
a) bringing a sample comprising at least one of the polypeptide of the present invention into contact with an antibody immobilized to a suitable substrate (e.g., ELISA plate, matrix, SDS-PAGE, Western blot membranes), b) adding to step a) a detection reagent comprising a label or marker, and; c) detecting a signal resulting from a label or marker.
Suitable detection reagents may comprise, for example, an antibody or a polypeptide having an affinity for a polypeptide(s) of the present invention, and the detection reagent may have preferably, a different binding site than the antibody. As described herein, the detection reagent may either be directly coupled (conjugated) to a label (or marker) or able to be recognized by a second molecule carrying (conjugated with) the label or marker.
An example of an antibody that may be used in step a) is the monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243. In that case, the monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4242 may be used as a detection reagent in step c).
Any antibodies able to bind to a PSP94-binding protein (SEQ ID NO.:2, SEQ ID NO.:3, etc.), such as those antibodies listed in table 10 (identified as clones), may be used in the methods described herein (e.g., (clone) 2B10, 1B11, 9B6, P8C2, B3D1, 26B10, 1A6). When two antibodies are needed to perform the present methods it may be preferable to choose antibodies binding to different epitopes.
Another example of an antibody that may be used in step a) is the monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4242. In that case the monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4243 may be used as a detection reagent in step c).
In a further aspect, the present invention relates to a method for measuring, in a sample the amount of a polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8 and SEQ ID NO.:9 (variants, analogues, fragments) or combination thereof, that is not bound (i.e., free (unbound)) to PSP94, the method comprising;
a) removing, from the sample, a complex formed by PSP94 and any one of the polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8 and SEQ ID NO.:9 (variants, analogues, fragments) generating a complex-free sample, and; b) contacting the complex-free sample with an antibody able to recognize any one of the polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8 and SEQ ID NO.:9 (variants, analogues, fragments) and combination thereof.
In one embodiment of the present invention, the antibody used in step b) may be selected from the group consisting of the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243.
The method for measuring the amount of the polypeptide of the present invention that is not bound to PSP94 contemplated above may, for example, comprise the following step;
a) removing, from the sample, a complex formed by PSP94 and any one of the polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8 and SEQ ID NO.:9, generating a complex-free, b) immobilizing (coating, adsorbing) an antibody to a suitable substrate (ELISA plate, matrix, SDS-PAGE, Western blot membranes), c) adding the complex-free sample, d) adding a detection reagent comprising a label or marker, and; e) detecting a signal resulting from a label or marker.
The removal of the complex may be performed, for example, by using the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241.
Suitable antibodies that may be used in step b) are antibodies selected from the group consisting of the monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and the monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243.
In an additional aspect, the present invention includes the use of an (monoclonal) antibody selected from the group consisting of a monoclonal antibody (2D3) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240, a monoclonal antibody (P1E8) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241, a monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and a monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243, for evaluating (in a sample) the amount (quantity, concentrations) (free, bound, and/or total amounts) of SEQ ID NO.:2, SEQ ID NO.: 3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9, variants, fragments, analogues, and/or combination thereof.
In another aspect, the present invention includes the use of a molecule selected from the group consisting of a polypeptide as set forth in SEQ ID NO.:2, a polypeptide as set forth in SEQ ID NO.: 3, a polypeptide as set forth in SEQ ID NO.: 7, a polypeptide as set forth in SEQ ID NO.: 8, a polypeptide as set forth in SEQ ID NO.: 9, a monoclonal antibody (2D3) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240, a monoclonal antibody (P1E8) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241, a monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242, a monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243, and a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599, for evaluating (in a sample) the amount of PSP94 or for the diagnostic of a condition linked with abnormal or elevated levels of PSP94 or of a PSP94-binding protein.
In another aspect, the present invention relates to an antibody conjugate comprising a first moiety and a second moiety, the first moiety being selected from the group consisting of a monoclonal antibody (2D3) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240, a monoclonal antibody (P1E8) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241, a monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and a monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243 and the second moiety being selected from the group consisting of a pharmaceutical agent, a solid support, a reporter molecule, a group carrying a reporter molecule, a chelating agent, an acylating agent, a cross-linking agent, and a targeting group, wherein the second moiety or conjugation of the second moiety does not interfere with the biological activity (e.g., affinity, stability) of the first moiety.
In an additional aspect, the present invention relates to an antibody conjugate which may comprise a first moiety and a second moiety, the first moiety may be an antibody able to bind to an epitope of PSP94 which may be available when PSP94 is in a free form and the second moiety may be selected, for example, from the group consisting of a pharmaceutical agent, a solid support, a reporter molecule, a group carrying a reporter molecule, a chelating agent, an acylating agent, a cross-linking agent, and a targeting group.
In accordance with the present invention, the solid support may be selected, for example, from the group consisting of carbohydrates, liposomes, lipids, colloidal gold, microparticles, microcapsules, microemulsions, and a solid matrix.
Also in accordance with the present invention, the reporter molecule may be selected, for example, from the group consisting of a fluorophore, a chromophore, a dye, an enzyme, a radioactive molecule and a molecule of a binding/ligand complex.
Further in accordance with the present invention, the pharmaceutical agent may be selected, for example, from the group consisting of a toxin, a drug and a pro-drug.
More particulalry, in accordance with the present invention, the first moiety may be, for example, an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 or may be an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599.
In one embodiment of the present invention, examples of solid support may comprise, for example, carbohydrates, liposomes, lipids, colloidal gold, microparticles, microcapsules, microemulsions, and the matrix of an affinity column.
In an additional embodiment, reporter molecule may be selected from the group consisting of a fluorophore (e.g., rhodamine, fluoroscein, and green fluorescent protein), a chromophore, a dye, an enzyme (e.g., alkaline phosphatase, horseradish peroxidase, beta-galactosidase, chloramphenicol acetyl transferase), a radioactive molecule and a molecule of a binding/ligand (e.g., biotin/avidin (streptavidin)) complex.
In yet an additional embodiment, the pharmaceutical agent may be selected from the group of a toxin (e.g., bacterial toxins), a (e.g., anti-cancer) drug and a pro-drug.
In a further aspect, the present invention includes a kit for use in evaluating (in a sample) the amount of PSP94 or for the diagnosis of a condition linked with abnormal (e.g., high, elevated) levels of PSP94 (or of a PSP94-binding protein) comprising a container having a molecule able to recognize (bind) PSP94. It is to be understood herein that the kit may be provided (sold) in separate constituents.
In one embodiment of the present invention, the molecule able to recognize PSP94 that may be included in the kit, may (comprise, for example) be a molecule selected from the group consisting of (one or more of the following) a monoclonal antibody (2D3) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240, a monoclonal antibody (P1E8) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241, a monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242, a monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243, the antibody conjugate(s) of the present inventions and a polypeptide selected from the group consisting of SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8 and SEQ ID NO.:9.
In another embodiment of the present invention, the kit may further comprise a container having an antibody able to recognize (bind) a polypeptide selected from the group consisting of the polypeptide set forth in SEQ ID NO.:2, the polypeptide set forth in SEQ ID NO.:3 and the polypeptide set forth in SEQ ID NO.:7, the polypeptide set forth in SEQ ID NO.:8, the polypeptide set forth in SEQ ID NO.:8, variant, fragment, analogues and combination thereof. Contemplated by the present invention are the monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243 and a monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242.
It is to be understood herein that kits may be provided in separate constituents. The antibodies provided with the kit may be in different forms such as bound to plates or membranes or other type of solid matrix or in vials containing concentrated forms or suitable working dilutions of the antibodies.
More particularly, the present invention relates to a kit comprising an antibody (a first antibody) which is able to bind to an epitope of PSP94 which may be available when PSP94 is in a free form.
In accordance with the present invention, the kit may be use in evaluating the amount of PSP94 or for the diagnosis of a condition linked with abnormal or elevated levels of PSP94. The kit may comprise a container having a molecule able to recognize PSP94.
In accordance with the present invention, the antibody used in the kit may be conjugated, for example, with a reporter molecule. The reporter molecule may be, for example, an enzyme such as a peroxidase (e.g., horseradish peroxidase).
Also in accordance with the present invention, the kit may further comprise a control sample containing a known (predetermined) amount of PSP94 (for example in a substantially purified form). Suitable (first) antibody which may be used in the kit of the present invention includes, for example, the antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599.
Further in accordance with the present invention, the kit may also comprise a second antibody which may bind to a different epitope of PSP94 or may alternatively comprise a polyclonal antibody which binds to PSP94. The second antibody may be, for example, the antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240.
Alternatively, another suitable (first) antibody which may be used in the present invention includes an antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240. In accordance with the present invention, the kit may further comprise a second antibody which may bind to a different epitope of PSP94 or alternatively, the kit may further comprise a polyclonal antibody which may bind to PSP94.
It is to be understood herein that one of the antibody of the kits may be bound to a solid matrix (e.g., a plate, a membrane, etc.). Any unspecific binding sites of the solid matrix may also be blocked (using bovine serum albumin, milk protein, etc.) if desired.
The present invention, more particularly relates to a kit which may comprise a first and second antibody which binds to PSP94. In accordance with the present invention, at least one of the first or second antibody may bind to a free form of PSP94 (only). Also in accordance with the present invention, the first and second antibody may bind to a different epitope of PSP94.
In accordance with the present invention, the kit may comprise a control sample which may contain a known (predetermined) amount of PSP94 (for example, in a substantially purified form).
In accordance with the present invention, the first antibody may be selected, for example, from the group consisting of a polyclonal antibody, an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240, an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241 and an antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599. The second antibody may be selected, for example, from the group consisting of a polyclonal antibody, an antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240, an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241 and an antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599.
In accordance with the present invention, the first antibody may be a polyclonal antibody and the second antibody may be selected, for example, from the group consisting of an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599 and an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240.
In accordance with the present invention, the first antibody may be produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241 and the second antibody may be selected, for example, from the group consisting of an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599 and an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240.
In accordance with the present invention, the second antibody may be conjugated with a reporter molecule. Also in accordance with the present invention, the reporter molecule may be, for example, an enzyme such as a peroxidase (e.g., horseradish peroxidase).
In another aspect, the present invention provides a method for preparing a polypeptide as defined herein (a PSP94-binding protein, e.g., a polypeptide selected from the group consisting of the polypeptide set forth in SEQ ID NO.:2, the polypeptide set forth in SEQ ID NO.:3, the polypeptide set forth in SEQ ID NO.:7, the polypeptide set forth in SEQ ID NO.:8 and the polypeptide set forth in SEQ ID NO.:9) comprising:
a) cultivating a host cell under conditions which provide for the expression of the polypeptide by the cell; and b) recovering the polypeptide by one or more purification step.
In yet another aspect, the present invention provides a method for preparing the polypeptide as defined herein (a PSP94-binding protein, e.g., a polypeptide selected from the group consisting of the polypeptide set forth in SEQ ID NO.:2, the polypeptide set forth in SEQ ID NO.:3, the polypeptide set forth in SEQ ID NO.:7 the polypeptide set forth in SEQ ID NO.:8, the polypeptide set forth in SEQ ID NO.:9 and combination thereof) comprising:
a) collecting one or more biological sample containing the polypeptide; and b) recovering the polypeptide by one or more purification step.
It is to be understood herein that the purification step either alone or in combination may be selected from the group consisting of ammonium sulfate precipitation, size exclusion chromatography, affinity chromatography, ion-exchange chromatography or the like.
In another embodiment of the present invention, the purification step may comprise;
a) adding ammonium sulfate to the biological sample, b) performing ion-exchange chromatography, c) performing affinity-chromatography using a PSP94-conjugated affinity matrix, d) performing size-exclusion chromatography, and e) recovering a fraction containing a substantially pure PSP94-binding protein.
In a further aspect, the present invention also includes a process for the purification of a PSP94-binding protein from a sample comprising:
a) adding ammonium sulfate to the sample (e.g., human male serum) in a manner as to provide precipitation of a PSP94-binding protein, b) centrifuging the mixture of step a) to recover precipitated proteins, c) resuspending the precipitated proteins, d) performing ion-exchange chromatography to recover a fraction of proteins containing a PSP94-binding protein, e) performing affinity-chromatography using a PSP94-conjugated affinity matrix to recover a fraction of proteins containing a PSP94-binding protein, f) performing size exclusion chromatography to recover a fraction of proteins containing a PSP94-binding protein and; g) recovering a fraction containing a substantially pure PSP94-binding protein (e.g., a polypeptide selected from the group consisting of the polypeptide defined in SEQ ID NO.:2, the polypeptide defined in SEQ ID NO.:3, the polypeptide defined in SEQ ID NO.:7, the polypeptide set forth in SEQ ID NO.:8, the polypeptide set forth in SEQ ID NO.:9 and combination thereof.
In one embodiment of the present invention, the precipitation of a PSP94-binding protein in step a) may be effected by adding ammonium sulfate to a final concentration of up to 47%.
In a second embodiment of the present invention, the ion-exchange chromatography of step d) may be performed by using an anion-exchange chromatography matrix.
The present invention in a further aspect thereof comprises a purification process for a PSP94-binding protein (e.g., a polypeptide selected from the group consisting of the polypeptide defined in SEQ ID NO.:2, the polypeptide defined in SEQ ID NO.:3, the polypeptide defined in SEQ ID NO.:7, the polypeptide defined in SEQ ID NO.:8, the polypeptide defined in SEQ ID NO.:9 and combination thereof) (summarized in FIG. 8 ). The purification of a PSP94-binding protein from serum may comprise, for example, the following steps:
a) adding ammonium sulfate to a human (male) serum sample to provide a solution with a final concentration of ammonium sulfate of 32%, b) centrifuging the solution of the previous step to recover a pellet fraction of proteins containing unspecific human serum proteins and a supernatant fraction of proteins containing a PSP94-binding protein, c) recovering the supernatant fraction of proteins containing a PSP94-binding protein and adjusting the concentration of ammonium sulfate to a final concentration of 47% to provide a solution of precipitated proteins containing a PSP94-binding protein, d) centrifuging the mixture to recover precipitated proteins containing a PSP94-binding protein, e) resuspending the precipitated proteins containing a PSP94-binding protein in an aqueous media (e.g., water, phosphate buffered saline, 10 mM MES, 10 mM MOPS, 10 mM Bicine: these solution (when applicable) may be at a pH comprised, for example, between 4.7 and 9.0, preferably between 5.7 and 8.0 and more preferably between 5.7 and 6.7) However a preferred aqueous media is 10 mM MES buffer at a pH of 6.5, f) loading (contacting, charging) the aqueous solution of proteins containing a PSP94-binding protein in an ion-exchange (anion-exchange) chromatography column containing an ion-exchange (anion-exchange) chromatography matrix (resin, gel), g) adding a salt solution selected from the group consisting of sodium chloride, magnesium chloride, potassium chloride to recover (elute, detach) proteins containing a PSP94-binding protein from the ion-exchange chromatography column, preferably sodium chloride with a molarity ranging from, for example, 100 mM to 1000 mM, h) recovering a fraction (peak) of proteins containing a PSP94-binding protein, i) contacting (charging, passing through) a PSP94-conjugated affinity matrix with the fraction recovered in order to generate a PSP94-conjugated affinity matrix bound to a PSP94-binding protein, j) adding an eluting reagent (free PSP94, urea, sodium acetate or CAPS; preferably free PSP94) to the PSP94-conjugated affinity matrix bound to a PSP94-binding protein to recover (elute, detach) a PSP94-binding protein, k) recovering a fraction containing a PSP94-binding protein, l) loading the PSP94-binding protein in a size exclusion chromatography column containing a size exclusion chromatography matrix to separate PSP94-binding protein from contaminants, and; m) recovering a fraction containing a (substantially) pure PSP94-binding protein.
It is to be understood that some of the purification steps described herein may prove to be unnecessary depending on the level of purification required or depending on the optimization of one or more of the remaining steps.
In a further aspect, the present invention relates to the product obtained from the purification process defined above.
In accordance with the present invention, samples (e.g., biological sample) referred herein may comprise, for example, blood, plasma, serum, urine, seminal fluid, cell culture media, cell lyzate, etc. The sample is preferably a human (e.g., male) sample.
In another aspect, the present invention relates to an antibody, and antigen binding fragments thereof, able to recognize a PSP94 epitope (i.e., exposed epitope) that is available even when PSP94 is bound to another polypeptide (another molecule). Such polypeptide may be for example, a polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.: 3, SEQ ID NO.: 7, SEQ ID NO.:8, SEQ ID NO.:9, variant, fragment, analogue and combination thereof. The hybridoma cell line producing such antibody is also contemplated by the present invention. An example of such antibody is the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit NO.: PTA-4241 (P1E8) or a polyclonal antibody able to recognize free and bound forms of PSP94.
The identification of an exposed epitope may be performed by testing a panel of antibody for their specificity to free and bound forms of PSP94. Antibodies which react (recognize) with both forms may represent candidate antibodies. In parallel, partial trypsin digestion may be performed on the PSP94/PSP94-binding protein complex. PSP94 epitopes (e.g., linear epitopes) available in the complexed forms may then be identified by amino acid sequence analysis. Antibodies able to bind to this or these (available) epitope(s) may be generated. Exposed epitopes are to be understood herein, as epitopes of a molecule (e.g., PSP94, SEQ ID NO.:2, SEQ ID NO.:3. SEQ ID NO.: 7, SEQ ID NO.:8, SEQ ID NO.:9 and their complex) that are accessible to an antibody, preferably when the molecule(s) or complex is in its native (natural) state (e.g., non-denatured, natural or 3D form).
In a further aspect, the present invention provides a method for removing PSP94 from a sample, the method comprising
a) contacting the sample with a molecule able to bind to PSP94 (the molecule may be directly or indirectly bound to a matrix or solid support) and; b) recuperating a sample free of PSP94.
It may prove useful to remove PSP94 from a sample (biological sample) for example, removing excess PSP94 from serum of individuals (i.e., serum depletion of PSP94) having elevated levels of PSP94 and to reinfuse a depleted serum into the individual (e.g., patient in need). In other instance, it may be useful to remove PSP94 from a sample in order to optimize measurement of other serum constituents. Removal of PSP94 is based on the affinity between PSP94 and any one of the sequence set forth in SEQ ID NO.: 2, SEQ ID NO.: 3, SEQ ID NO.: 7, SEQ ID NO.: 8, SEQ ID NO.: 9, PSP94 antibodies, and combination thereof.
The molecule referred above may be selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.: 7, SEQ ID NO.:8, SEQ ID NO.: 9, a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 and a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241.
In yet a further aspect, the present invention provides a method for removing a complex formed by PSP94 and any one of the polypeptide defined in SEQ ID NO: 2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9 and combination thereof (e.g., PSP94/SEQ ID NO:2 and/or PSP94/SEQ ID NO.:3 and/or PSP94/SEQ ID NO:7, etc.) from a sample, the method comprising;
a) contacting the sample with an antibody able to recognize an available (exposed) epitope of the complex (e.g., the antibody may be directly or indirectly bound to a matrix or solid support) and; b) recuperating a sample free of the complex.
In one embodiment of the present invention, the antibody used in step b) may comprise, for example, a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241, a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243. Preferably used is the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243.
Other aspects of the present invention encompass the antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit (e.g., Accession) No.: PTA-4240, the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit (e.g., Accession) No.: PTA-4241 as well as antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599 and antigen binding fragments thereof.
Also covered by the present invention are the hybridoma cell lines producing the antibodies described herein. These include the hybridoma cell line deposited to the ATCC under Patent Deposit (e.g., Accession) No.: PTA-4240, the hybridoma cell line deposited to the ATCC under Patent Deposit (e.g., Accession) No.: PTA-4241 and the hybridoma cell line deposited to the ATCC under Patent Deposit No. PTA-6599.
In another aspect, the present invention provides a method for measuring, in a sample, the total amount of PSP94, the method may comprise contacting the sample with an antibody able to recognize PSP94 even when PSP94 is bound to another polypeptide (such as for example, SEQ ID NO.:2, SEQ ID NO.:3. SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9 variants, fragments and analogues). This aspect of the invention encompasses any method which comprises this step, irrelevant of the fact that one or more steps are to be performed or not.
In one embodiment, the antibody that may be used in measuring the total amount of PSP94 in a sample, may be, for example, the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241 or it may be a polyclonal antibody able to recognize free and bound forms of PSP94.
The method for measuring total (free (unbound) and bound) amount of PSP94 in a sample contemplated above may comprise the following steps;
a) immobilizing (coating, adsorbing) a PSP94-antibody to a suitable substrate (ELISA plate, matrix, SDS-PAGE, Western blot membranes). The antibody may be able to recognize PSP94 even when bound to a PSP94-binding protein (such as SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9); b) adding a sample comprising PSP94, c) adding a PSP94 detection reagent comprising a label or marker, and; d) detecting a signal resulting from a label or marker.
Examples of suitable detection reagents that may be used in step c) of the present method, include an antibody and a polypeptide having an affinity for PSP94. However, the detection reagent may preferably have a different binding site than the PSP94-antibody and a PSP94-binding protein. The detection reagent may either be directly coupled to a label (or marker) (e.g., antibody conjugate of the present invention) or able to be recognized by a second molecule carrying (conjugated with) the label or marker.
An example of a PSP94-antibody that may be used in step a) is the antibody (P1E8) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4241. In that case, the detection reagent may be, for example, the antibody (2D3) (e.g., antibody-conjugate) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4240 or any other suitable PSP94 antibody.
It is to be understood herein that a polyclonal antibody (one or more polyclonal antibodies) able to recognize free and bound forms of PSP94 may be suitable for any of steps a) or c) in combination with any of the monoclonal antibody described herein. For example, total PSP94 may be captured with a polyclonal antibody (an antibody able to recognize free and bound forms of PSP94) and detection may be performed (directly or indirectly) with another antibody such as P1E8 (and vice versa).
In addition, total PSP94 may be captured with an antibody able to recognize PSP94 in its free and bound forms (e.g., bound to a PSP94-binding protein as described herein), such as, for example, a polyclonal antibody or the P1E8 antibody (produced by the hybridoma cell line PTA-4241), and detection of the captured proteins (complex) may be performed with a combination of two or more antibodies i.e., one able to detect the free PSP94 (e.g., 2D3 produced by hybridoma cell line PTA-4240) and one or more antibodies able to detect PSP94-binding protein (e.g., 17G9 produced by the hybridoma cell line PTA-4243; and/or 3F4 produced by the hybridoma cell line PTA-4242).
In yet another aspect, the present invention provides an improved method for measuring the amount of free PSP94 in a sample, the method comprising contacting the sample with an antibody able to recognize PSP94 (e.g., in its free form).
More particularly, the present invention relates to a method for measuring the amount of free PSP94 in a sample, the method may comprise contacting the sample with an antibody able to recognize PSP94 (a free form of PSP94).
Also more particularly, the present invention relates to a method for detecting or measuring a free form of PSP94 in a sample, the method may comprise for example,
contacting the sample with an antibody of the present invention (e.g., an antibody able to bind to an epitope of PSP94 which is available when PSP94 is in a free form) and; detecting a signal from a label that is provided by the antibody or by a second molecule carrying the label.
In accordance with the present invention, suitable antibody used with the method of the present invention includes the antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 antigen binding fragments thereof ot the antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.:PTA-6599 and antigen binding fragments thereof.
In accordance with the present invention, the signal obtained for the sample may be compared with a signal obtained for a control sample containing a predetermined amount of PSP94.
The present invention also relates to a method for detecting or measuring a free form of PSP94 in a sample, the method may comprise:
contacting the sample with a first antibody able to bind to PSP94; contacting the sample with a second antibody which may bind to an epitope of PSP94 which is available when PSP94 is in a free form; and detecting a signal from a label coupled to the second antibody or from a label provided by a third antibody carrying the label.
In accordance with the present invention, the first and second antibody may bind to a different PSP94 epitope.
In accordance with the present invention, the first antibody may be selected, for example, from the group consisting of a polyclonal antibody, an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 and an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599.
In accordance with the present invention, the first antibody may be a polyclonal antibody and the second antibody may be an antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240.
Also in accordance with the present invention, the first antibody may be a polyclonal antibody and the second antibody may be an antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599.
Further in accordance with the present invention, the sample may be selected, for example, from the group consisting of blood, plasma, serum, urine, seminal fluid, cell culture media and cell lyzate.
In an additional aspect, the present invention relates to a method for detecting or measuring a free form of PSP94 in a sample, the method may comprise:
contacting the sample with a first antibody which may be able to bind to an epitope of PSP94 which is available when PSP94 is in a free form; contacting the sample with a second antibody which may be able to bind to PSP94; and detecting a signal from a label coupled to the second antibody or from a label provided by a third antibody carrying the label,
Further in accordance with the present invention, the first and second antibody may bind to a different PSP94 epitope.
In accordance with the present invention, the first antibody may be an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 and the second antibody may be selected from the group consisting of a polyclonal antibody, an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241 and an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599.
Also in accordance with the present invention, the first antibody may be an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-6599 and the second antibody may be selected from the group consisting of a polyclonal antibody, an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241 and an antibody produced by a hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240.
In a further aspect, the present invention relates to a method for detecting or measuring a free form of PSP94 in a sample, the method may comprise contacting the sample with an antibody conjugate able to bind to an epitope of PSP94 which may be available when PSP94 is in a free form. The antibody conjugate may comprise a first moiety and a second moiety. The first moiety may be an antibody able to bind to an epitope of PSP94 which may be available when PSP94 is in a free form and the second moiety may be selected from the group consisting of a reporter molecule and a group carrying a reporter molecule.
In yet a further aspect, the present invention relates to a method for measuring free PSP94 in a sample, the method may comprise contacting the sample with a first antibody and second antibody. Each of the first antibody and second antibody may be able to bind to a different epitope of PSP94. In accordance with the present invention at least one of the first antibody and second antibody may bind to PSP94 in its free form only.
In an embodiment of the present invention, suitable antibodies may include for example, the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 and the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241. However, other suitable antibodies are encompassed by the present invention, such as the 12C3 antibody (Table 10).
Any of the antibodies binding to PSP94 described herein may be used to detect PSP94 in other types of assays such as immunohistochemistry, Western blot, etc. For example a tissue section (e.g., from a prostate) which comprises PSP94 expressing cells may be contacted with one of the anti-PSP94 antibody of the present invention and the presence of PSP94 is assessed by detecting a signal from a label carried by the anti-PSP94 antibody. The presence of PSP94 may also be assessed by detecting a signal, for example, from a label carried by a second antibody able to bind to the anti-PSP94 antibody. An example of a suitable second antibody is an anti-mouse IgG (e.g., anti-mouse IgG 1 κ) for the monoclonal antibodies (e.g., 1A6, 2D3, 12C3, P1E8, etc.) or for the anti-PSP94 polyconal antibody, an anti-rabbit antibody (e.g., anti rabbit IgG). It is to be understood herein that the anti-PSP94 antibodies described herein are able to recognize human PSP94.
An example of an immunodetection assay (a sandwich ELISA assay measuring free PSP94) may be performed with an antibody able to recognize PSP94 coated onto the wells of an ELISA plate which is contacted with a sample containing PSP94. A second antibody able to bind to an epitope of PSP94 available when PSP94 is in a free form may be added and detection may be performed. The second antibody may carry a reporter molecule. In this type of assay, two antibodies are used; (a first antibody and a second antibody) each one may be able to bind a different epitope of PSP94. It is to be understood that the first and second antibody may be interchanged without affecting the results. One of the first or second antibody may be an antibody able to bind to PSP94 in its free form only (e.g., not in a form bound to a PSP94 binding protein described herein).
For example, the first antibody may be an antibody able to bind to all forms of PSP94 (bound and free, for example, a polyclonal antibody) and the second antibody may be an antibody able to bind to the free form of PSP94 only (i.e., an antibody able to bind to an epitope of PSP94 which is available when PSP94 is in a free form only, i.e., the antibody may bind to an epitope of PSP94 which is masked when PSP94 is bound (e.g., to a PSP94 binding protein described herein)). Therefore although all forms of PSP94 are captured by the first antibody, only the free form of PSP94 may be detected by the second antibody in this type of assay.
Alternatively, the first antibody may be an antibody which may bind to the free form of PSP94 only (1A6), as described herein, and the second antibody may be an antibody which may bind to all (every) form of PSP94 (bound and unbound). As the first antibody captures only the free form of PSP94 and the bound form is not retained, the second antibody may detect the free form of PSP94 only.
Also alternatively, the first antibody may be an antibody which binds to the free form of PSP94 only (1A6), as described herein, and the second antibody may also be an antibody which binds to the free form of PSP94 (only). The first and second antibody may bind to different epitopes of PSP94.
The second antibody may carry an enzyme, i.e. horseradish peroxidase which, when the enzyme's substrate is added, produces a colorimetric reaction. In some cases, it may be useful to use a third antibody as a detection reagent instead of conjugating one of the specific antibodies (a first or a second antibody). In cases where a third antibody is used as detection reagent, this third antibody may carry itself a reporter molecule (or else). This third antibody may be able to recognize the second antibody (it may recognize the isotype and species of the second antibody).
In an additional aspect, the present invention provides an improved method for measuring the amount of free (unbound PSP94) PSP94 (and/or PSP94 fragments and analogues thereof) in a sample, the method comprising, contacting a sample free of the PSP94/PSP94-binding protein complex with an antibody able to recognize PSP94, PSP94 fragments and analogues thereof. For example, the improved method may for measuring the amount of free PSP94 in a sample may comprise;
a) removing a complex formed by PSP94 and any one of the polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.:7 SEQ ID NO.:8, SEQ ID NO.:9 and combination thereof, generating a complex-free sample, and; b) contacting the complex-free sample with an antibody able to recognize PSP94.
The improved method for measuring the amount of free (unbound PSP94) PSP94 in a sample contemplated herein may also comprise, for example, the following steps;
a) removing a complex formed by PSP94 and any one of the polypeptide selected from the group consisting of SEQ ID NO.: 2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9 variants, fragments analogues and combination thereof, generating a complex-free sample (e.g., using methods described herein) b) immobilizing (coating, adsorbing) a PSP94-antibody to a suitable substrate (ELISA plate, matrix, SDS-PAGE, Western blot membranes), c) adding the complex-free sample comprising free (unbound) PSP94, d) adding a (PSP94) detection reagent comprising a label or marker, and; e) detecting a signal resulting from a label or marker.
Examples of suitable detection reagents that may be used in the present invention are reagents selected from the group consisting of an antibody, a polypeptide or other molecule having an affinity for PSP94. The detection reagent may have a different binding site than the PSP94-antibody, and the detection reagent may either be directly coupled to a label (or marker) or able to be recognized by a second molecule carrying (conjugated with) the label or marker.
An example of a PSP94-antibody used in step b) is the monoclonal antibody (2D3) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4240. In that case, the monoclonal antibody (P1E8) (e.g., conjugated) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4241 may be used as a detection reagent (directly or indirectly as described herein).
Another example of a PSP94-antibody that may be used in step b) is the monoclonal antibody (P1E8) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4241. In that case the monoclonal antibody (2D3) (e.g., conjugated) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit no.: PTA-4240 may be used as a detection reagent (directly or indirectly as described herein).
In a further aspect, the present invention relates to a method for measuring the amount of total PSP94 (bound and unbound (free)) in a sample, the method may comprise using a first and a second antibody able to bind to PSP94 even when PSP94 is bound to another polypeptide (e.g., SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9). It may be preferable that the first and second antibodies bind to a different PSP94 epitope.
In yet a further aspect, the present invention relates also to a method for measuring total PSP94 in a sample, the method comprising using a first and a second antibody, wherein the first antibody is able to bind to PSP94 even when PSP94 is bound to a polypeptide and wherein the second antibody is able to bind to PSP94 and to displace any one of the polypeptide selected from the group consisting of SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9 from a complex formed by PSP94 and the polypeptide.
In an embodiment of the present invention, the first antibody may be, for example, the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241, or any other suitable antibody. The second antibody may be, for example, the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240.
In an additional aspect the present invention provides a method for measuring the level (amount, concentration) of PSP94 in a sample the method comprising contacting the sample with an antibody that is able to recognize PSP94 in its free and bound forms (e.g., bound to SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9 etc.) forms.
In an embodiment of the present invention, the monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit NO.: PTA-4241 may be used.
When methods (e.g., measuring total PSP94, free PSP94, free or total PSP94-binding protein and calculating ratios) described herein are applied to clinical samples (serum, blood, plasma, etc.), they may be useful for screening subjects for a condition linked to abnormal or elevated levels of PSP94 (e.g., prostate cancer (e.g., prediction of relapse free interval in post-radiotherapy prostate cancer)) and for assessing, for example, prognosis in a subject diagnosed with prostate cancer. For example, it may be found that the higher the level of total PSP94 (or ratio of free PSP94/total PSP94, or total PSP94-binding protein) in individual with prostate cancer, relative to control subjects, the poorer the prognosis or higher the chance of having (developed recurrent) prostate cancer. In addition, when a raised level of total PSP94 (or other parameter described herein) is observed in a subject, it may be predictive (or suggestive) of prostate cancer in that subject. Thus, diagnostic and prognostic methods for screening subject for prostate cancer (or any other condition linked with an abnormal or elevated level of PSP94 or of PSP94-binding protein) are also encompassed by the present invention.
If desired or necessary, methods of the present invention may also include a step of collecting a sample; for example, a blood sample from an individual with a condition linked with elevated levels of PSP94 or other condition and performing the above-mentioned methods and assays.
Methods of the present invention may further comprise detecting a signal from a label that is provided (carried) by the molecule (antibody, polypeptide; e.g., from the label attached to the molecule) or by a second molecule (antibody or binding/ligand system) carrying the label.
Methods of the present invention may also include comparing (detecting) the signal (results) obtained for the sample with signal (results) obtained for a control sample containing a known amount of the polypeptide of interest.
In a further aspect, the present invention relates to the use of a PSP94 antibody for the treatment of a condition associated with elevated levels of PSP94. It is to be understood that a method of treating a patient with such condition, comprising administering a PSP94 antibody is also encompassed herein.
In yet a further aspect, the present invention relates to the use of a PSP94 antibody in the manufacture of a medicament for the treatment of a condition associated with elevated levels of PSP94.
The PSP94 antibodies may be for example, a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240 or a monoclonal antibody produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241.
A sample, is to be understood herein as an aliquot of blood, serum, plasma, biological fluid, or it may be, for example, proteins (containing other constituents or not) bound to the well of an ELISA plate, a membrane, a gel, a matrix, etc.
In yet a further aspect, the present invention relates to the use of a molecule selected from the group consisting of the polypeptide as set forth in SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.: 7, SEQ ID NO.:8, SEQ ID NO.:9, a monoclonal antibody (2D3) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4240, a monoclonal antibody (P1E8) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4241, a monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4242 and a monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit No.: PTA-4243, for evaluating the amount of PSP94 (free and/or bound and/or total), PSP94 variants and analogues thereof in a sample.
According to the present invention, conditions that are contemplated for methods and uses described herein may comprise, for example, prostate cancer, stomach cancer, breast cancer, endometrial cancer, ovarian cancer, other cancers of epithelial secretory cells and benign prostate hyperplasia (BPH).
It is to be understood herein that other antibody may be used (are suitable) in the methods described herein. For example, PSP94-binding protein specific antibodies listed in table 10 are interchangeable and are encompassed by the present invention (including their hydridoma cell lines). For example the monoclonal antibody (3F4) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit NO.: PTA-4242 may be interchanged with the monoclonal antibodies 2B10, 9B6, 1B11, etc. and the monoclonal antibody (17G9) produced by the hybridoma cell line deposited to the ATCC under Patent Deposit NO.: PTA-4243 may be interchanged with the monoclonal antibody P8C2, 1B11, 26B10, 9B6, etc. A variety of other conditions are possible. However, when two antibodies are needed to perform the present methods it is preferable to choose antibodies that bind to different epitopes.
It is also to be understood herein that antibody fragments, such as an antigen-binding fragment (e.g., antigen binding site) of any of the (monoclonal) antibodies disclosed herein are encompassed by the present invention.
General Molecular Biology and Definitions
Unless otherwise indicated, the recombinant DNA techniques utilized in the present invention are standard procedures, known to those skilled in the art. Solutions, reagents and buffer described herein may be prepared using reagents and methods known in the art. Example of techniques, solutions and reagents are explained in the literature in sources such as J. Perbal, A Practical Guide to Molecular Cloning, John Wiley and Sons (1984), J. Sambrook et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory Press (1989), T. A. Brown (editor), Essential Molecular Biology: A Practical Approach, Volumes 1 and 2, IRL Press (1991), D. M. Glover and B. D. Hames (editors), DNA Cloning: A Practical Approach, Volumes 1-4, IRL Press (1995 and 1996), and F. M. Ausubel et al. (editors), Current Protocols in Molecular Biology, Greene Pub. Associates and Wiley-Interscience (1988, including all updates until present) and are incorporated herein by reference.
“Polynucleotide” generally refers to any polyribonucleotide or polydeoxyribonucleotide, which may be unmodified RNA or DNA, or modified RNA or DNA. “Polynucleotides” include, without limitation single- and double-stranded DNA, DNA that is a mixture of single- and double-stranded regions, single- and double-stranded RNA, and RNA that is a mixture of single- and double-stranded regions, hybrid molecules comprising DNA and RNA that may be single-stranded or, more typically, double-stranded or a mixture of single- and double-stranded regions. In addition, “polynucleotide” refers to triple-stranded regions comprising RNA or DNA or both RNA and DNA. The term polynucleotide also includes DNAs or RNAs containing one or more modified bases and DNAs or RNAs with backbones modified for stability or for other reasons. “Modified” bases include, for example, tritylated bases and unusual bases such as inosine. A variety of modifications has been made to DNA and RNA; thus “polynucleotide” embraces chemically, enzymatically or metabolically modified forms of polynucleotides as typically found in nature, as well as the chemical forms of DNA and RNA characteristic of viruses and cells. “Polynucleotide” includes but is not limited to linear and end-closed molecules. “Polynucleotide” also embraces relatively short polynucleotides, often referred to as oligonucleotides.
Therefore, in accordance with the present invention, the polynucleotide may be, for example, a polyribonucleotide, a polydeoxyribonucleotide, a modified polyribonucleotide, a modified polydeoxyribonucleotide, a complementary polynucleotide (e.g., antisense) or a combination thereof.
“Polypeptide” refers to any peptide or protein comprising two or more amino acids joined to each other by peptide bonds or modified peptide bonds (i.e., peptide isosteres). “Polypeptide” refers to both short chains, commonly referred as peptides, oligopeptides or oligomers, and to longer chains generally referred to as proteins. As described above, polypeptides may contain amino acids other than the 20 gene-encoded amino acids.
“Variant” as the term used herein, is a polynucleotide or polypeptide that differs from reference polynucleotide or polypeptide respectively, but retains essential properties. A typical variant of a polynucleotide differs in nucleotide sequence from another, reference polynucleotide. Changes in the nucleotide sequence of the variant may or may not alter the amino acid sequence of a polypeptide encoded by the reference polynucleotide. Nucleotide changes may result in amino acid substitutions, additions, deletions, fusion and truncations in the polypeptide encoded by the reference sequence, as discussed herein. A typical variant of a polypeptide differs in amino acid sequence from another, reference polypeptide. Generally, differences are limited so that the sequence of the reference polypeptide and the variant are closely similar overall and, in many regions, identical. A variant and reference polypeptide may differ in amino acid by one or more substitutions, additions, deletions, or any combination therefore. A substituted or inserted amino acid residue may or may not be one encoded by the genetic code. A variant polynucleotide or polypeptide may be a naturally occurring such as an allelic variant, or it may be a variant that is not known to occur naturally. Non-naturally occurring variants of polynucleotides and polypeptides may be made by mutagenesis techniques or by direct synthesis. “Variants” as used herein encompass (active) mutants, analogues, homologues, chimeras, fragments and portions thereof. However, “variants” as used herein may retain parts of the biological activity of the original polypeptide.
As used herein, “pharmaceutical composition” means therapeutically effective amounts of the agent together with suitable diluents, preservatives, solubilizers, emulsifiers, adjuvant and/or carriers. A “therapeutically effective amount” as used herein refers to that amount which provides a therapeutic effect for a given condition and administration regimen. Such compositions are liquids or lyophilized or otherwise dried formulations and include diluents of various buffer content (e.g., Tris-HCl., acetate, phosphate), pH and ionic strength, additives such as albumin or gelatin to prevent absorption to surfaces, detergents (e.g., Tween 20, Tween 80, Pluronic F68, bile acid salts) solubilizing agents (e.g., glycerol, polyethylene glycerol), anti-oxidants (e.g., ascorbic acid, sodium metabisulfite), preservatives (e.g., Thimerosal, benzyl alcohol, parabens), bulking substances or tonicity modifiers (e.g., lactose, mannitol), covalent attachment of polymers such as polyethylene glycol to the protein, complexation with metal ions, or incorporation of the material into or onto particulate preparations of polymeric compounds such as polylactic acid, polyglycolic acid, hydrogels, etc, or onto liposomes, microemulsions, micelles, unilamellar or multilamellar vesicles, erythrocyte ghosts, or spheroplasts. Such compositions will influence the physical state, solubility, stability, rate of in vivo release, and rate of in vivo clearance. Controlled or sustained release compositions include formulation in lipophilic depots (e.g., fatty acids, waxes, oils). Also comprehended by the invention are particulate compositions coated with polymers (e.g., poloxamers or poloxamines). Other embodiments of the compositions of the invention incorporate particulate forms protective coatings, protease inhibitors or permeation enhancers for various routes of administration, including parenteral, pulmonary, nasal and oral routes. In one embodiment the pharmaceutical composition is administered parenterally, paracancerally, transmucosally, transdermally, intramuscularly, intravenously, intradermally, subcutaneously, intraperitonealy, intraventricularly, intracranially and intratumorally.
An “immunizing composition” or “immunogenic composition” as used herein refers to a composition able to promote an immune response in the host receiving such composition. An “immunizing composition” includes a compound, such as for example, a polypeptide (or a DNA or RNA able to encode a polypeptide) for which an antibody is sought. The polypeptide is usually diluted in a buffer, diluent or a pharmaceutically acceptable carrier. An “immunizing composition” may comprise an adjuvant such as or example complete Freund's adjuvant, incomplete Freund's adjuvant and aluminum hydroxide.
Further, as used herein “pharmaceutically acceptable carrier” or “pharmaceutical carrier” are known in the art and include, but are not limited to, 0.01-0.1 M and preferably 0.05 M phosphate buffer or 0.8% saline. Additionally, such pharmaceutically acceptable carriers may be aqueous or non-aqueous solutions, suspensions, and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's orfixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers such as those based on Ringer's dextrose, and the like. Preservatives and other additives may also be present, such as, for example, antimicrobials, antioxidants, collating agents, inert gases and the like.
As used herein, “PSP94-binding protein” relates to a protein (such as SEQ ID NO.:2, SEQ ID No.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9) that is able to bind (i.e., associate) to PSP94, usually in a reversible fashion.
As used herein, the term “free PSP94” relates to a PSP94 protein that is not associated with another polypeptide (e.g., with a PSP94-binding protein). The term “free PSP94” means that PSP94 is in an unbound form (state).
As used herein, the term “antibody” refers to either monoclonal antibody, polyclonal antibody, humanized antibody, single-chain antibody, antibody fragments including Fc, F(ab)2, F(ab)2′ and Fab and the like. It is to be understood that a “polyclonal antibody” is a term used to refer to antibodies generated by immunizing an animal against an antigen and which are often directed to multiple epitopes of the antigen.
As used herein, the term “antigen binding fragment” relates to an antibody fragment (antigen binding domain) able to recognize (bind) the antigen of interest. An “antigen binding fragment”, may be isolated from the gene(s) (e.g., gene encoding a variable region) encoding the antibody using molecular biology methods. The isolated gene(s) may engineered to create, for example, a single chain antibody. The “antigen binding fragment” of an antibody is known to be responsible for the specific binding of the antibody to the antigen.
As used herein “PSP94” or “PSP” relates to the native and recombinant PSP94.
Gene (cDNA) Cloning and Protein Expression
The identified and isolated gene (i.e., polynucleotide) may be inserted into an appropriate cloning or expression vector (i.e., expression system). A large number of vector-host systems known in the art may be used. Possible vectors include, but are not limited to, plasmids or modified viruses (e.g., bacteriophages, adenoviruses, adeno-associated viruses, retroviruses), but the vector system must be compatible with the host cell used. Examples of cloning vectors include, but are not limited to, Escherichia coli ( E. coli ), bacteriophages such as lambda derivatives, or plasmids such as pBR322 derivatives or pUC plasmid derivatives (e.g., pGEX vectors, pmal-c, pFLAG, etc). Examples of expression vectors are discussed bellow. The insertion into a cloning or expression vector can, for example, be accomplished by ligating the DNA fragment into a cloning vector, which has complementary cohesive termini. However, if the complementary restriction sites used to fragment the DNA are not present in the cloning vector, the ends of the DNA molecules may be enzymatically modified.
Alternatively, any site desired may be produced by ligating nucleotide sequences (linkers) onto the DNA termini; these ligated linkers may comprise specific chemically synthesized oligonucleotides encoding restriction endonuclease recognition sequences. Recombinant molecules can be introduced into host cells via transformation, transfection, lipofection, infection, electroporation, etc. The cloned gene may be contained on a shuttle vector plasmid, which provides for expansion in a cloning cell, e.g., E. coli , and facilitate purification for subsequent insertion into an appropriate expression cell line, if such is desired. For example, a shuttle vector, which is a vector that can replicate in more than one type of organism, can be prepared for replication in both E. coli and Saccharomyces cerevisiae by linking sequences from an E. coli plasmid with sequences from the yeast 2.mu. plasmid.
It is to be understood herein that when the polynucleotide (e.g., gene, cDNA, RNA) of the present invention is inserted into the appropriate vector, it may be used, for example, as a way to express the protein in a foreign host cell for its isolation (such as bacteria, yeast, insect, animal or plant cells) or in a (isolated) cell from an individual for purpose of gene therapy treatment or cell-mediated vaccination (using, for example, dendritic cells). For example, cells may be isolated from a mammal and treated (e.g., exposed, transfected, lipofected, infected, bombarded (using high velocity microprojectiles)) ex-vivo with the polynucleotide (cDNA, gene, RNA, antisense) of the present invention before being re-infused in the same individual or in a compatible individual. In vivo delivery of a polynucleotide may be performed by other methods than the one described above. For example, liposomal formulations when injected, may also be suitable for mediating in vivo delivery of a polynucleotide.
Any of a wide variety of expression systems may be used to provide a recombinant polypeptide (protein). The precise host cell used is not critical to the invention. Polypeptides of the present invention may be produced in a prokaryotic host (e.g., E. coli or Bacillus subtilis ( B. subtilis )) or in a eukaryotic host (yeast e.g., Saccharomyces or Pichia Pastoris ; mammalian cells, e.g., monkey COS cells, mouse 3T3 cells (Todaro G J and Green H., J. Cell Biol. 17: 299-313, 1963), Chinese Hamster Ovary cells (CHO) (e.g., Puck T T et al., J. Exp. Med. 108: 945-956, 1958), BHK, human kidney 293 cells (e.g., ATCC: CRL-1573), or human Heal cells (e.g., ATCC: CCL-2); or insect cells).
In a yeast cell expression system such as Pichia Pastors ( P. Pastoris ), DNA sequence encoding polypeptides of the present invention may be cloned into a suitable expression vector such as the pPIC9 vector (Invitrogen). Upon introduction of a vector containing the DNA sequence encoding all or part of the polypeptides of the present invention into the P. Pastors host cells, recombination event may occur for example in the AOX1 locus. Such recombination event may place the DNA sequence of polypeptides of the present invention under the dependency of the AOX1 gene promoter. Successful insertion of a gene (i.e. DNA sequence) encoding polypeptides of the present invention may result in an expression of such polypeptides that is regulated and/or induced by methanol added in the growth media of the host cell (for reference see Buckholz, R. G. and Gleeson, M. A. G., Biotechnology, 9:1067-1072, 1991; Cregg, J. M., et al., Biotechnology, 11:905-910, 1993; Sreekrishna, K., et al., J. Basic Microbiol., 28:265-278, 1988; Wegner, G. H., FEMS Microbiology Reviews, 87:279-284, 1990).
In mammalian host cells, a number of viral-based expression systems may be utilized. For example, in the event where an adenovirus is used as an expression vector for the polypeptides of the present invention, nucleic acid sequence may be ligated to an adenovirus transcription/translation control complex (e.g., the late promoter and tripartite leader sequence). This chimeric gene may be inserted into the adenovirus genome, for example, by in vitro or in vivo recombination. Insertion into a non-essential region of the viral genome (e.g., region E1 or E3) may result in a recombinant virus that is viable and capable of expressing polypeptides of the present invention in infected hosts.
Proteins and polypeptides of the present invention may also be produced by plant cells. Expression vectors such as cauliflower mosaic virus and tobacco mosaic virus and plasmid expression vectors (e.g., Ti plasmid) may be used for the expression of polypeptides in plant cells. Such cells are available from a wide range of sources (e.g., the American Type Culture Collection, Rockland, Md.). The methods of transformation or transfection and the choice of expression vehicle are of course to be chosen accordingly to the host cell selected.
In an insect cell expression system such as Autographa californica nuclear polyhedrosis virus (AcNPV), which grows in Spodoptera frugiperda cells, AcNPV may be used as a vector to express foreign genes. For example, DNA sequence coding for polypeptides of the present invention may be cloned into non-essential regions of the virus (for example the polyhedrin gene) and placed under control of an AcNPV promoter, (e.g., the polyhedrin promoter). Successful insertion of a gene (i.e., DNA sequence) encoding polypeptides of the present invention may result in inactivation of the polyhedrin gene and production of non-occluded recombinant virus (i.e., virus lacking the proteinaceous coat encoded by the polyhedrin gene). These recombinant viruses may be used to infect spodoptera frugiperda cells in which the inserted gene is expressed.
In addition, a host cell may be chosen for its ability to modulate the expression of the inserted sequences, or to modify or process the gene product in a specific, desired fashion. Such modifications (e.g., glycosylation) and processing (e.g., cleavage) of protein products may be important for the function of the protein. Different host cells have characteristics and specific mechanisms for posttranslational processing and modification of proteins and gene products. Of course, cell lines or host systems may be chosen to ensure desired modification and processing of the foreign protein expressed. To this end, eukaryotic host cells that possess the cellular machinery for proper processing of the primary transcript, glycosylation, and phosphorylation of the gene product may be used. Such mammalian host cells comprise for example, but are not limited to, CHO, VERO, BHK, Heal, COS, MDCK, 293, and 3T3.
Alternatively, polypeptides of the present invention may be produced by a stably-transfected mammalian cell line. A number of vectors suitable for stable transfection of mammalian cells are available to the public; methods for constructing such cell lines are also publicly available. In one example, cDNA encoding the rHuPSP94 protein may be cloned into an expression vector that includes the dihydrofolate reductase (DHFR) gene. Integration of the plasmid and, therefore, DNA sequence of polypeptides of the present invention, into the host cell chromosome may be selected for by including methotrexate in the cell culture media. This selection may be accomplished in most cell types.
Specific initiation signals may also be required for the efficient translation of DNA sequences inserted in a suitable expression vehicle as described above. These signals may include the ATG initiation codon and adjacent sequences. For example, in the event where gene or cDNA encoding polypeptides of the present invention, would not have their own initiation codon and adjacent sequences, additional translational control signals may be needed. For example, exogenous translational control signals, including, perhaps, the ATG initiation codon, may be needed. It is known in the art that the initiation codon must be in phase with the reading frame of the polypeptide sequence to ensure proper translation of the desired polypeptide. Exogenous translational control signals and initiation codons may be of a variety of origins, including both natural and synthetic. The efficiency of expression may be enhanced by the inclusion of appropriate transcription enhancer elements, transcription terminators. The transcription, translation signals may be specifically engineered to provide a desired expression pattern and level (e.g., signals that may require a specific inducer, signals that will allow expression in a defined cell type or in a specific time frame).
However, these signals may be provided by the expression vector, which often contains a promoter enabling the expression of the polypeptide in a desired host cell.
Polypeptide Modifications (Mutants, Variants, Analogues, Homologues Chimeras and Portions/Fragments).
As may be appreciated, a number of modifications may be made to the polypeptides and fragments of the present invention without deleteriously affecting the biological activity of the polypeptides or fragments. Polypeptides of the present invention comprises for example, those containing amino acid sequences modified either by natural processes, such as posttranslational processing, or by chemical modification techniques which are known in the art. Modifications may occur anywhere in a polypeptide including the polypeptide backbone, the amino acid side-chains and the amino or carboxy-termini. It will be appreciated that the same type of modification may be present in the same or varying degrees at several sites in a given polypeptide. Also, a given polypeptide may contain many types of modifications. Polypeptides may be branched as a result of ubiquitination, and they may be cyclic, with or without branching. Cyclic, branched and branched cyclic polypeptides may result from posttranslational natural processes or may be made by synthetic methods. Modifications comprise for example, without limitation, acetylation, acylation, addition of acetomidomethyl (Acm) group, ADP-ribosylation, amidation, covalent attachment to fiavin, covalent attachment to a heme moiety, covalent attachment of a nucleotide or nucleotide derivative, covalent attachment of a lipid or lipid derivative, covalent attachment of phosphatidylinositol, cross-linking, cyclization, disulfide bond formation, demethylation, formation of covalent cross-links, formation of cystine, formation of pyroglutamate, formylation, gamma-carboxylation, glycosylation, GPI anchor formation, hydroxylation, iodination, methylation, myristoylation, oxidation, proteolytic processing, phosphorylation, prenylation, racemization, selenoylation, sulfation, transfer-RNA mediated addition of amino acids to proteins such as arginylation and ubiquitination (for reference see, Protein-structure and molecular properties, 2 nd Ed., T. E. Creighton, W. H. Freeman and Company, New-York, 1993).
Other type of polypeptide modification may comprises for example, amino acid insertion (i.e., addition), deletion and substitution (i.e., replacement), either conservative or non-conservative (e.g., D-amino acids, desamino acids) in the polypeptide sequence where such changes do not substantially alter the overall biological activity of the polypeptide. Polypeptides of the present invention comprise for example, biologically active mutants, variants, fragments, chimeras, and analogs; fragments encompass amino acid sequences having truncations of one or more amino acids, wherein the truncation may originate from the amino terminus (N-terminus), carboxy terminus (C-terminus), or from the interior of the protein. Polypeptide analogs of the invention involve an insertion or a substitution of one or more amino acids. Variants, mutants, fragments, chimeras and analogs may have the biological property of polypeptides of the present invention.
It should be further noted that if the polypeptides are made synthetically, substitutions by amino acids, which are not naturally encoded by DNA may also be made. For example, alternative residues include the omega amino acids of the formula NH2(CH2)nCOOH wherein n is 2-6. These are neutral nonpolar amino acids, as are sarcosine, t-butyl alanine, t-butyl glycine, N-methyl isoleucine, and norleucine. Phenylglycine may substitute for Trp, Tyr or Phe; citrulline and methionine sulfoxide are neutral nonpolar, cysteic acid is acidic, and ornithine is basic. Proline may be substituted with hydroxyproline and retain the conformation conferring properties.
It is known in the art that mutants or variants may be generated by substitutional mutagenesis and retain the biological activity of the polypeptides of the present invention. These variants have at least one amino acid residue in the protein molecule removed and a different residue inserted in its place. For example, one site of interest for substitutional mutagenesis may include but are not restricted to sites identified as the active site(s), or immunological site(s). Other sites of interest may be those, for example, in which particular residues obtained from various species are identical. These positions may be important for biological activity. Examples of substitutions identified as “conservative substitutions” are shown in table 1. If such substitutions result in a change not desired, then other type of substitutions, denominated “exemplary substitutions” in table 1, or as further described herein in reference to amino acid classes, are introduced and the products screened.
Example of substitutions may be those, which are conservative (i.e., wherein a residue is replaced by another of the same general type). As is understood, naturally-occurring amino acids may be sub-classified as acidic, basic, neutral and polar, or neutral and non-polar. Furthermore, three of the encoded amino acids are aromatic. It may be of use that encoded polypeptides differing from the determined polypeptide of the present invention contain substituted codons for amino acids, which are from the same group as that of the amino acid be replaced. Thus, in some cases, the basic amino acids Lysine (Lys), Arginine (Arg) and Histidine (His) may be interchangeable; the acidic amino acids Aspartic acid (Asp) and Glutamic acid (Glu) may be interchangeable; the neutral polar amino acids Serine (Ser), Threonine (Thr), Cysteine (Cys), Glutamine (Gin), and Asparagine (Asn) may be interchangeable; the non-polar aliphatic amino acids Glycine (Gly), Alanine (Ala), Valine (Val), Isoleucine (lie), and Leucine (Leu) are interchangeable but because of size Gly and Ala are more closely related and Val, lie and Leu are more closely related to each other, and the aromatic amino acids Phenylalanine (Phe), Tryptophan (Trp) and Tyrosine (Tyr) may be interchangeable.
TABLE 1
Exemplary amino acid substitution
Original
Exemplary
Conservative
residue
substitution
substitution
Ala (A)
Val, Leu, Ile
Val
Arg (R)
Lys, Gln, Asn
Lys
Asn (N)
Gln, His, Lys, Arg
Gln
Asp (D)
Glu
Glu
Cys (C)
Ser
Ser
Gln (Q)
Asn
Asn
Glu (E)
Asp
Asp
Gly (G)
Pro
Pro
His (H)
Asn, Gln, Lys, Arg
Arg
Ile (I)
Leu, Val, Met, Ala, Phe,
Leu
norleucine
Leu (L)
Norleucine, Ile, Val, Met,
Ile
Ala, Phe
Lys (K)
Arg, Gln, Asn
Arg
Met (M)
Leu, Phe, Ile
Leu
Phe (F)
Leu, Val, Ile, Ala
Leu
Pro (P)
Gly
Gly
Ser (S)
Thr
Thr
Thr (T)
Ser
Ser
Trp (W)
Tyr
Tyr
Tyr (Y)
Trp, Phe, Thr, Ser
Phe
Val (V)
Ile, Leu, Met, Phe, Ala,
Leu
norleucine
In some cases it may be of interest to modify the biological activity of a polypeptide by amino acid substitution, insertion, or deletion. For example, modification of a polypeptide may result in an increase in the polypeptide's biological activity, may modulate its toxicity, may result in changes in bioavailability or in stability, or may modulate its immunological activity or immunological identity. Substantial modifications in function or immunological identity are accomplished by selecting substitutions that differ significantly in their effect on maintaining (a) the structure of the polypeptide backbone in the area of the substitution, for example, as a sheet or helical conformation. (b) the charge or hydrophobicity of the molecule at the target site, or (c) the bulk of the side chain. Naturally occurring residues are divided into groups based on common side chain properties:
(1) hydrophobic: norleucine, methionine (Met), Alanine (Ala), Valine (Val), Leucine (Leu), Isoleucine (lie) (2) neutral hydrophilic: Cysteine (Cys), Serine (Ser), Threonine (Thr) (3) acidic: Aspartic acid (Asp), Glutamic acid (Glu) (4) basic: Asparagine (Asn), Glutamine (Gin), Histidine (His), Lysine (Lys), Arginine (Arg) (5) residues that influence chain orientation: Glycine (Gly), Proline (Pro); and (6) aromatic: Tryptophan (Trp), Tyrosine (Tyr), Phenylalanine (Phe)
Non-conservative substitutions will entail exchanging a member of one of these classes for another.
Mutant polypeptides will possess one or more mutations, which are deletions (e.g., truncations), insertions (e.g., additions), or substitutions of amino acid residues. Mutants can be either naturally occurring (that is to say, purified or isolated from a natural source) or synthetic (for example, by performing site-directed mutagenesis on the encoding DNA or made by other synthetic methods such as chemical synthesis). It is thus apparent that the polypeptides of the invention can be either naturally occurring or recombinant (that is to say prepared from the recombinant DNA techniques).
A protein at least 50% identical to those polypeptides of the present invention, as determined by methods known to those skilled in the art (for example, the methods described by Smith, T. F. and Waterman M. S. (1981) Ad. Appl. Math., 2:482-489, or Needleman, S. B. and Wunsch, C. D. (1970) J. Mol. Biol., 48: 443-453) is included in the invention, as are proteins at least 70% or 80% and more preferably at least 90% identical to the protein of the present invention. This will generally be over a region of at least 5, preferably at least 20, contiguous amino acids.
Amino acid sequence variants may be prepared by introducing appropriate nucleotide changes into DNA, or by in vitro synthesis of the desired polypeptide. Such variant include, for example, deletions, insertions, or substitutions of residues within the amino acid sequence. A combination of deletion, insertion and substitution can be made to arrive at the final construct, provided that the final protein product possesses the desired characteristics. The amino acid changes also may alter posttranslational processes such as changing the number or position of the glycosylation sites, altering the membrane anchoring characteristics, altering the intra-cellular location by inserting, deleting or otherwise affecting the transmembrane sequence of the native protein, or modifying its susceptibility to proteolytic cleavage.
Protein Purification
Some aspects of the present invention concern the purification, and in particular embodiments, the substantial purification, of a polypeptide. The term “purified polypeptide” as used herein, is intended to refer to a composition, isolatable from other components, wherein the polypeptide is purified to any degree relative to its naturally-obtainable state, (i.e., in this case, relative to its purity within a prostate, cell extract). A purified polypeptide therefore also refers to a polypeptide, free from the environment in which it may naturally occur.
Generally, “purified” will refer to a polypeptide composition, which has been subjected to fractionation to remove various other components, and which composition substantially retains its expressed biological activity. Where the term “substantially purified” is used, this will refer to a composition in which the polypeptide forms the major component or portion of the composition, such as constituting about 50% or more of the polypeptides in the composition.
Various techniques suitable for use in polypeptide purification will be well known to those of skill in the art. These include, for example, precipitation with ammonium sulfate, PEG, antibodies and the like or by heat denaturation, followed by centrifugation; chromatography steps such as ion exchange, gel filtration (i.e., size exclusion chromatography), reverse phase, hydroxylapatite and affinity chromatography; isoelectric focusing; gel electrophoresis; and combinations of such and other techniques. These techniques may be used either alone or in combination. As is generally known in the art, it is believed that the order of conducting the various purification steps may be changed, or that certain steps may be omitted, and still result in a suitable method for the preparation of a substantially purified polypeptide.
The ability of purifying a protein by ammonium sulfate precipitation is based on the fact that a protein's solubility is lowered at high salt concentration. However, the solubility of proteins is affected in a different manner depending on their properties.
Size exclusion chromatography or gel filtration separates molecules based on their size. The gel (i.e., matrix, resin) media may consist of beads containing pores of a specific distribution. Separation may occur when molecules of different size are included or excluded from the pores within the matrix. Small molecules may diffuse into the pores and their flow through the column is retarded, while large molecules do not enter the pores and are eluted in the column's void volume. Consequently, molecules separate based on their size as they pass through the column and are eluted in order of decreasing molecular weight.
Proteins can be separated on the basis of their net charge by ion-exchange chromatography. For example, if a protein has a net positive charge at pH 7, it will usually bind (adsorb) to beads (i.e., matrix) containing a negatively charged group. For example, a positively charged protein can be separated on a negatively charged carboxymethyl-cellulose or carboxymethyl-agarose matrix. Following elution, proteins that have a low density of net positive charge will tend to emerge first from the column followed by those having a higher charge density. Negatively charged proteins can be separated by chromatography on positively charged diethylaminoethyl-cellulose (DEAE-cellulose) or DEAE-agarose matrix. A charged protein bound to an ion-exchange matrix may be eluted (released, detached) by increasing the concentration of sodium chloride or another salt solution as an eluting buffer. Ions will compete with the charged groups on the protein for binding to the matrix.
Salt solutions may be added to the matrix in a sequential manner (i.e., by adding a solution of a specific molarity (e.g., 100 mM sodium chloride) followed by the addition of one or more solutions of different molarity (e.g., 200 mM, followed by a solution of 300 mM, followed by a solution of 400 mM, followed by a solution of 500 mM, followed by a solution of 1000 mM)) until the specific polypeptide of the invention (i.e., PSP94-binding protein (SEQ ID NO.:2, SEQ ID NO.:3, SEQ ID NO.:7, SEQ ID NO.:8, SEQ ID NO.:9) is eluted. In addition, salts solution may be added as a continuous gradient. For example, a salt solution of high molarity (e.g., 1000 mM) may be gradually added to a second solution of lower molarity (e.g., 100 mM) before entering the ion-exchange chromatography column. The salt solution entering the column will have a molarity slowly increasing from 100 mM to up to 1000 mM.
Affinity chromatography may be used when the specificity (affinity) of a polypeptide for a compound is known or suspected. For example, as a first step such compound (e.g., PSP94) is covalently attached to a column (e.g., a cyanogen bromide activated sepharose matrix) and a mixture (solution) containing a desired polypeptide (e.g., a PSP94-binding protein) may be added to the matrix. After washing the matrix, to remove unbound proteins, the desired polypeptide may be eluted from the matrix by adding a high concentration of the compound (e.g., PSP94) in a soluble form. Antibodies are an example of a compound, which is often used to purify proteins to which it binds.
It is known in the art, that equilibration and substantial washing of chromatography matrix (i.e., resin) (e.g., ion-exchange matrix, size-exclusion matrix, affinity matrix) is preferred in order to minimize binding of unwanted (i.e., unspecific) proteins (non-specific binding).
Antibodies and Hybridoma
Other aspects of the present invention relates to antibodies and hybridoma cell lines. The preparation and characterization of antibodies are well known in the art (See, e.g., Antibodies: A Laboratory Manual., Cold Spring Harbor Laboratory, 1988; incorporated herein by reference) and has been discussed in U.S. Pat. No. 6,156,515, the entire content of which is incorporated herein by reference.
For example, a polyclonal antibody preparation may be obtained by immunizing an animal with an immunogenic (immunizing) composition and collecting antisera from that immunized animal. A wide range of animal species may be used for the production of antisera. Typically the animal used for production of anti-antisera is a rabbit, a mouse, a rat, a hamster, a guinea pig or a goat.
It is often necessary to boost the host immune system by coupling, for example, an immunogen to a carrier (e.g., keyhole limpet hemocyanin (KLH) and bovine serum albumin (BSA)) or by incorporating an adjuvant to the immunizing composition, as described herein.
The production of antibodies may be monitored by sampling blood of the immunized animal at various time points following immunization. Sometimes, additional boosts may be required to provide a sufficient titer of the antibody(ies).
The desired antibody may be purified by known methods, such as affinity chromatography using, for example, another antibody or a peptide bound to a solid matrix.
Monoclonal antibodies (mAbs) may be readily prepared through use of known techniques, such as those exemplified in U.S. Pat. No. 4,196,265, the entire content of which is incorporated herein by reference. Mice (e.g., BALB/c mouse) and rats are the animals that are usually used for the immunization. Following immunization, B lymphocytes (B cells), are selected for use in the mAb generating protocol. Often, a panel of animals will have to be immunized and the animal having the highest antibody titer will be chosen. The antibody-producing B lymphocytes from the immunized animal are then fused (e.g., using polyethylene glycol) with cells of an immortal myeloma cell. Any one of a number of myeloma cells may be used, as are known to those of skill in the art (Goding, pp. 65-66, 1986; Campbell, pp. 75-83, 1984). For example, where the immunized animal is a mouse, one may use P3-X63/Ag8, X63-Ag8.653, NS1/1.Ag 4 1, Sp210-Ag14, FO, NSO/JU, MPC-11, MPC11-X45-GTG 1.7 and S194/5XXO Bul; for rats, one may use R210.RCY3, Y3-Ag 1.2.3, IR983F and 4B210; and U-266, GM1500-GRG2, LICR-LON-HMy2 and UC729-6 are all useful in connection with human cell fusions.
Fused hybrids are grown in a selective medium that enables the differentiation between fused cells and the parental cells (i.e., myeloma and B cells). The selective medium usually contains an agent (e.g., aminopterin, methotrexate, azaserine) that blocks the de novo synthesis of nucleotides. When aminopterin or methotrexate is used, the media is supplemented with hypoxanthine and thymidine as a source of nucleotides (HAT medium). Where azaserine is used, the media is supplemented with hypoxanthine. Only cells capable of operating nucleotide salvage pathways are able to survive in HAT medium. The myeloma cells are defective in key enzymes of the salvage pathway, e.g., hypoxanthine phosphoribosyl transferase (HPRT), and they cannot survive. The B cells may operate this pathway, but they have a limited life span in culture and generally die within about two weeks. Therefore, the only cells that can survive in the selective media are those hybrids formed from myeloma and B cells.
Selection of hybridomas is performed by culturing the cells by single-clone dilution in microtiter plates, followed by testing the individual clonal supernatants for the desired reactivity. The selected hybridomas may then be serially diluted and cloned into individual antibody-producing cell lines, which clones may then be propagated indefinitely to provide mAbs.
Fragments of monoclonal antibody(ies) are encompassed by the present invention. These may be obtained by methods, which include digestion with enzymes such as pepsin or papain and/or cleavage of disulfide bonds by chemical reduction. Alternatively, monoclonal antibody fragments encompassed by the present invention may be synthesized using an automated peptide synthesizer or may be produced from cloned gene segments engineered to produce such fragment (e.g., single-chain antibody) in a suitable cell (cell line).
Antibody conjugates are also encompassed by the present invention. These may be generated by coupling the antibody with a erporter molecule, a fluorophore, a chromophore or dye (e.g., rhodamine, fluoroscein, and green fluorescent protein) or any other agent or label that gives rise to a detectable signal, either by acting alone or following a biochemical reaction (e.g., enzymes such as horseradish peroxidase, alkaline phosphatase and beta-galactosidase). A molecule such as diethylenetriaminepentaacetic acid (DTPA) may also be linked to the antibody. DTPA may act as a chelating agent that is able to bind to heavy metal ions including radioisotopes (e.g. Isotope 111 of Indium ( 111 In)). These conjugates may be used as detection tools in immunoassays or in imaging. Alternatively, conjugates having a therapeutic agent such as a toxin may be prepared from the monoclonal antibodies of the present invention, these may be used to target cancer cells and to promote their destruction.
It will be appreciated by those of skill in the art that monoclonal or polyclonal antibodies specific for proteins that are linked to prostate cancer will have utilities in several types of applications. These may include the production of diagnostic kits for use in detecting, diagnosing or evaluating the prognosis of individual with prostate cancer.
Antigen Detection
In terms of antigen detection, the biological sample analyzed may be any sample that is suspected of containing an antigen of interest, either a tissue, cell lysate, urine, blood, serum, plasma, etc.
Contacting the biological sample with the antigen detection (detecting) reagent (protein, peptide or antibody) is generally a matter of simply adding the composition to the sample and incubating the mixture for a period of time long enough for the antibodies to form immune complexes with the antigen. Washing of the sample (i.e., tissue section, ELISA plate, dot blot or Western blot) is generally required to remove any non-specifically bound antibody species. The antigen-antibody complex (immunocomplex) is then detected using specific reagents.
When, for example, the antigen detecting reagent is an antibody (a specific antibody), this antibody may be (directly) labeled with a marker (fluorophore, chromophore, dye, enzyme, radioisotope, etc.) for enabling the detection of the complex. In other instances, it may be advantageous to use a secondary binding ligand such as a secondary antibody or a biotin/avidin (streptavidin) (binding/ligand complex) arrangement, as is known in the art. Again, secondary antibodies may be labeled with a marker as described above or with an arrangement of biotin/avidin (i.e. avidin peroxidase) or biotin/streptavidin (i.e. streptavidin coupled with a reporter molecule (e.g., peroxidase)), which allow the detection of the immunocomplex. United States patents concerning the use of such labels include U.S. Pat. Nos. 3,817,837; 3,850,752; 3,939,350; 3,996,345; 4,277,437; 4,275,149 and 4,366,241, each incorporated herein by reference. Usually, the secondary antibody will be an antibody directed to the specific antibody (primary antibody) of a defined isotype and species such as, for example, an anti-mouse IgG.
On the other hand, the antigen detecting reagent may also be a polypeptide having affinity for an antibody or another polypeptide, which forms a complex (i.e., polypeptide-polypeptide complex or antibody-polypeptide complex). In that case, the polypeptide itself may be labeled using the markers described above, allowing direct detection. Again, the complex may be detected indirectly by adding a secondary (labeled) antibody or polypeptide.
Immunodetection methods, such as enzyme-linked immunosorbent assays (ELISA), Western blots, etc. have utility in the diagnosis of conditions such as prostate cancer. However, these methods also have applications to non-clinical samples, such as in the titering of antigen or antibody samples, in the selection of hybridomas, and the like.
ELISA
The methods, assays, kits, antibodies and reagent described herein may find utility for example, in the diagnosis/prognosis of prostate cancer.
Immunoassays that may be performed using reagents of the present invention includes, for example, enzyme linked immunosorbent assays (ELISAs) and radioimmunoassays (RIA), which are known in the art. Immunohistochemical detection using tissue sections is also particularly useful. However, it will be readily appreciated that detection is not limited to such techniques, and Western blotting, dot blotting, FACS analyses, and the like also may be used.
Examples of ELISA assays include the following; antibodies binding to a polypeptide (e.g., antibodies to PSP94) are immobilized onto a selected surface (i.e., suitable substrate) exhibiting protein affinity, such as a well in a polystyrene microtiter plate (ELISA plate). Then, a sample suspected of containing the polypeptide is added to the wells of the plate. After binding and washing to remove non-specifically bound immunocomplexes, the bound antigen may be detected. Detection may be achieved by the addition of a second antibody specific for the target polypeptide, which is linked to a detectable label. This type of ELISA is a simple “sandwich ELISA.” Detection also may be achieved by the addition of a second antibody, followed by the addition of a third antibody that has binding affinity for the second antibody, with the third antibody being linked to a detectable label (marker).
Another example of ELISA assay is the following; the samples suspected of containing the polypeptide of interest are immobilized onto the surface of a suitable substrate and then contacted with the antibodies of the invention. After binding and washing to remove non-specifically bound immunocomplexes, the bound antigen is detected. The immunocomplexes may be detected directly or indirectly as described herein.
An additional example of an ELISA assay is the following; again, polypeptides are immobilized to a substrate, however, in that case the assay involves a competition step. In this ELISA, a known amount of the polypeptide of interest is adsorbed to the plate. The amount of polypeptide in an unknown sample is then determined by mixing the sample with a specific antibody before or during incubation with wells containing the immobilized polypeptide. A detection reagent is added (e.g., antibody) to quantify the antibody that is able to bind to the immobilized polypeptide. The presence of the polypeptide in the sample acts to reduce the amount of antibody available for binding to the polypeptide contained in the well (immobilized polypeptide) and thus reduces the signal.
In order to get a correlation between the signal and the amount (concentration) of polypeptide in an unknown sample, a control sample may be included during the assay. For example, known (predetermined) quantities of a polypeptide (usually in a substantially pure form) may be measured (detected) at the same time as the unknown sample. The signal obtained for the unknown sample is then compared with the signal obtained for the control. The intensity (level) of the signal is usually proportional to the amount of polypeptide (antibody bound to the polypeptide) in a sample. However, the amount of control polypeptide and antibodies required to generate a quantitative assay needs to be evaluated first.
In coating a plate with either an antigen (polypeptide) or antibody, one will generally incubate the wells of the plate with a solution of the antigen or antibody, either overnight or for a specified period of hours. The wells of the plate will then be washed to remove incompletely adsorbed material. Any remaining available surfaces of the wells are then “coated” with a nonspecific protein that is antigenically neutral with regard to the test antisera. These include bovine serum albumin (BSA), casein and solutions of milk powder. The coating allows for blocking of nonspecific adsorption sites on the immobilizing surface and thus reduces the background caused by nonspecific binding of antisera onto the surface.
Conditions that may allow immunocomplex (antigen/antibody) formation include diluting the antigens and antibodies with solutions such as BSA, bovine gamma globulin (BGG) and phosphate buffered saline (PBS)/Tween. These added agents also tend to assist in the reduction of nonspecific background.
Suitable conditions involves that the incubation is at a temperature and for a period of time sufficient to allow effective binding. Incubation steps are typically from about 1 to 2 to 4 h, at temperatures preferably on the order of 20° C. to 27° C., or may be overnight at about 4° C. or so.
Often, the detection of the immunocomplex is performed with a reagent that is linked to an enzyme. Detection usually requires the addition of the enzyme's substrate. Enzymes such as, for example, a phosphatase (e.g., alkaline phosphatase), a peroxidase, etc. when given an appropriate substrate will generate a reaction that may be quantified by measuring the intensity (degree) of color (radioactivity, fluorescence, etc.) produced. The reaction is usually linear over a wide range of concentrations and may be quantified using a visible spectra spectrophotometer.
Kits
The present invention also relates to immunodetection kits and reagents for use with the immunodetection methods described above. As the polypeptide of the present invention may be employed to detect antibodies and the corresponding antibodies may be employed to detect the polypeptide, either or both of such components may be provided in the kit. The immunodetection kits may thus comprise, in suitable container means, a polypeptide (PSP94, or PSP94-binding protein), or a first antibody that binds to a polypeptide and/or an immunodetection reagent. The kit may comprise also a suitable matrix to which the antibody or polypeptide of choice may already be bound. Suitable matrix include an ELISA plate. The plate provided with the kit may already be coated with the antibody or polypeptide of choice. The coated ELISA plate may also have been blocked using reagents described herein to prevent unspecific binding. Detection reagents may also be provided and may include, for example, a secondary antibody or a ligand, which may carry the label or marker and/or an enzyme substrate. Kits may further comprise an antibody or polypeptide (usually of known titer or concentration) that may be used for control. Reagents may be provided, for example, lyophilized or in liquid form (of a defined concentration) and are provided in suitable containers (ensuring stability of reagents, safety etc.).
It is to be understood herein, that if a “range”, “group of substances” or particular characteristic (e.g., temperature, concentration, time and the like) is mentioned, the present invention relates to and explicitly incorporates herein each and every specific member and combination of sub-ranges or sub-groups therein whatsoever. Thus, any specified range or group is to be understood as a shorthand way of referring to each and every member of a range or group individually as well as each and every possible sub-ranges or sub-groups encompassed therein; and similarly with respect to any sub-ranges or sub-groups therein. Thus, for example,
with respect to reaction time, a time of 1 minute or more is to be understood as specifically incorporating herein each and every individual time, as well as sub-range, above 1 minute, such as for example 1 minute, 3 to 15 minutes, 1 minute to 20 hours, 1 to 3 hours, 16 hours, 3 hours to 20 hours etc.; and similarly with respect to other parameters such as concentrations, temperature, etc. . . .
It is also to be understood herein that non-PSP94-binding protein (or DNA encoding such polypeptide) are excluded of the polypeptide or polynucleotide of the present invention.
TABLE 2
Table of abbreviation.
Abbreviation
Signification
M
Molar
mM
milliMolar
g
gram
mg
milligram
μg or ug
microgram
ng
nanogram
° C. or ° C.
Degree Celcius
%
percent
cm
centimeter
cpm (CPM)
Counts per minute
PBS
Phosphate buffered saline
NaCl
Sodium chloride
MES
2-(N-Morpholino)ethanesulfonic acid
MOPS
3-(N-Morpholino)propanesulfonic acid
UV
ultraviolet
Da
dalton
kDa
kilodalton
Kd
Dissociation constant
nm
nanometer
OD
Optical density
CAPS
3-(Cyclohexylamino)-1-propanesulfonic acid
HMW
High molecular weight
DMSO
Dimethylsulfoxide
PVDF
Polyvinylidene difluoride
LMW
Low molecular weight
FSH
Follicle stimulating hormone
PSP94 or PSP
Prostate Secretory Protein of 94 amino acids
SDS
Sodium dodecyl sulfate
PAGE
Polyacrylamide gel electrophoresis
EDTA
Ethylene diamine tetra acetate
MWCO
Molecular weight cut off
A280
Absorbance at 280 nm
MES
2-Morpholinoethanesulfonic acid
HPLC
High performance liquid chromatography
RP-HPLC
Reverse phase HPLC
RPM
Rotation per minute
The content of each publication, patent and patent application mentioned in the present application is incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrates exemplary embodiment of the invention;
FIG. 1 is a graph showing size exclusion chromatography results of proteins from human male serum bound to PSP94 radiolabeled with isotope 125 of iodine ( 125 I) (specific binding). Binding of 125 I-PSP94 to human male serum protein is determined by the radioactivity, expressed in counts per minute (cpm), in each fraction. Non-specific binding was determined by including free PSP94 in the incubation mixture together with human male serum and 125 I-PSP94. The location of fractions containing free- and complexed-PSP94 (PSP94 associated with a carrier) are indicated in the graph;
FIG. 2 is a graph depicting results of 125 I-PSP94 binding in fractions of proteins, from human male serum, partially purified by ammonium sulfate precipitation. Whole human male serum was precipitated with various concentrations of ammonium sulfate (0 to 32%, 32 to 47%, 47 to 62% and 62 to 77% of ammonium sulfate (% are calculated in w/v)), and the presence of PSP94-binding activity within the fractions was assessed by measuring the ability of radiolabeled PSP94 to associate with proteins contain in each fraction (high molecular weight components) of serum. Results are expressed as the amount of radioactivity bound to human male serum proteins in each fraction relative to the total amount of radioactivity used in the binding assay (in terms of percentage);
FIG. 3 is a graph showing anion-exchange chromatography results using a MacroPrep High Q anion exchange column, loaded with proteins purified by ammonium sulfate. Proteins are eluted with sodium chloride. The peak located between point A and B represents the protein fraction containing PSP94-binding protein. Proteins are detected and quantified by the absorbance measured at 280 nm;
FIG. 4 is a picture of a reducing sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) gel loaded with samples obtained following PSP94-affinity chromatography. The gel was run in an electric field and stained with Gelcode® Blue Code Reagent (Pierce). Lane 1 represents the molecular weight marker. Lane 2 represents proteins bound to the PSP94-conjugated affinity matrix. Lane 3 represents proteins that bound to the PSP94-conjugated affinity matrix when excess free PSP94 was included within the incubation mixture;
FIG. 5 is a picture of a non-reducing SDS-PAGE gel loaded with samples obtained following the elution of the PSP94-binding protein from the PSP94-conjugated affinity matrix using different eluting (dissociation) conditions. After incubation, in the different eluting buffers, the affinity matrix was removed from the eluting buffer by centrifugation. The matrix was washed in PBS, and boiled in non-reducing SDS-PAGE sample buffer. The SDS-PAGE was run in an electric field and was stained with Gelcode® Blue Code Reagent (Pierce). Arrows represent the position of the high molecular weight binding protein (HMW) and the low molecular weight binding protein (LMW). Lane A represents the molecular weight marker. Lane B represents untreated sample. Lane C represents sample incubated for 1 hour in PBS at 34° C. Lane D represents sample incubated for 1 hour in water at 34° C. Lane E represents sample incubated with 300 μg of PSP94 in 1 ml of PBS at 34° C. Lane F represents the competition control. Lane G represents sample incubated in 2 M urea. Lane H represents sample incubated in 8 M urea. Lane I represents sample incubated in 100 mM sodium acetate at pH 2.7. Lane J represents sample incubated in 100 mM 3-(Cyclohexylamino)-1-propanesulfonic acid (CAPS) at pH 11.0;
FIG. 6 is a graph showing affinity chromatography (using PSP94-conjugated affinity matrix) results of samples purified by ammonium sulfate precipitation followed by anion-exchange chromatography. PSP94-binding protein was eluted from the column by adding excess PSP94. The peak located between point A and B represents the PSP94-binding protein fraction. Proteins are detected and quantified by the absorbance at 280 nm;
FIG. 7 is a picture of a SDS-PAGE performed in non-reducing conditions. Lane A is the molecular weight marker. Lane B represents the PSP94-affinity matrix after incubation with PSP94-binding protein purified by ammonium sulfate precipitation and anion-exchange chromatography, and prior to elution with competing PSP94. Lane C represents the competition control. Lane D represents the affinity matrix after elution with excess PSP94. Lane E represents the final eluted and concentrated (substantially) pure PSP94-binding protein;
FIG. 8 is a schematic of a proposed purification process for the PSP94-binding protein;
FIG. 9 a is a picture of a Northern blot performed on samples of human tissue poly-A RNA. Lane 1 represents brain RNA, lane 2 represents heart RNA, lane 3 represents skeletal muscle RNA, lane 4 represents colon RNA, lane 5 represents thymus RNA, lane 6 represents spleen RNA, lane 7 represents kidney RNA, lane 8 represents liver RNA, lane 9 represents small intestine RNA, lane 10 represents placenta RNA, lane 11 represents lung RNA and lane 12 represents peripheral blood lymphocytes (PBL) RNA;
FIG. 9 b is a picture of a Northern blot performed on samples of human tissue poly-A RNA. Lane 1 represents spleen RNA, lane 2 represents thymus RNA, lane 3 represents prostate RNA, lane 4 represents testis RNA, lane 5 represents ovary RNA, lane 6 represents small intestine RNA, lane 7 represents colon RNA and lane 8 represents peripheral Blood Lymphocytes (PBL) RNA;
FIG. 10 is a picture of a Western blot showing recognition (binding) of PSP94-binding protein with a specific monoclonal antibody (1B11). Lane 1 is molecular weight markers (from top to bottom, 212, 132, 86, 44 kDa). Lane 2 is 0.2 μg of (substantially) purified PSP94-binding protein and lane 3 is 25 μl of partially pure PSP94-binding protein;
FIG. 11 is a picture of an ELISA plate where the specificity of monoclonal antibodies for bound and free forms of PSP94 is evaluated. Colored wells represent a positive result;
FIG. 12A is a schematic of a method used to measure the amount of free PSP94;
FIG. 12B is a result of an ELISA assay using the method illustrated in FIG. 12 a;
FIG. 12C is a schematic of a sandwich ELISA assay used to measure the amount of free PSP94;
FIG. 12D is a graph illustrating the results of a sandwich ELISA assay for measuring free PSP94;
FIG. 13 is a schematic of a proposed method used to measure the amount (PSP94 sandwich ELISA) of total PSP94 in a sample;
FIG. 14 a is a schematic of a method used to measure the amount of total PSP94-binding protein (using a PSP94-binding protein sandwich ELISA) in a sample. FIG. 14 b is a result of an ELISA assay used to measure the PSP94-binding protein in a sample using the method illustrated in FIG. 14 a;
FIG. 15A represents concentration of total PSP94 levels from serum of individuals in low (<4 ng/ml) and high (>4 ng/ml) PSA categories;
FIG. 15B represents concentration of free PSP94 levels from serum of individuals in low (<4 ng/ml) and high (>4 ng/ml) PSA categories;
FIG. 15C represents concentration of total PSP94 Binding protein levels from serum of individuals in low (<4 ng/ml) and high (>4 ng/ml) PSA categories;
FIG. 15D represents concentration of corrected free PSP94 levels from serum of individuals in low (<4 ng/ml) and high (>4 ng/ml) PSA categories. Free PSP94 values were corrected since 1-5% of PSP94 binding protein (and complexed PSP94) remained after absorption protocol. The correction subtracts the bound PSP94×proportion of PSP94 binding protein not absorbed from the uncorrected free PSP94 value and;
FIG. 16 represents total PSP94 binding protein concentration compared to total PSP94.
DETAILED DESCRIPTION OF THE INVENTION
PSP94 was used as bait in the isolation, identification and purification of a PSP94-binding protein. For that purpose, labeled-PSP94 was used to detect the presence of the PSP94-binding protein(s) in serum fractions that were submitted to various purification steps. In addition, PSP94 was used for affinity chromatography purification of the PSP94-binding protein. Examples described below illustrate the purification, identification and utility of the PSP94-binding protein.
PSP94 was also used for producing antibodies and for isolating, identifying and purifying anti-PSP94 antibodies.
EXAMPLE 1
Isolation of PSP94, Radiolabeling of PSP94 and PSP94-Binding Protein Kinetic Analysis
Isolation and Purification of PSP94 from Human Seminal Plasma
PSP94 was either prepared as described in Baijal Gupta et al. (Prot. Exp. and Purification 8:483-488, 1996) or alternatively, PSP94 was isolated and (substantially) purified as follow.
The procedures were carried out at 4° C. Semen samples (Bioreclamation) were thawed at 4° C. for 4-6 hours. Samples were pooled together and the volume was measured. A sample was kept for SDS-Page analysis. Samples were cleared of the sperms by centrifugation (4° C.) at 5000×g for 10 minutes.
Seminal plasma was precipitated overnight by adding 7 volumes of cold ethanol (without stirring). The next day, the sample was centrifuged (4° C.) at 3000 g for 10 min, washed twice with cold ethanol and was centrifuged between washings. Then, the pellet was resuspended with Endotoxin-free H 2 O, to the original volume. The sample was transfered to a cold container about 4 times bigger in volume than the volume to lyophilise. Prior to lyophilisation, the sample were frozen by placing the Erlenmeyer at 45° in a slurry of dry ice/methanol and swirled until the seminal plasma was completely frozen, then it was lyophilised. This powder was found to be stable and was kept at −80° C. in a tight container filled with Nitrogen.
The mixture was reconstituted by adding 1 volume of endotoxin-free water (with reference to the original volume of seminal plasma) and 2 volumes of ice cold Buffer A (50 mM PBS pH 7.5, 2.5 mM EDTA pH 8.0, 1.5 mM PMSF), to which PMSF was freshly added, and was mixed to homogenise.
The pH of the reconstituted seminal plasma was adjusted to 6.0 using 0.1 M acetic acid and the volume of the resulting solution (pH 6.0) was measured.
Solid ammonium sulfate was added to from concentration of 0-30% (176 g/L) by slowly and constant stirring. The solution was stirred in cold for 1.5 hour.
The equilibration of cation exchange column was started with 10 mM sodium phosphate Buffer pH 6.3 according to the manufacturer's instructions for use the next day. The solution was transferred into appropriate centrifuge tubes and was centrifuged 60 min at 12,000×g in a refrigerated centrifuge.
The supernatant was saved and transfered into a fresh cold container. A sample was kept for SDS-Page analysis. The pellet was kept for record.
The supernatant volume was measured with a graduated cylinder. Ammonium sulfate was slowly added to the supernatant to obtain a final concentration of 30-70% (273 g/L). The mixture was stirred for 1.5 hour.
The solution was transferred into centrifuge tubes and was centrifuged 60 min at 12,000×g in a refrigerated centrifuge.
The pellet was saved and the supernatant was set aside. The pellets were scooped from each tube into a cold glass Dounce Tissue grinder. The pellet was dissolved in as small a volume of Buffer B (2.5 mM EDTA pH 8.0, 10 mM sodium phosphate pH 6.3) as possible (around 1 ml/2 ml of starting material).
A 1,000 MWCO dialysis tubing (Biolynk (Spectrum): 132103) for dialysis was prepared and the resuspended pellet was added to the tubing which was then sealed with clips. One volume of empty space was left to allow volume increase during dialysis. Dialysis was carried out against Buffer B overnight, using a container of around 15 liters of buffer. The next day, pH was verified to be similar or the same as buffer B.
Material was removed from dialysis tubing and was kept on ice. The material was tested by UV absorption at 280 nm. A sample was kept for SDS-Page analysis. Total protein concentration was calculated assuming that A280 (absorbance at 280 nm) of 1.0 equals to 1 mg/ml of protein.
The 200 mls Macro-prep High S Support column (BioRad: 156-0030, BioRad column: 737-5031) was used for a subsequent purification step. This column has a capacity of approximately 1600 mg of proteins. So, if needed, the sample may be divided for multiple runs making sure not to go over the capacity of the column.
Before loading the sample, the column was equilibrated with 10 mM Phosphate Buffer pH 6.3.
The dialysed, ammonium sulfate precipitated sample was loaded on the column. 10-13 mls fractions were collected and placed at 4° C.
Once the entire sample volume had passed into the column, further equilibration buffer (10 mM Phosphate Buffer, pH 6.3) was added. Fractions were collected until A280 measured below 0.1. Several fractions were analyzed on SDS-Page to determine the limit of PSP94 elution. Fractions containing PSP94 were pooled and all the other fractions (O.D.>0.1) are kept at −80° C. The volume of the pooled fractions was measured and the A280 read. Again, total protein concentration was calculated assuming that A280 (absorbance at 280 nm) of 1.0 equals 1 mg/ml of protein.
A sample of the pooled fractions was kept for SDS-Page analysis. The samples may be frozen or may be further purified by anion exchange.
Equilibration of the anion exchange column with 30 mM of Tris-HCl pH 8.8 was started according to the manufacturer's instructions.
The material collected from the cation column was pooled and brought to pH 8.8 using 2M Tris-HCl, pH 8.8. The final Tris concentration was below 50 mM. The protein concentration was kept at or higher than 0.8 mg/ml.
60 mls Macro-prep High Q Support (BioRad: 156-0040, BioRad column: 737-5031) column was used for a subsequent purification step. This column has a capacity of approximately 480 mg of proteins. So, if needed, the sample may be divided for multiple runs making sure not going over the capacity of the column.
Before loading the sample, the column was equilibrated with 30 mM Tris-HCl Buffer pH 8.8 (according to the manufacturer's instructions).
The sample was loaded on the column and 10-13 mls fractions were collected and placed at 4° C.
Once the entire sample volume had passed through the column, 50 mM Tris-HCl pH 8.8 (washing buffer) was added until the A280 returned to baseline. Stepwise elution with 250 mM Tris-HCl pH 8.8 until the A280 reached baseline was performed. A final elution with 300 mM Tris-HCl pH 8.8 until the A280 reached baseline was carried out. When no peak was seen, elution was continued with 350 mM Tris-HCl pH 8.8 and 400 mM until a peak was observed. Samples were kept for SDS-Page analysis. Fractions that did not contain pure PSP94 were frozen.
Fractions that contained pure PSP94 protein were pooled and concentrated with Amicon concentrator using a 1,000 MWCO membrane (molecular weight cut-off) according to the manufacturer's instructions (VWR: 29300-714) until the volume was approximately 10 ml. Dialysis was carried out for 18 hrs against 500-1000× volumes of 10 mM PBS pH 7.4.
Regeneration and packing of Detoxi-gel columns was performed according to the manufacturer's instructions (Biolynx: 20339). The regenerated matrix of one of the two columns was added to a 15 ml of 50 ml tube along with concentrated PSP94 and was incubated for 1 hr at room temperature on a rocking platform.
After incubation, the material was slowly transferred on the other packed column. All material was collected with gravity flow, on ice. Once all the material had passed into the column, cell culture grade PBS (endotoxin-free, Wisent (Multicell): 21 031CV) was added and the material was collected until A280 was lower than 25.
The optical density was measured and protein concentration was calculated as indicated above. When PSP94 (protein) concentration was more than 1 mg/ml, there was no need to concentrate the material. However, when the protein concentration was lower, 1,000 MWCO centrifuge concentrators were used to bring it to at least 1 mg/ml and the filter was rinsed with cell culture grade PBS to remove PSP (PSP94) completely.
The material was sterilized by filtration using a 0.22 um syringe filter (ex. Millex: SLGP033RS). Aliquots were made in cryogenic tubes provided with a rubber sealing to prevent evaporation and were frozen at −80° C. Some aliquots were kept for characterization.
Multiple analyses were done to assess the purity, concentration and ‘activity’ of PSP94. For example, SDS-Page using coomassie and silver staining (e.g. using a 12% Polyacrylamide gel with MES buffer (Invitrogen NP0342BOX, NP0002)), Western blot using for example, the P1E8 antibody, endotoxin level (Charles River), Elisa to measure the binding capacity to the PSP Binding Protein, amino acid sequencing, Mass Spectrometry and RP-HPLC. Results of PSP94 purification are presented in Table A.
TABLE A *Total ω Total % Volume proteins PSP94 Recovery φ Purification Step (ml) (mg) (Elisa)(mg) of PSP94 (folds) Seminal Plasma 70 2,200 (100) 49 100 — Ammonium Sulfate 40 1,300 (59) 37 76 1.3 Macro-Prep Hi S 125 180 (8.2) 33 68 8.3 Macro-Prep Hi Q 15 37 (1.7) 27 55 32.4 Percentage yields based on the total protein in seminal plasma are indicated in parentheses ( ) *Total Protein estimated using Macro-BCA (BSA as a standard) ω Total PSP94 based on UV Abs 280 1.53 = 1 mg/ml φ Purification (folds) = % Recovery of PSP94/Percentage yield
Preparation of Labeled PSP94
Experiments to optimize 125 I-PSP94 labeling, 125 I-PSP94 binding assay to human male serum proteins and development of means to separate free—(i.e., unbound) and complexed—(i.e., bound, associated) 125 I-PSP94 were undertaken. Human male serum protein(s) that will bind to PSP94 (in the present case; 125 I-PSP94) will generate the formation of a complex of higher molecular weight than free-PSP94 (or free 125 I-PSP94).
Iodination of PSP94 was performed as followed. Twenty micrograms of native human PSP94 prepared as described in Baijal Gupta et al. (Prot. Exp. and Purification 8:483-488, 1996) in 15 microliters of 100 mM sodium bicarbonate (pH 8.0) was labeled using one millicurie of mono-iodinated Bolton-Hunter reagent at 0° C. following the manufacturer's instructions (NEN Radiochemicals). The reaction was terminated after 2 hours by the addition of 100 microliters of 100 mM glycine. The free iodine was separated from the iodine incorporated into the PSP94 by a PD10 disposable gel filtration column according to manufacturer's instructions (BIORAD). Typically, the proportion of iodine that became incorporated into the PSP94 protein was about 60%, giving a specific activity of about 30 microcuries per microgram of PSP94.
Optimization of the binding assay of human male serum proteins to 125 I-PSP94 was performed in order to identify the optimal incubation time, temperature, and separation conditions. Equilibrium (e.g., no further significant increase in binding as incubation time lengthens) was approached after a considerable incubation time at 37° C., so a 16 hours incubation time was selected. Separation of the complexed form (i.e., bound form) PSP94 (or complexed- 125 I-PSP94), having a higher molecular weight and the free-PSP94 (or free- 125 I-PSP94), having a low molecular weight, was effected by gel filtration chromatography, using Sephadex G100 resin (Amersham Pharmacia Biotech Ltd) packed into a 1×20 cm column. The molecular sieve chromatography was performed at 4° C. since at higher temperatures dissociation of the complex during the procedure was shown to be significant.
Based on the optimization results described above, radioligand binding analysis of PSP94-binding serum components (i.e., PSP94-binding protein) was performed. This assay was done in a total volume of 500 microliters. The test samples contained PSP94-binding protein (neat serum, or fractions from purification trials) 50 ng of radiolabeled PSP94, with or without excess free competitor (10 micrograms free PSP94 (unlabeled)) in phosphate buffered saline-gelatin (PBS-gelatin: 10 mM sodium phosphate, 140 mM NaCl, 0.1% gelatin (Fisher Scientific, Type A), pH 7.5, including 8 mM sodium azide as an antibacterial agent). Those were incubated for 16 hours at 37° C. At this time, the equilibrated mixture was placed on ice, and the components separated according to their molecular weight by molecular sieve chromatography at 4° C. using a 1×20 cm sephadex G100 column equilibrated with PBS-gelatin. After the sample had run into the column, 3 ml was discarded, and 20 fractions of 0.5 ml were collected. A single fraction of 30 ml was also collected at the end of the run.
The radioactivity (expressed in counts per minute (cpm)) in the collected fractions was measured using an LKB rack gamma counter, and the total radioactivity in the high molecular weight peak (generally contained within fractions 4-14) and low molecular weight peak (the remainder of the 0.5 ml fractions and the single 30 ml fraction) were calculated. A typical elution profile is illustrated in FIG. 1 .
FIG. 1 shows size exclusion chromatography results of proteins from human male serum bound to PSP94 radiolabeled with isotope 125 of iodine ( 125 I) (i.e., 125 I-PSP94) (specific biding). Binding of 125 I-PSP94 to human male serum protein is determined by the radioactivity, expressed in counts per minute (cpm), in each fraction. Non-specific binding was determined by including 10 μg of free PSP94 in the incubation mixture together with 250 μl of human male serum and 50 ng of 125 I-PSP94. The location of fractions containing free—(i.e., unbound) and complexed (i.e., bound)-PSP94 are indicated in the graph. The majority of the free PSP94 ( 125 I-PSP94) eluted later than fraction 20. Typically, about 33% of the total radioactive PSP94 added to the 250 microliters of human serum eluted in the earlier fractions as part of the PSP94-binding protein complex, and about 67% of the radioactive PSP94 remained uncomplexed eluting in the later fractions. In the competitive control, with the inclusion of 10 micrograms of unlabelled PSP94 in the incubation mixture, only about 3% of the radioactive PSP94 eluted in the earlier fractions as part of a high molecular weight complex, confirming the specificity of the PSP94 for the PSP94-binding protein.
Using this methodology, and by varying the concentration of radiolabeled and competing PSP94 and maintaining the quantity of human male serum, constant (250 μl) it was possible to perform kinetic analysis of the equilibrium binding data. Assuming that PSP94 is about one fifth of the molecular weight of a PSP94-binding protein, this would suggest that each milliliter of serum has about 1 microgram of PSP94-binding protein. The total protein content of serum is about 80 milligrams per milliliter, so the PSP94-binding protein:total protein ratio in serum is approximately 1:80,000.
Further information from radioligand binding analysis indicated that a PSP94-binding protein is present in human female serum, virgin female human serum, fetal bovine serum, and pooled mouse serum.
EXAMPLE 2
Ammonium Sulfate Precipitation
From the kinetic results obtained in example 1, it was shown that the PSP94-binding protein was poorly abundant in human serum.
In order to isolate a PSP94-binding protein for further characterization and identification, a first purification step was performed by ammonium sulfate precipitation. To establish the appropriate concentration of ammonium sulfate necessary to precipitate a PSP94-binding protein, small scale ammonium sulfate precipitation trials were performed. The presence of a PSP94-binding protein in the precipitate was determined after dissolution and dialysis against PSP94 by radioligand binding analysis as discussed in example 1. These trials determined that the 32-47% ammonium sulfate fraction contained the vast majority of a PSP94 binding material as illustrated in FIG. 2 .
Ammonium sulfate precipitation was routinely performed on a larger scale. Briefly, 1 liter of male frozen serum (Bioreclamation Inc, New York) was thawed and added to 1 liter of cold 10 mM Sodium Phosphate, 140 mM NaCl, pH 7.5 (phosphate buffered saline; PBS), and to this 370 g of ammonium sulfate (BDH ACS reagent grade) was added slowly under constant stirring to bring the ammonium sulfate concentration up to 32%. After dissolution of the salt, the mixture (i.e., male serum containing ammonium sulfate) was stirred for 20 minutes before centrifugation at 5,000×g for 15 minutes.
The pellet was discarded, and the supernatant fraction of proteins containing a PSP94-binding protein was collected. Further ammonium sulfate (188 g) was added slowly under constant stirring to the supernatant fraction, bringing the total ammonium sulfate concentration to 47%. After 20 minutes, this mixture was also spun at 5,000×g, the supernatant was discarded, and the pellet was dissolved in a total of 500 ml of 10 mM MES ((2-[N-Morpholino]ethanesulfonic acid) hydrate), 100 mM NaCl, pH 6.5. This pellet was dialyzed using 6-8,000 molecular weight cut off dialysis tubing (Spectra/Por, Fisher Scientific Canada) with 16 liters of 10 mM MES, 100 mM NaCl, pH 6.5 for 16 hours at 4° C. followed by another dialysis step using a further 16 liters of the same buffer for an additional 7 hours. The protein concentration within the product was measured using 280 nm ultraviolet (UV) absorbance and the preparation was stored at −20° C. in 4 g of protein aliquots (generally about 150 ml). A typical ammonium sulfate precipitation assay is shown in FIG. 2 .
EXAMPLE 3
Ion-Exchange Chromatography Assays
Ion exchange chromatography (IEX) separates molecules based on their net charge. Negatively or positively charged functional groups are covalently bound to a solid support matrix yielding a cation or anion exchanger. When a charged molecule is applied to an exchanger of opposite charge it is adsorbed, while neutral ions or ions of the same charge are eluted in the void volume of the column. The binding of the charged molecules is reversible, and adsorbed molecules are commonly eluted with a salt or pH gradient.
Without prior knowledge of any characteristics of the PSP94-binding protein, the ability of anion and cation exchange matrices to absorb a PSP94-binding protein at a range of pH values was determined in a series of ion-exchange assays. Aliquots of ammonium sulfate precipitated serum were exchanged into the buffers indicated in table 3 using a Biorad DG 10 column equilibrated with the appropriate buffer according to the manufacturer's instructions. Seven hundred microliters aliquots were incubated with 500 microliters of ion-exchange matrix (prepared according to the manufacturer's recommendations). After incubation for 90 minutes at room temperature with gentle agitation, the mixture was spun at 1000×g for 5 minutes to separate the matrix from the supernatant. If a PSP94-binding protein is bound (adsorbed) to the matrix, it will remain bound to it after centrifugation and will not be present in the supernatant. The supernatant was immediately neutralized with 0.3 volumes of 250 mM TRIS pH 7.5 and 250 microliters of this solution was assessed in the 125 I-PSP94 binding assay described herein (example 1). Conditions tested and results of these assays are presented in table 3.
TABLE 3
125 I-PSP94
125 I-PSP94 binding
binding
before incubation
after incubation
Buffer
with matrix
with matrix
Cation Matrix:
Macro Prep
High S
(BIORAD)
pH 4.7
10 mM Citrate
9.5%
0.08%
pH 5.7
10 mM MES
11.9%
7.7%
pH 6.7
10 mM MES
20.6%
18.6%
pH 7.9
10 mM MOPS
20.5%
11.9%
Anion Matrix:
Macro Prep
High Q
(BIORAD)
pH 5.7
10 mM MES
11.9%
0.73%
pH 6.7
10 mM MES
20.6%
0.66%
pH 8.0
10 mM Bicine
14.1%
0.81%
pH 9.0
10 mM Bicine
12.5%
0.65%
The major findings from these ion-exchange chromatography assays indicate that temporary exposure of a PSP94-binding protein to extremes of pH (8 and above, and 6 and below) resulted in a reduced ability of a PSP94-binding protein to bind to PSP94, suggesting that a PSP94-binding protein is pH sensitive. No adsorption of PSP94-binding protein to the cation matrix was seen at pH 4.7. Some adsorption to the cation matrix was seen at pH 5.7 and maximal adsorption was seen at pH 6.7. These results may suggest an isoelectric point of about pH 5.
The anion-exchange chromatography assays indicated good adsorption of a PSP94-binding protein to the matrix between pH 5.7 and 9.0, consistent with an isoelectric point of 5. It was clear that a preferred purification strategy would have to use the anion-matrix, because good adsorption could be attained at neutral (non-denaturing) pH values. So the anion-exchange matrix, and the 10 mM MES buffer at pH 6.5 was selected for further work using salt concentration elution rather than pH elution.
Optimization of conditions of PSP94-binding protein elution from the anion-exchange matrix was performed using various sodium chloride concentration.
A column (1×15 cm) containing Macro Prep High Q was equilibrated with buffer containing 10 mM MES, 100 mM NaCl, pH 6.5 and run at 0.5 ml per minute. Seven milliliters of the 32-47% ammonium sulfate cut (i.e., starting material of table 4) equilibrated into the same buffer, was applied to the column, and various buffers were applied to elute a PSP94-binding protein. The eluant was monitored with a UV recorder. The fractions were collected, and buffer was exchanged into PBS using CentriPrep concentrators with a molecular weight cut off of 10 kDa (Amicon). These samples were tested in the 125 I-PSP94 binding assay described in example 1. Table 4 summarizes the different conditions used and the results obtained in this experiment. A star (*) indicate that some losses was experienced during buffer exchange. Protein concentrations were estimated from absorbance at 280 nm (A280) with 1 OD unit equivalent to 1 mg of protein.
TABLE 4
Sodium chloride
Total protein
Total protein in
% 125 I-PSP94
concentration
Eluted (mg)
binding assay
bound
Starting material
179 mg*
7.2 mg
12.7%
(ammonium sulfate cut)
100 mM (flow through)
50 mg
0.67 mg
0.89%
200 mM
37 mg
0.80 mg
1.4%
300 mM
12 mg
0.63 mg
24.4%
400 mM
5 mg
0.30 mg
1.5%
500 mM
8 mg
0.62 mg
0.9%
1000 mM
7 mg
—
—
From these data, it is clear that the buffer containing 300 mM NaCl was effective and would be preferably used for eluting a PSP94-binding protein from the anion-exchange matrix. Using these results, a scale up ion-exchange protocol was developed allowing the application of 4 g of ammonium sulfate precipitated serum extract to a 5 cm×12 cm anion-exchange matrix as described below.
EXAMPLE 4
Large-Scale Anion-Exchange Chromatography Purification of PSP94-Binding Protein
An anion exchange column (5 cm diameter×12 cm length, Macro-Prep Hi Q, Biorad) was prepared and equilibrated in accordance with the manufacturer's guidelines in 10 mM MES, 100 mM NaCl, pH 6.5 and run at room temperature with a flow rate of about 3 ml per minute. An aliquot of ammonium sulfate precipitated serum (from example 2; 4 g total protein in about 150 ml of solution) was applied to the column which, was then washed with about 250 ml of 10 mM MES, 100 mM NaCl, pH 6.5 ( FIG. 3 ). Elution was performed with about 400 ml of 10 mM MES, 200 mM NaCl, pH 6.5 buffer, followed by elution with 10 mM MES, 300 mM NaCl. The 300 mM eluting fraction was collected ( FIG. 3 ). The profile of the eluting proteins was monitored by UV absorbance at 280 nm on a chart recorder. A typical profile is illustrated in FIG. 3 . FIG. 3 is a graph showing anion-exchange chromatography results using a MacroPrep High Q anion exchange column, loaded with proteins purified by ammonium sulfate (about 4 grams). Proteins are eluted with stepwise increases in sodium chloride concentration. The peak located between point A and B represents the protein fraction containing a PSP94-binding protein. Proteins are detected by the absorbance measured at 280 nm.
The column could be regenerated with 10 mM MES, 1 M NaCl, pH 6.5 (300 ml) followed by an equilibration with 500 ml of 10 mM MES, 100 mM NaCl, pH 6.5. Sodium azide was added to this buffer at 0.05% (w/v) for storage of the column for greater than 24 hours.
The 300 mM fraction (about 90 ml) was collected (between markers A and B, FIG. 3 ) and this was shown previously to contain the majority of a PSP94-binding activity. This preparation identified “partially pure PSP94-binding protein” (PPBP) was concentrated to about 20 ml in centrifugal concentrators according to the manufacturer's instruction (Centriprep 10, Amicon) diluted with PBS to 60 ml, concentrated to 20 ml, further diluted with PBS to 60 ml, concentrated to 20 ml, and finally diluted with PBS to give a solution with an A280 of 2.0 (generally a final volume of about 150 ml). This solution was stored at −20° C. After a total application of 20 g of protein (5 cycles) the column was sanitized using 1 M NaOH and re-equilibrated in 10 mM MES, 100 mM NaCl, pH 6.5 using the protocol described by BIORAD.
Ammonium sulfate fractionation (i.e., precipitation) and anion exchange chromatography have resulted in approximately 4 fold and 10 fold purification of a PSP94-binding protein respectively. In neat serum, estimations indicated that the ratio of PSP94-binding protein:total protein was 1:80,000. The efficiency of the two protein purification steps described in example 2 and example 4 were monitored using the PSP94 radioligand binding assay described in example 1. In both steps, the vast majority of the PSP94 binding material was confined within a single fraction. From this information, it appears that in combination, these two steps result in an efficient purification process with little loss (qualitatively) of the PSP94 binding material. However, assuming losses are small, the partially purified binding protein (PPBP) yielded by the combination of the two protein purification steps described in examples 2 and 4, should contain about 1 part of binding protein: 2000 parts of other proteins, by mass.
EXAMPLE 5
Affinity Chromatography Assays
Preparation of affinity matrix for PSP94-binding protein purification was performed as followed. Approximately 0.5 g of cyanogen bromide activated sepharose CL 4B (Sigma Chemical Company) was swelled in 1 mM HCl and prepared as per the manufacturer's recommendations. To 1 ml of this matrix, 5 ml of a solution containing 5 mg of PSP94 purified as described in Baijal Gupta et al. (Prot. Exp. and Purification 8:483-488, 1996) in 100 mM NaHCO 3 0.5 M NaCl, pH 8.0 was added and the reactants incubated at 4° C. with periodic agitation. At time intervals, the reactants were spun at 200×g for 2 minutes, and the absorbance at 280 nm (A280) expressed in optical density (OD) units, of an aliquot of supernatant was measured in order to determine the proportion of binding of PSP94 to the matrix. Results showing the time course of conjugation (i.e., binding) of PSP94 to the activated sepharose (i.e., matrix) are summarized in table 5.
TABLE 5
Duration of
A280 (OD) units
A280 (OD) units
% of PSP94
reaction (min)
not bound to matrix
bound to matrix
incorporation
0 (start)
5.1
0
0
5
4.7
0.48
9.6
15
3.0
2.1
41
30
2.0
3.1
61
60
1.6
3.5
69
The conjugation reaction was continued until 70-80% of the PSP94 had bound to the matrix (after about 60 minutes in the preparation illustrated in table 5). At this time, 1 ml of 200 mM glycine was added to block any further reactive groups and the slurry was incubated overnight at 4° C. with gentle agitation. The matrix was washed according to the manufacturer's recommendations and diluted in PBS to give a slurry with a concentration with respect to PSP94 of 1 microgram per microliter. Sodium azide (NaN 3 ) was added to 0.05% as an anti-microbial agent.
Based on the results of optimization assay described above, a PSP94 affinity matrix was prepared by conjugating PSP94 to cyanogen bromide activated sepharose. The matrix typically had 4 micrograms of PSP94 per microliter of packed matrix, and a working slurry with 1 microgram of PSP94 per microliter was prepared by dilution with PBS containing 0.05% NaN 3 . The PSP94 affinity matrix (at a concentration of 5 micrograms per milliliter with respect to PSP94) was added to the partially pure PSP94-binding protein. Tween 20 at a concentration of 0.1% (v/v) and NaN 3 at 0.05% (w/v) were also included in the mixture, which was then incubated at 34° C. for 18 hours on a rocking table. In a parallel control experiment, free-PSP94 was also added at a concentration of 50 micrograms per milliliter. The addition of free PSP94 in this control experiment would compete with the PSP94 conjugated to the matrix for the binding of a PSP94-binding protein. This will reverse the binding of a PSP94-binding protein to the affinity column thus enabling the identification of proteins specifically binding to PSP94. The affinity matrix was separated from the supernatant by rapid filtration, and the matrix was extensively washed in PBS at 4° C. The matrix was collected and boiled in sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) reducing sample buffer (final concentration in sample: 5 mM Tris pH 6.8, 2% (w/v) SDS, 10% glycerol (v/v), 8 mM dithiothreitol, 0.001% Bromophenol blue) to dissociate the bound proteins and these were resolved by 7.5% SDS-PAGE. Result of this experiment is illustrated in FIG. 4
FIG. 4 shows results of a sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) loaded with samples obtained following PSP94-affinity chromatography. The gel was run in an electric field and stained with Coomassie Brilliant Blue. Lane 1 represents the molecular weight marker (Kaleidoscope prestained standards, Bio-Rad). Lane 2 represents proteins bound to the PSP94-conjugated affinity matrix. Lane 3 represents proteins bound to PSP94-conjugated affinity matrix and incubated with excess of PSP94. Note that at least two proteins, A and C, remain present in the two lanes, (lane 2 and 3). Two bands, B and D, are present in the lane 3 but not in the control experiment (lane 2). These bands (B and D) are likely to be specific PSP94-binding proteins.
EXAMPLE 6
Optimization of PSP94-Binding Protein Elution from the PSP94-Affinity Matrix
A range of conditions were assessed in order to dissociate a PSP94-binding protein from the affinity matrix using less denaturing conditions than boiling in SDS-PAGE sample buffer (either in non-reducing conditions or not). Conditions tested are summarized in table 6. Undenatured active PSP94-binding protein is required for antibody generation and further experimentation and development. Aliquots of PSP94-affinity matrix that had been pre-incubated with partially pure PSP94-binding protein and washed (i.e., with binding protein attached) were incubated for 1 hour in the elution (dissociation) conditions listed in table 6. After incubation, the affinity matrices were removed from the eluting buffers by centrifugation. The matrices were washed in PBS, and boiled in non-reducing SDS-PAGE sample buffer (final concentration in sample: 5 mM Tris pH 6.8, 2% (w/v) SDS, 10% glycerol (v/v), 0.001% Bromophenol blue) and proteins were resolved on 7.5% SDS-PAGE. If proteins remains associated with the matrix after elution, the conditions are not suitable for an appropriate dissociation. Thus if a PSP94-binding protein is absent from the SDS-PAGE illustrated in FIG. 5 , elution (dissociation) conditions are suitable. Non-reducing conditions were found to provide superior separation conditions, because the major contaminating band was left at the top of the gel, rather than between the two PSP94-binding protein bands. Conditions tested and results of this experiment are illustrated in FIG. 5 and summarized in table 6.
TABLE 6
Effect on
Lane
Dissociation conditions
PSP94-binding protein
A
Molecular weight marker
—
B
No treatment
None
C
1 hour in PBS at 34° C.
None observable
D
1 hour in water at 34° C.
None observable
E
300 μg PSP94 in 1 ml
Near total elution from matrix
PBS at 34° C.
F
(Competition control)
(near full competition)
G
2 M urea
None observable
H
8 M urea
Some loss of binding
I
100 mM sodium acetate pH 2.7
Some loss of binding
J
100 mM CAPS pH 11.0
Some loss of binding
FIG. 5 shows a SDS-PAGE loaded with samples obtained following the elution of a PSP94-binding protein from the PSP94-conjugated affinity matrix using different eluting (dissociation) conditions. After incubation, in the different eluting buffers, the affinity matrix was removed from the eluting buffer by centrifugation. The matrix was washed in PBS, and boiled in non-reducing SDS-PAGE sample buffer. The SDS-PAGE was run in an electric field and was stained with Gelcode® Blue Code Reagent (Pierce). Arrows represent the position of the high molecular weight binding protein (HMW) and the low molecular weight binding protein (LMW). Lane A represents the molecular weight marker (Kaleidoscope prestained standards, Bio-Rad). Lane B represents untreated sample. Lane C represents sample incubated for 1 hour in PBS at 34° C. Lane D represents sample incubated for 1 hour in water at 34° C. Lane E represents sample incubated with 300 μg of PSP94 in 1 ml of PBS at 34° C. Lane F represents the competition control, where the matrix was incubated with the PPBP in the same way as the sample from lane B, but included in this incubation was a saturating excess of free PSP94. Lane G represents sample incubated in 2 M urea. Lane H represents sample incubated in 8 M urea. Lane I represents sample incubated in 100 mM sodium acetate at pH 2.7. Lane J represents sample incubated in 100 mM 3-(Cyclohexylamino)-1-propanesulfonic acid (CAPS) at pH 11.0.
From the experiment described above, it is clear that a PSP94-binding protein and PSP94-affinity matrix interaction was highly stable under a variety of conditions. Some dissociation was seen with 8 M urea, and extremes of pH, however these denaturing conditions were less favored than non-denaturing competitive dissociation using excess free ligand (i.e., PSP94). This approach was therefore selected in order to purify the active PSP94-binding protein.
Data indicate that the HMW and LMW bands of FIG. 5 are the same as bands B and D of FIG. 4 , respectively.
EXAMPLE 7
PSP94-Binding Protein Purification by PSP94-Affinity Chromatography
One hundred milliliters of partially pure PSP94-binding protein (preparation generated as described in example 4), containing 0.1% (v/v) Tween-20 and 0.05% (w/v) NaN 3 , was incubated with 250 micrograms (with respect to PSP94) of affinity matrix for 16 hours at 34° C. The matrix was separated from the soluble fraction by rapid filtration using a disposable Poly-Prep Column (Bio Rad). The liquid was forced through the column by applying air pressure from a 10 ml syringe attached to the column end cap. The matrix was washed three times with 10 ml of ice cold PBS similarly, and the matrix was collected from the column's polymer bed support with a micropipette. The matrix was resuspended in 1 milliliter of 10 mM sodium phosphate, 500 mM NaCl pH 7.5 containing 2 mg of free PSP94 and incubated with gentle agitation for 5 hours at 34° C. The matrix was then separated from the solution by centrifugation (1000×g for 30 seconds) and the supernatant (containing the eluted PSP94-binding protein and free PSP94) was resolved by molecular sieve chromatography at room temperature using a 1×20 cm sephadex G100 column equilibrated with 10 mM sodium phosphate, 500 mM NaCl, pH 7.5 and run at a flow rate of approximately 0.7 ml per minute. The absorbance at 280 nm of the eluant was recorded on a chart recorder ( FIG. 6 ). Qualitative assessments of PSP94-binding protein capture, elution, and purified product were made by non-reducing 7.5% SDS-PAGE ( FIG. 7 ).
FIG. 6 shows affinity chromatography (using PSP94-conjugated affinity matrix (Sephadex G-100)) results of samples purified by ammonium sulfate precipitation and anion-exchange chromatography. PSP94-binding protein was eluted from the column by adding excess PSP94 (free-PSP94). The high molecular weight proteins were collected (between points A and B) in a total volume of 4 ml. This solution was buffer exchanged into PBS (150 mM NaCl) using centrifugal concentrators (Centricon-10 from Amicon) and concentrated to approximately 100 ng per microliter. Typical yield=40 micrograms from 100 ml of PPBP starting material. The peak located between points A and B represents a PSP94-binding protein fraction. Proteins are detected and quantified by the absorbance measured at 280 nm. Results obtained indicate a proper separation between free PSP94 and a PSP94-binding protein.
FIG. 7 is a picture of a SDS-PAGE (7.5%) performed in non-reducing conditions. Lane A is the molecular weight marker (Kaleidoscope prestained standards, Bio-Rad). Lane B represents a PSP94-affinity matrix after incubation with a PSP94-binding protein purified by ammonium sulfate precipitation and anion-exchange chromatography, and prior to elution with competing (i.e., excess) PSP94 (i.e., free-PSP94). Lane C represents the competition control. Lane D represents the affinity matrix after elution with excess PSP94. Lane E represents the final eluted and concentrated (substantially) pure PSP94-binding protein. Results obtained indicate that affinity chromatography increase the purity of a PSP94-binding protein(s) in a significant manner.
The purification process of a PSP94-binding protein has been summarized in FIG. 8 .
EXAMPLE 8
PSP94-Binding Protein Amino-Terminal Amino Acid Sequencing
A SDS-PAGE gel was prepared as described in example 5. However the proteins were transferred to sequencing grade PVDF membranes (ProBlott membranes, Applied Biosystem) using a Mini Trans-Blot transfer cell (Bio-Rad) according to the manufacturer's recommendations for sequencing preparation. This membrane was stained with Coomassie Brilliant blue, and analyzed by amino-terminal (i.e., N-terminal) amino acid sequencing. The amino-terminal amino acid sequencing was carried out for bands B, C and D illustrated in FIG. 4 .
TABLE 7
Band
Amino acid Sequence
B
(L)TDE(E)KRLMVELHN
(Corresponding to residues 28-41 of SEQ ID NO.:2)
C
Ubiquitous immunoglobulin sequence
D
LTDEEKRLMVELHNLYRAQVSPTASDMLHM
(Corresponding to residues 28-57 of SEQ ID NO.:2)
As seen in table 7 bands B and D have the same N-terminal amino acid sequences, so these are likely to be different forms of the same protein, with B possibly representing some form of aggregate (multi-mere), or alternatively, B and D being alternatively spliced, or processed.
EXAMPLE 9
Cloning of a PSP94-Binding Protein Gene Sequences
Total RNA was isolated from 2×10 6 Jurkat clone E6-1 cells (TIB 152, American Type Culture Collection, Manassas, Va.) or from healthy blood donor peripheral blood mononuclear cells using Tri-reagent (Molecular Research Center Inc., Cincinnati, Ohio). RNA was ethanol-precipitated and resuspended in water. RNA was reverse transcribed into cDNA using the Thermoscript RT-PCR System (Life Technologies, Rockville, Md.). The cDNA was subsequently amplified by polymerase chain reaction (PCR) using Platinum Taq DNA Polymerase High Fidelity (Life Technologies) using a 5′-primer (5′-ATGCACGGCTCCTGCAGTTTCCTGATGCTT-3′) and a 3′-primer (5′-GCCCACGCGTCGACTAGTAC(T) 17 -3′)(Life Technologies 3′ Race adapter primer, Life Technologies). The 5′-primer DNA sequence was based on PSP94-binding protein amino acid sequence and partial cDNA sequence published in Gene Bank database (National Institute of Health, U.S.A.) G.B. Accession No. AA311654 (EST182514 Jurkat T-cells VI Homo sapiens cDNA 5′ mRNA sequence). Amplified DNA was resolved by agarose gel electrophoresis, excised from the gel and concentrated using Qiagen II DNA extraction kit (Qiagen, Mississauga, ON, Canada). Purified DNA was ligated into pCR2.1 plasmid (Invitrogen, Carlsbad, Calif.) and used to transform E. coli , strain TOP10 (Invitrogen). Ampicillin-resistant colonies were screened for cDNA-positive inserts by restriction enzyme analysis and DNA sequence analysis.
Blasting of DNA sequence of PSP94-binding protein into Gene Bank has identified some DNA sequence of unknown utility such as, for example, Gene Bank accession numbers XM 094933 (PRI Feb. 6, 2002), BC022399 (PRI Feb. 4, 2002), NM 153370 (PRI Apr. 7, 2003), BC035634 (PRI Sep. 23, 2002), etc.
EXAMPLE 10
Tissue Expression of PSP94-Binding Protein Messenger RNA
A PSP94-binding protein messenger RNA (mRNA) was isolated and the size and relative expression level in human tissues was determined by Northern blot. Commercial Northern blots containing 1 or 2 micrograms of human tissue poly-A RNA per lane (Multiple Tissue Northern (MTN™) Blot, Clontech, Palo Alto, Calif.) were hybridized as per the manufacture's recommendations with a [ 32 P]-labeled PSP94-binding Protein cDNA probe which spanned PSP94-binding Protein cDNA sequences 346 to 745. The intensity of the band was quantified with an alpha imager 2000, model 22595. The relative intensity of the band was determined and given an arbitrary score ranging from + to +++. This scoring was based on the lowest detectable 2.0 kb signal band seen.
Quantification of the results illustrated in FIGS. 9 a and 9 b are summarized in tables 8 and 9 respectively. Briefly, RNA from brain, heart, skeletal muscle, colon, thymus, spleen, kidney, liver, small intestine, placenta, lung, prostate, testis, ovary, and peripheral blood lymphocytes (PBL) was analyzed for the expression of a PSP94-binding protein RNA expression.
TABLE 8
Tissue
RNA signal (+) size kb
Relative intensity
Brain
0
Heart
+2.0
+++
Skeletal muscle
+2.0
++
Colon
+2.0
+
Thymus
+2.0
+
Spleen
Kidney
Liver
Small intestine
+2.0
+
Placenta
Lung
Liver
TABLE 9
RNA signal (+)
Tissue
and size kb
Relative intensity
Spleen
Thymus
Prostate
+2.0
+++
Testis
+2.0 and 2.5
++
Ovary
+2.0
++
Small intestine
+2.0
+++
Colon
+2.0
+
PBL
EXAMPLE 11
Generation of Polyclonal Antibodies and Monoclonal Antibodies for Free PSP94, Bound PSP94 and PSP94-Binding Protein
Antibody Generation
The immunization scheme described herein was developed to promote the production of antibodies to PSP binding protein, or to PSP94. Anti-PSP94 antibodies such as, antibodies which bind to an epitope of PSP94 that is exposed when PSP94 is in a bound form (e.g., bound to a PSP94-binding protein), antibodies which bind to an epitope of PSP94 that is available only when PSP94 is in a free form (free of PSP binding protein) or antibodies which bind both the free and bound forms of PSP94.
Monoclonal Antibodies
Four Balb/c mice (identified a, b, c and d) were immunized subcutaneously with 15 micrograms each of a (substantially) pure PSP94-binding protein (i.e., this preparation also contains PSP94) preparation in TiterMax™ adjuvant. Twenty-one days later, all mice were given a second boost and after a further 8 days, the mouse serum was tested for reactivity for both PSP94 and PSP94-binding protein in the ELISA screening assay described above. Since the purification of a PSP94-binding protein involves saturating all the binding sites with PSP94, the sera of the animals immunized with the substantially pure PSP94-binding protein preparation, had also the possibility of being tested positive for both antigens.
Mice a and b were boosted intra-peritoneally with a further 15 μg of a PSP94-binding protein with no adjuvant. The remaining two mice (c and d) were boosted subcutaneously with a further 15 μg of a PSP94-binding protein together with 15 μg of native PSP94 in Titer Max™ adjuvant in order to increase the likelihood of obtaining antibodies to exposed epitopes of PSP94.
After a further 4 days, the spleens of mice a and b were harvested, the B lymphocytes collected, and fused with NSO myeloma cells in order to generate hybridomas (Galfre G. and Milstein C, Meth. Enzymol. 73:3-46, 1981). A hundred thousand splenocytes, in Iscove's MDM selection medium (supplemented with 20% FBS, HAT, 10 ng per ml interleukine-6, and antibiotics), were plated into each well of 96 well plates. Since antibodies are secreted from the cells, cell culture media (i.e., supernatant) may be harvested for characterization of the antibodies produced. After 10 days of incubation at 37° C., the supernatants of wells containing clones were assessed by an ELISA screening assay (see bellow). Clones producing antibodies showing a positive recognition (binding) of the PSP94 or PSP94-binding protein plates and free of unspecific binding to PBS coated plate, were selected for further investigation and characterization.
Desired (positive) hybridoma clones were plated into 6 well plates. The supernatants were re-tested for the presence of the specific antibody, and those of the clones remaining positive were passed through successive cycles of cloning by limiting dilution. Cloning in such a manner to ensure that the hybridoma cell line produced is stable and pure. Typically, two cycles of cloning were necessary to achieve this goal. Multiple vials of frozen stocks were prepared, with one vial from each batch tested for viability and antibody production. Results of clone characterization are illustrated in table 10.
Alternatively, for the generation of anti-PSP94 antibodies, mice are immunized with a PSP94 preparation (substantially pure PSP94) in TiterMax™ adjuvant. Boosting and hybridoma procedures are performed as described above.
Therefore, antibodies which bind to an epitope of PSP94 that is exposed when PSP94 is in a bound form are produced using the immunization schemes described above. The binding specificity of the antibody is determined in an ELISA assay or in a Western blot assay by contacting the desired antibody which is conjugated with a reporter molecule with a complex formed by PSP94 and a PSP94-binding protein. When the antibody binds to the complex, a positive reaction arises upon detection of the signal generated by the reporter molecule.
Antibodies which bind to an epitope of PSP94 that is available only when PSP94 is in a free form (free of a PSP binding protein) are also produced using the immunization schemes described above. The binding specificity of the antibody is determined in an ELISA assay or in a Western blot by contacting the desired antibody which is conjugated with a reporter molecule with a substantially purified PSP94 and in a parallel experiment by contacting the antibody with a complex formed by PSP94 and a PSP94-binding protein. An antibody (e.g., conjugated with a reporter molecule) which binds to an epitope of PSP94 that is available only when PSP94 is in a free form will produce a positive reaction when contacted with a substantially purified PSP94 and a negative reaction (i.e., no signal (color) is detected) when contacted with the complex.
Antibodies which bind both the free and bound forms of PSP94 (total PSP94) are also produced using the immunization schemes described above. However an antibody which binds both the free and bound forms of PSP94 will produce a positive reaction when contacted with a substantially purified PSP94 and will also produce a positive reaction when contacted with the complex formed by PSP94 and a PSP94-binding protein.
Hybridomas producing a desired antibody are isolated, expanded and stored as described above.
Monoclonal Antibody Purification.
Mouse IgG1 monoclonal antibodies were purified using a high salt protein A procedure as detailed in Antibodies: A Laboratory Manual eds Harlow and Lane, Cold Spring Harbor Laboratory (for reference see above).
Monoclonal Antibody Isotyping
Isotyping was performed using a Mouse Monoclonal Antibody Isotyping Kit (Roche Diagnostics Corporation Indianapolis USA). This kit provides information relating to the class (IgG, IgA or IgM) the type of light chain (kappa or lambda) and IgG subtype (IgG1, IgG2a, IgG2b or IgG3). The antibodies tested were mainly of the IgG1 kappa subtype. However, one antibody was shown to be of the IgM kappa subtype (B26B10).
Polyclonal Antibodies
The polyclonal antibody to PSP94 of the present invention was produced by immunizing New Zealand white rabbits. Each rabbit was immunized with 50 micrograms of purified human PSP94 (>95% purity) in Freunds complete adjuvant. 3 weeks later the rabbits were boosted with a further 50 micrograms of PSP94. After a further 4 weeks, the rabbits were bled every week for a period of 12 weeks (25 ml bleed each week). The serum was separated from the whole blood and affinity purified antibodies were purified from the IgG fraction as described below.
First Step: Purification of IgG Fraction Using Protein A
1.5 g of Protein A immobilized on Sepharose CL-4B obtained from Sigma (Cat no. P-3391) was swelled and washed in 20 volumes of PBS (0.14 m NaCl, 10 mM sodium Phosphate, pH 7.4). Once the sepharose was swelled, two additional aliquots of PBS were used to wash the matrix twice. The total volume of swelled matrix was about 5 ml which correspond to a capacity of binding of at least 50 mg of rabbit IgG.
Twenty-five milliliters of rabbit serum was diluted with an equal volume of PBS and filtered through a 0.22 micron filter. Five milliliters of protein A slurry were added to this mixture and the mixture was agitated on a rocker for 1 hour at room temperature. The suspension was then poured into a 20 ml disposable plastic chromatography column, and the flow through discarded. The column was washed with PBS and the O.D. (or OD; optical density) of the flow through monitored periodically at 280 nM until it was stabilized to less than 0.1.
0.1 M glycine at pH 3.0 was carefully applied to the matrix and 1 ml fractions were collected directly into 100 microlitres of 1.0 M Tris pH 8.0. The IgG eluted within 10 ml. Any tightly bound proteins were then eluted and discarded with 0.1 M Glycine pH 2.0, and the column was re-equilibrated with PBS. The OD280 of the collected fractions was measured, and the fractions containing the majority of the IgG were pooled. The yield was about 40-50 mg of IgG from an initial starting volume of 25 ml of rabbit serum (an OD280 of 1.4 for a 1 mg/ml solution). The IgG fraction were either stored at 4° C. with 0.05% azide for short term storage (about 1 week) or frozen for long term storage.
Step 2: Affinity Purification of Anti-PSP94 IgG on PSP94 Affinity Column.
Step 2 A: Matrix Preparation
A first step in purification of an anti-PSP94-specific IgG antibody was to produce an affinity purification matrix. It was found that a good efficiency may be achieved using a column with about 1 mg of PSP94 per milliliter of matrix. This protocol produces about a 5 ml column with 5 mg of conjugated PSP94.
Seven milligrams of PSP94 were prepared in 5 ml of 200 mM sodium bicarbonate buffer (about pH 8, no need for pH adjustment). The OD 280 of this solution was about 2.24.
Two grams of cyanogen bromide activated sepharose (Sigma) was weighted and swelled for 3×10 minutes in 100 ml of ice cold 1 mM HCl to remove stabilizers. The matrix was kept in suspension during the process, and the buffer was changed either by cold rapid filtration or cold centrifugation. Finally, the sepharose was washed with 100 ml of ice cold water. The matrix was pelleted and excess water removed.
The OD of the cold PSP94 solution was first measured and the solution was added to 5 ml of the cold matrix, and mixed. After 1 minute, 1 ml of slurry was removed and spined for 10 seconds in a microfuge. The supernatant was removed and the OD 280 was measured. The removed slurry and antibody solution was replaced to the conjugation mixture. The reaction was continued until the OD measurement indicated that between about 70 and 80% of the PSP94 has been removed from the solution. The reaction was stopped by adding 10 ml of 0.1 m Glycine in 100 mM sodium bicarbonate. The mixture was incubated for 30 minutes at about 4° C. Exemplary results of conjugation of PSP94 to the sepharose matrix are illustrated in Table B.
TABLE B
Progress of PSP94 conjugation to sepharose
Time
OD280 of
Volume
A units
A units
Conjugation
(min.)
solution
(ml)
on (mg)
off (mg)
efficiency
0
2.24
5
0.0 (0.0)
11.2 (7.0)
0%
1
0.96
10
1.6 (1.0)
9.6 (6.0)
14%
2
0.63
10
4.9 (3.1)
6.3 (3.9)
44%
5
0.35
10
8.3 (4.8)
3.5 (2.2)
69%
Stop
0.16
20
8.6 (5.0)
3.2 (2.0)
71%
Since 71% of the PSP94 has been removed from the solution, it is assumed that the 71% is attached to the matrix. To condition the matrix and to remove any loosely bound PSP94 a series of high salt washes at low and high pH was performed. A disposable 20 ml column was packed with the PSP94 affinity matrix, and washed through 3 cycles of 10 ml volumes of 0.1 M sodium bicarbonate, 0.5 M NaCl, followed by 0.1 M glycine, 0.5 M NaCl, pH 2.5. A peristaltic pump at a flow rate of about 2 ml per minute may be used. Finally the column was equilibrated in PBS containing 0.05% NaN 3 and stored at 4° C.
Step 2 B: Affinity Purification of PSP94 Specific IgG.
The protein A purified IgG was at a concentration of about 5-10 mg per ml in 0.1 M glycine, 100 mM Tris at neutral pH. This solution was diluted in PBS to a concentration of 1 mg per ml, (OD 280 of 1.4). This buffer composition was adequate for the affinity purification.
A hundred and fifty milliliters of protein A purified IgG (1 mg/ml) were applied to the 5 ml PSP affinity column at a flow rate of 2.5 ml per minute. The OD 280 of the flow through was monitored and was kept to provide a reduction of about 30% (OD 280 of about 1.0). The reduction in OD indicates that specific antibodies are binding to the column. When the OD of the flow through approaches the OD of the solution being applied, then the column is saturated. If the OD of the eluant is the same as the solution being applied from the start, the column is inactive, or the protein A purified IgG has no PSP94 specific antibodies in it.
Once all the protein A purified IgG had flowed through the column, the column was whashed with PBS until the OD 280 stabilizes (less than 0.05). The antibody was eluted with 0.1 M glycine, pH 2.5 and 1 ml aliquots were collected directly into eppendorf tubes containing 150 microlitres of 1 M TRIS, pH 8.0. Ten fractions were collected and the column was equilibrated with PBS containing 0.05% NaN 3 . The OD280 of the eluant was measured and the major fractions were pooled. Three milliliters aliquots were desalted using a PD10 desalting column (BioRad) equilibrated with PBS. The concentration of antibody was estimated using OD280 (1 mg/ml=1.40) and aliquots were stored at −80° C. The yield was about 25 mg of polyclonal anti-PSP94 IgG antibody.
EXAMPLE 12
Antibody Characterization
ELISA-Based Hybridoma Screening Assay
In order to evaluate the titer and the specificity of the antibodies produced from mice or from the hybridoma generated from mouse B cells, an ELISA screening assay was developed.
Briefly, microtitre plates (Nunc, MaxiSorp) were coated with 100 μl aliquots of either native PSP94 (isolated from human seminal plasma; 5 μg/ml in 0.1 M sodium carbonate pH 9.6) or with a PSP94-binding protein (0.1 μg/ml in 0.1 M NaHCO 3 ) or phosphate buffered saline (PBS; 140 mM NaCl 10 mM sodium phosphate pH 7.5) overnight at 4° C. Plates were blocked for 1 hour with a solution of 1% bovine serum albumin (BSA) in phosphate buffered saline at 34° C. (BSA allows the saturation of the binding sites and limit unspecific binding to the plates). The plates (wells) were then washed in PBS containing 0.1% polyoxyethyylene-sorbitan monolaurate (PBS-Tween), prior to application of the mouse serum samples, or hybridoma supernatants diluted in 0.5% BSA. The plates were incubated for 1 hour at 34° C. prior to application of a 1:1000 dilution in PBS 0.5% BSA of peroxidase conjugated polyclonal rabbit immunoglobulins recognizing mouse immunoglobulins. (rabbit anti-mouse IgG peroxidase). After a further 1 hour incubation at 34° C. the plates were extensively washed in PBS Tween, prior to development of the peroxidase signal in 3,3′,5,5′-Tetramethylbenzidine (TMB). After 30 minutes the optical density at 630 nm was read in a micro plate reader.
Antibody Biotinylation
The diluent (buffer) of the purified antibody was exchanged for 0.1 M NaHCO 3 buffer pH 8.0 and the protein concentration was adjusted to 1 mg/ml. A 2 mg/ml solution of biotinamidocaproate N-hydroxysuccinimide ester was prepared in DMSO and an appropriate volume of this solution was added to the antibody to give either a 5, 10 or 20 fold excess of biotinylating agent. The solution was incubated on ice for 2 hours with occasional agitation before an equal volume of 0.2 M glycine in 0.1 M NaHCO 3 was added to give a final concentration of 0.1 M glycine.
After one further hour incubation on ice, the antibody was separated from the free biotinylating agent by gel filtration using a PD10 gel filtration column (Biorad). Biotinylated antibodies were stored at 4° C. in with 0.05% sodium azide added as preservative. The optimal extent of biotinylation and optimal usage concentration of the biotinylated antibodies was determined on antigen-coated plates.
Relative Epitope Analysis
ELISA plates were coated either with a PSP94-binding protein or PSP94 and blocked as described above. Appropriate concentrations of the biotinylated antibodies prepared as described above were incubated with the coated plates in the presence or absence of a 50-fold excess of a panel of unlabelled antibodies. Competition with the unlabelled antibodies indicates epitopes that are shared between the two antibodies. Detection is performed using streptavidin peroxidase.
Lack of competition indicates independent epitopes. Results of epitope analysis are illustrated in table 10.
TABLE 10 Class and Epitope shared ATCC Patent Clone Specificity subclass with Depository No. 2B10 Binding protein IgG 1 κ 9B6, 3F4 — 1B11 Binding protein IgG 1 κ Unique — 9B6 Binding protein IgG 1 κ 2B10, 3F4 — 17G9 Binding protein IgG 1 κ Unique PTA-4243 3F4 Binding protein IgG 1 κ 2B10, 9B6 PTA-4242 P8C2 Binding protein IgG 1 κ Unique — B3D1 Binding protein IgG 1 κ — — 26B10 Binding protein IgMκ — — 2D3 Free PSP94 IgG 1 κ Unique PTA-4240 P1E8 Free and bound IgG 1 κ Unique PTA-4241 (total) PSP94 12C3 Free PSP94 IgG 1 κ Unique — 1A6 Free PSP94 IgG 1 κ PTA-6599* *PTA-6599 was deposited to the ATCC on Feb. 23, 2005
Antibody Conjugation
Kits using antibodies conjugated with a reporter molecule were developed. Antibodies listed in table 10 were conjugated with a reporter molecule using the following procedures.
Horse radish peroxidase (3 mg) (HRP) was diluted into 0.6 ml of deionized water. 0.2 ml of sodium periodate 0.01 M in PBS pH 7.5 was added to the diluted HRP and the mixture was incubated for 25 minutes at room temperature. Dialysis was carried out against sodium acetate solution (1 mM pH 4.0) at 4° C. Buffer changes (3 times) were effected at each two hours.
For example, five milligrams of protein-A purified and lyophilized 1A6 antibody was diluted with 50 μl of carbonate buffer (0.2M, pH 9.5). The dialyzed HRP mixture was added to the antibody mixture. 0.2 ml of the same carbonate buffer was added. Reaction was allowed to proceed for 2 hours at room temperature with agitation. 0.1 ml of sodium borohydrate (4 mg/ml in deionized water) was added and incubation was perfomed for 2 hours at 4° C. with agitation.
The mixture was transferred in a conical tube and 1.2 ml of ammonium sulfate saturated solution (300 g of (NH 4 ) 2 SO 4 in 400 ml of deionized water) was added and was left for 1 hour at 4° C. with agitation. The precipitated solution was centrifuged at 300 RPM for 20 minutes. The pellet was resuspended in the ammonium sulfate saturated solution. Centrifugation was again performed as described above. The pellet was then resuspended in 2 ml of PBS (0.01M pH 7.1). Dyalisis was performed against 0.01M PBS pH 7.4. The buffer was changed every 2 hours with fresh 0.01M PBS pH 7.4 (4 buffer changes). HRP conjugated antibody was diluted in a stabilizing solution (50% fetal bovine serum in Tris-HCl (31.52 g/L in deionized water), pH 6.8) and was used at a concentration of between 1.5 to 10 mg/ml in the assays, methods and kits of the present invention.
Preparation of PSP94 Master Solution Standard
A PSP94 master solution standard was prepared and lyophylized in bovine serum albumin/mannitol stabilization buffer (5 micrograms of PSP94 in 4 mg/ml mannitol, 2% BSA (fraction v) in 10 mM sodium phosphate, 20 mM EDTA, 40 micrograms per ml Thimerosal pH 7.5 in 0.5 ml). For this purpose PSP94 was purchased from US Biologicals and quantified using ultraviolet absorbance (1 mg/ml at 280 nm=1.53). Multiple vials of the master solution were stored at −20° C. and this material was used to calibrate the standard curves used in each batch of ELISA kits. Several dilution of the standard for use within the kits was prepared as indicated below.
Specificity of PSP94 Antibodies for Free or Total PSP94
In order to further characterize the specificity of the antibodies generated herein, an assay was developed to determine if the monoclonal antibodies recognize PSP94 in its free form and/or when it is bound to a PSP94-binding protein.
In order to promote the formation of a PSP94/PSP94-binding protein complex, the two (substantially or partially) purified proteins were pre-incubated together. Briefly, a partially pure PSP94-binding protein preparation (see example 4), at a concentration of 1 mg/ml (total protein concentration) in PBS containing 0.5% BSA was pre-incubated for 1 hour at 34° C. with or without 5 μg/ml of native PSP94.
An ELISA plate (96 well plate) was coated with 17G9 monoclonal antibody at a concentration of 2 μg/ml (in 0.1M NaHCO 3 pH 8.0) by an overnight incubation at 4° C. As described herein, this antibody recognizes a PSP94-binding protein. Wells of the plate were subsequently blocked with 1% BSA for 1 hour at 34° C. The PSP94/PSP94-binding protein complex generated above was incubated with the 17G9 coated plates for 1 hour at 34° C. before washing off any unbound material. The plates were then incubated with biotinylated PSP94-specific antibodies (2 μg/ml in PBS 0.5% BSA). Any positive binding of these antibodies would indicate that the PSP94 epitope that is recognized is exposed (available) even when bound to a PSP94-binding protein. These results are illustrated in table 10. Binding of the biotinylated PSP94-specific antibodies to the bound PSP94 was visualized with a streptavidin peroxidase system and developed with TMB giving a blue color.
Results illustrated in FIG. 11 indicate that none of the antibodies tested react with captured PSP94-binding protein when the binding sites are not saturated with PSP94. When the binding sites are saturated with PSP94, P1E8 shows strong reactivity towards the complex. However, 2D3 and 12C3 do not. Thus, PIE8 recognize bound and free PSP94 and the other two antibodies (2D3 and 12C3) only recognize the free form of the protein. Antibodies 2D3 and 12C3 probably recognize a PSP94 epitope that is masked when it is bound to a PSP94-binding protein. Each of these antibodies detects native and recombinant PSP94 when coated onto ELISA plates. All three antibodies function as capture or detector antibodies in sandwich ELISA formats to produce a linear standard curve over a useful range of concentrations of PSP94. However, 12C3 appears to be of lower affinity than 2D3 or P1E8 toward PSP94.
The utility of these antibodies to detect PSP94 was illustrated in the following assay; an ELISA plate was coated with 5 μg/ml of PSP94 in pH 9.6 carbonate buffer and incubated overnight at 4° C. The plate was blocked with 1% BSA for 1 h at 34° C. Samples were then incubated in the plate overnight at 4° C. Biotinylated P1E8 was applied at 1 microgram/ml for 2 hrs at 34° C. and peroxidase streptavidin was applied for 1 h at 34° C. before development in TMB. The lower limit of quantification (LLQ) was shown to be in the range of 1 ng/ml. It is of particular interest that the assay (e.g., standard curve) may be performed with native PSP94 (i.e., PSP94 isolated from human serum) or recombinant PSP94.
Western Blots
Some antibodies described herein were assessed by Western blot. Briefly, 0.2 micrograms of (substantially) purified PSP94-binding protein, or 25 microliters of partially pure PSP94-binding protein were run on 7.5% SDS PAGE gels under non-reducing conditions. The proteins were transferred to PVDF membranes, the membranes were blocked with 1% BSA, probed with the hybridoma supernatants at a dilution of 1:5 (in PBS/0.5% BSA), and the bound antibody was detected with an anti-mouse immunoglobulin peroxidase-conjugate raised in rabbit. The signal was developed in 0.05% diaminobenzidine 0.01% hydrogen peroxide.
EXAMPLE 13
Free PSP94 Immunodetection Assays
The PSP94 antibodies described above (2D3 (PTA-4240), P1E8 (PTA-4241), 12C3, polyclonal and 1A6 (PTA-6599)), may be used in a competitive ELISA assays e.g., coating plates with PSP94 (or sample), and using the PSP94 within the sample to inhibit the binding of the antibody to the PSP94 coated plates. These antibodies may also be used in standard ELISA assays where an antibody is coated to the plate and a sample containing PSP94 is added. Specific detection of the complex is subsequently performed with a second antibody able to bind to PSP94 (the first and second antibodies binding to a different epitope of PSP94).
In a first experiment, the use of 2D3 in a competitive ELISA format was investigated. As illustrated in FIG. 12 a , the plates were coated with the 2D3 antibody and samples containing PSP94 was added. The complex was detected with a biotynylated P1E8 (which recognizes a different epitope of PSP94). Detection is performed by adding streptavidin coupled with peroxidase and subsequently adding the perosidase's substrate. FIG. 12 b represent results of an ELISA assay using the method illustrated in FIG. 12 a.
In order to limit the possible dissociation (e.g., promoted by 2D3) of the PSP94/PSP94-binding protein complex during the ELISA assay, improvements were introduced. Briefly, the improved assay involves pre-absorption (removal) of the PSP94/PSP94-binding protein complex with a PSP94-binding protein antibody described herein before performing the assay. The PSP94-binding protein antibodies selectively remove PSP94-binding protein and the PSP94/PSP94-binding protein complex (i.e., bound PSP94). This is done without upsetting the kinetics of the equilibrium reaction between a PSP94-binding protein and PSP94. Pre-absorption can be done with, for example the 17G9 linked to a sepharose matrix, giving then a sample that is free of the complex (unbound PSP94 remains). The sample is then processed as described above (i.e., incubating the complex-free sample with the plate coated with 2D3 and detecting with biotinylated P1E8, streptavidin peroxidase and peroxidase's substrate.
Another standard immunodetection assay (a sandwich ELISA assay measuring free PSP94) was performed. Briefly, wells of an ELISA plate were coated with 150 microlitres of an anti-PSP94 polyclonal antibody (which has been generated as described herein) at 3 μg/mL in KPO 4 0.1M, Glutaraldehyde 0.001% at a pH of 6.5. The antibody is allowed to bind to the plates for 24 hours at room temperature and rinsed with 300 microlitres of deionized water. After washing, the wells were coated with 200 microlitres of 10 mM sodium phosphate, 140 mM NaCl, pH 7.5 with 0.5% BSA (fraction v) and 2% sucrose and incubated for 24 hours before aspiration of the solution. The plates were allowed to dry at room temperature overnight. The plates may be used right away or may be dried and stored for subsequent experiments.
Six PSP94 standards dilutions were prepared by diluting a master solution of PSP94 to obtain concentrations of 0, 1, 5, 10, 20, 40 ng/mL in a final volume of 0.5 mL of 10 mM sodium phosphate, 20 mM EDTA, 40 micrograms per ml Thimerosal, 0.25% BSA Twenty-five micro liters of serum samples containing PSP94 or PSP94 standards (the samples and standards were brought to room temperature, i.e., about 22° C.+/−2° C.) and added to independent wells. A hundred micro liters of the anti-free PSP94 antibody (1A6 (PTA-6599)) conjugated with horse-radish peroxidase was also added to each well. The plates were incubated for sixty minutes on a plate shaker (110+/−10 rpm) at room temperature (i.e., about 22° C.+/−2° C.). The well content was decanted by inverting the plates and excess liquid was absorbed by putting the inverted plate onto absorbing paper. The wells were then washed three times with 300 μL of washing solution. At the last wash, the plates were completely decanted by tapping them against absorbing paper until there was no trace of liquid remaining. A hundred microliters of the enzyme's substrate solution was added to each well and the reaction was allowed to proceed for 15 minutes on a plate shaker (110+/−10 rpm) at room temperature (i.e., about 22° C.+/−2° C.). Fifty microliters of stopping solution (0.5M sulfuric acid) was added to each well. When the enzyme's substrate (substrate-chromogen solution) is added, the enzyme catalyzes a reaction which produces a blue color. When the stopping solution is added, the color turns yellow. The intensity of the color is directly proportional to the concentration of PSP94 in the sample or standard. The intensity of the color was measured by reading the absorbance at 415 or 405 nm in a microplate reader (spectrophotometer) immediately after the assay was completed.
The quantity of free PSP94 in the sample was determined by making a plot of the optical density (on the ordinate) measured for the standards as a function of the concentration of standards (on the abscissa) and the corresponding concentration which gives the optical density measured for the sample was evaluated. Table 11 represents results obtained by measuring the concentration of PSP94 in 2 unknown human serum samples using the sandwich ELISA assay for measuring free PSP94 described above. These results are also illustrated as a graph in FIG. 12 c .
TABLE 11
CONCENTRATION
WELLS
OPTICAL DENSITY at 415 nm
(ng/mL)
0
ng/mL
0
0.25
ng/mL
0.013
0.5
ng/mL
0.025
1
ng/mL
0.049
5
ng/mL
0.475
10
ng/mL
1.261
20
ng/mL
2.665
Serum
0.638
6.1
Serum
1.915
14.4
Several parameters of the sandwich ELISA assay for measuring free PSP94 described herein have also been measured in order to verify the assay performance.
Precision:
The precision of an analytical method describes the closeness of mean test results obtained by the method to the true value (concentration) of the analyte. Precision is determined by replicate analysis of samples containing a known amount of the analyte.
In duplicate, the standard curve and five times each of the three control levels are measured. For each level of controls the mean, the standard deviation and the coefficient of variation (in percent) are calculated. The within assay % coefficient of variation is preferably below 15%.
Calculation:
%
Coefficient
of
variation
(
CV
)
=
Standard
Deviation
Mean
×
100
The intra-assay precision was determined for three (3) serum samples from the mean of 10 replicates each. Results are illustrated in Table 12 below.
TABLE 12
Intra-Assay
Standard
Coefficient
Mean
Deviation
of variation
Sample
N
(ng/mL)
(ng/mL)
(%)
1
10
7.4
0.2
2.1
2
10
14.3
0.2
1.4
3
10
23.3
0.8
3.5
The inter-assay precision was determined for three (3) serum samples from the mean of 20 replicates. Results are illustrated in Table 13 below.
TABLE 13
Inter-Assay
Standard
Coefficient
Mean
Deviation
of variation
Sample
N
(ng/mL)
(ng/mL)
(%)
1
20
7.7
0.4
4.8
2
20
14.6
1.4
2.5
3
20
24.0
1.0
4.1
Accuracy: or recovery study: known amounts of PSP94 were added to a human serum sample to determine recovery performance of the assay. The data obtained are indicated in Table 14 below.
TABLE 14 Expected Observed value % of Samples value (ng/mL) (ng/mL) recovery 1 19.2 15.7 81.5 2 29.2 21.8 74.5 3 39.2 28.7 73.2
Linearity:
The linearity is the ability of a diluted patient sample to show proportional values when read through the working standard curve. Two serum samples were diluted and run.
The patient dilution calculation was done as follows: The standard curve and the patient dilution curve were calculated and drawn. The controls values were read against the reference curve. The theoretical and expected values were then compared. Results of the linearity experiment are illustrated in Table 15:
TABLE 15 Samples Parameters 1 2 Undiluted 14.9 11.7 ½ 7.0 6.0 ¼ 2.7 2.5 ⅛ 1.2 1.2
Specificity
The cross-reactivity studies were performed using substances which may potentially interfere with the performance of the assay. The results were as shown in the Table 16 below (ND=not detectable):
TABLE 16
CROSS-REACTANT
CROSS-REACTIVITY
Prostate specific antigen (PSA) 10 μg/mL
ND
alpha feto protein (AFP) 10 μg/mL
ND
carcinoembryonic antigen (CEA) 10 μg/mL
ND
human chorionic gonadotrophin (HCG)
ND
10 μg/mL
PAP 1 μg/mL prostatic acid phosphatase
ND
LACTALBUMIN 10 mg/mL
ND
HEMOGLOBIN 500 mg/dL
ND
BILIRUBIN 20 mg/dL
ND
TRIGLYCERIDES 1000 mg/dL
ND
CYCLOPHOSPHAMIDE 800 μg/mL
ND
METHOTREXATE 50 μg/mL
ND
DOXORUBUCIN-HCL 20 μg/mL
ND
DIETHYSTILBESTROL 2 μg/mL
ND
FLUTAMIDE 10 μg/mL
ND
Other parameters such as reproducibility, recovery, hook effect, matrix effect, etc. were all determined and results obtained indicated that the free PSP94 assay may be used successfully to determine the levels of PSP94 in human samples and especially of free PSP94 in human serum sample.
EXAMPLE 14
Total PSP94 Immunodetection Assays
Since the P1E8 antibody is able to recognize PSP94 both in its free and bound form, an assay to measure total PSP94 has been developed. For example, P1E8 is immobilized to the plate and a sample containing free PSP94 and PSP94 complexed with a PSP94-binding protein is added. The PSP94 and the complex remains bound to the antibody and an antibody having a different affinity (a different binding site on PSP94) than P1E8 may be added. An example of such an antibody is 2D3 or any other suitable PSP94-antibody. Detection is performed by using a label that may be conjugated to 2D3 or by a secondary molecules (antibody or protein) recognizing directly or indirectly (e.g., biotin/avidin or streptavidin system) the 2D3 antibody.
However, based on the observation that 2D3 might disturb the binding equilibrium between PSP94 and PSP94-binding protein, the assay to measure total PSP94 (bound and unbound) was improved.
Particularly, the assay was performed as illustrated in FIG. 13 . In FIG. 13 , total PSP94 is captured with the P1E8 antibody, and a high concentration (excess) of biotinylated 2D3 is used to encourage the dissociation (displacement) of a PSP94-binding protein. In the previously described assay, the actual concentration of 2D3 for coating the plate is low as the plastic has a capacity of no more than 50 ng.
Note, that this assay may also measure free (unbound) PSP94, if the complex (PSP94/PSP94-binding protein) is adsorbed out from the serum prior to measurement.
EXAMPLE 15
PSP94-Binding Protein Immunodetection Assays
Specificity for all the PSP94-binding protein antibodies has been confirmed in the ELISA assay discussed previously, and by Western blot. Each of them recognizes both the high and low molecular weight form of the binding protein by western blot.
As shown in table 10, the antibody 17G9 recognize a different epitope than 3F4. Thus a sandwich ELISA assay, as illustrated in FIG. 14 a , has been developed using these two antibodies. FIG. 14 b illustrates a standard curve from the assays used to measure a PSP94-binding protein within serum samples. Note that these two antibodies may be interchanged. For example, the capture antibody can be switched to be used as detection reagent (when labeled).
Forty serum samples from male donors have been assessed with a PSP94-binding protein ELISA assay described above (illustrated in FIG. 14 a ). The PSP94-binding protein serum concentration was successfully measured. Values of PSP94-binding protein in these male donors ranged from about 1 μg/ml to about 10 μg/ml, with two cases having in excess of 20 μg/ml. Two cases from female donors have been assessed; one has about 3 μg/ml, the other about 7.8 μg/ml.
EXAMPLE 16
Immunodetection Assays Application
Male human serum samples with known total PSA values were obtained from a reference standard laboratory. Forty cases had low total PSA serum levels (<4 ng per ml) and 69 had high total PSA serum levels (>4 ng per ml). Analysis was performed on these low and high categories. There is no traceable link back to these patients, thus, there is no clinical information associated with the specimens, except for the total PSA value. The purpose of this analysis is to look for trends and patterns rather than determine the clinical relevance of PSP94 measurements. The distributions of the serum concentrations of total PSP94, PSP94-binding protein, free PSP94 and corrected free PSP94 are illustrated in additional figures described herein.
With respect to additional figures;
FIG. 15A , is a graph illustrating results obtained following measurement of total PSP94 in serum of individuals for which PSA values are known to be lower or higher than the cut-off value of 4 ng/ml and using an assay as illustrated in FIG. 13 and described in example 14. Results are expressed as the log of total PSP94 concentration (in ng/ml) measured for each individual. Each point represents results obtained for a specific individual. With respect to this figure, total PSP94 concentration of 1 to 2250 ng/ml were measured in serum of individuals.
With respect to FIG. 15B , this figure is a graph illustrating results obtained following measurement of free PSP94 in serum of individuals for which PSA values are known to be lower or higher than the cut-off value of 4 ng/ml. Results were obtained using an assay which is based on the removal (depletion) of PSP94-binding protein and PSP94/PSP94-binding protein complex from serum using an anti-PSP94-binding protein antibody as described herein prior to measurement of free PSP94 with the 2D3 and P1E8 monoclonal antibodies in a sandwich ELISA assay. Results are expressed as the log of free PSP94 concentration (in ng/ml) measured for each individual. Each point represent results obtained for a specific individual.
With respect to FIG. 15C , this figure is a graph illustrating results obtained following measurement of total PSP94-binding protein in serum of individuals for which PSA values are known to be lower or higher than the cut-off value of 4 ng/ml. Results were obtained using an assay which is illustrated in FIG. 14 a and described in example 15. Results are expressed as the log of total PSP94-binding protein concentration (in ng/ml) measured for each individual. Each point represent results obtained for a specific individual. With respect to this figure, PSP94-binding protein concentration ranging from 0.7 to 125 micrograms/ml were measured in serum of individuals.
With respect to FIG. 15D , this figure is a graph illustrating results obtained following correction of the free PSP94 concentration obtained in serum of individuals for which PSA values are known to be lower or higher than the cut-off value of 4 ng/ml; Results were corrected by taking into account that 1 to 5% of residual PSP94/PSP94-binding protein complex remains in the serum even after depletion which may affect the results obtain, i.e., PSP94 may be dissociated from the complex after the 2D3 antibody is added, falsely increasing the “free PSP94” value. Results are again expressed as the log of corrected free PSP94 concentration (in ng/ml) measured for each individual. Each point represent results obtained for a specific individual. With respect to this figure, corrected free PSP94 levels were significantly elevated in the high PSA category (>4 ng/ml).
FIG. 16 , is a graph illustrating the total PSP94-binding protein concentration (ng/ml) versus the total PSP94 concentration (ng/ml) measured in serum of individuals, where each point represent results obtained for a specific individual. With respect to this figure, a significant positive relationship between these two parameters may be observed.
All publications and patent applications cited in this specification are herein incorporated by reference as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. The citation of any publication is for its disclosure prior to the filing date and should not be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention.
Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is readily apparent to those of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims. | In the serum, PSP94 occurs as a free form or is associated with a carrier protein. PSP94 in its bound form has been quantified in the blood of prostate cancer patients and these measurements have shown utility as evaluation or prognosis of prostate cancer. Diagnostic assays, methods, and kits for detecting a free form of PSP94, and reagents such as antibodies able to bind to a free form of PSP94 are disclosed herein. | 2 |
FIELD OF THE INVENTION
This invention relates to the design of integrated circuits, and in particular, relates to the design of programmable logic devices.
BACKGROUND OF THE INVENTION
Unlike a conventional programmable logic device (PLD), an in-system programmable logic device (ISPLD) can be reprogrammed in place, i.e. without removal from the system in which it is deployed. ISPLDs are therefore especially suited for implementing dynamically reconfigurable circuits. The method of reprogramming a programmable logic device in place is known as in-system programming (ISP). Some ISPLDs, such as those available from Lattice Semiconductor Corporation, Hillsboro, Oreg, can be reprogrammed using an operating voltage power supply, rather than a high programming voltage, as in the case of many PLDs. U.S. Pat. No. 4,855,954, entitled "In-system Programmable Logic Device with Four Dedicated Terminals," by J. E. Turner et al., assigned to Lattice Semiconductor Corporation, which is also the assignee of the present Application, discusses ISPLD technology. U.S. Pat. No. 4,855,954 is hereby incorporated by reference in its entirety.
FIG. 1 shows an idealized pin-out of an ISPLD. As shown in FIG. 1, the ISPLD comprises a number of input-only pins (I 1 , I 2 , . . . , I n ), a number of programmable input/output pins (I/O 1 , I/O 2 , . . . , I/O m ), power (VCC) and ground (GND) pins, and a set of ISP pins (SDI, SDO, SCLK, and mode). During operation, if the ISPLD is to be reprogrammed, the signal associated with the SCLK pin is activated to place the ISPLD into the ISP mode. Once in the ISP mode, a state machine having numerous states takes over the control of the programming activities. The new program is input serially into the program memory of an ISPLD over the serial input pin SDI. The rate of serial input is 1-bit per clock period. A clock signal is provided on pin SCLK when the ISP mode is entered. Each ISPLD can also provide on its output pin SDO data received from its serial input pin SDI. Thus, a number of ISPLDs can be "daisy-chained" together by tying the serial input pin SDI of an ISPLD to the serial output pin SDO of another ISPLD. Any ISPLD in the daisy chain can be re-programmed by shifting in the new program at the serial input pin SDI of the first ISPLD in the daisy chain, and through every ISPLD in the daisy chain ahead in the daisy chain of the ISPLD to be programmed.
Because the pins of an integrated circuit package are considered a scarce resource, minimizing the number of pins dedicated for reprogramming purpose maximizes the number of pins available to the operation for which the ISPLD is deployed. Thus, it is highly desirable to have an ISPLD having very few pins dedicated to reprogramming purpose.
SUMMARY OF THE INVENTION
In accordance with the present invention, a structure and a method to implement an in-system programmable logic device are provided using only one dedicated in-system programming pin. Additional in-system programming pins are made available by multiplexing pins which are input/output pins, when not in in-system programming mode. When an enable signal is received, these pins relinquish their roles as functional pins to become in-system programming (ISP) pins. In-system programming is performed under the control of an instruction-based state machine. An instruction set is provided to control the ISP activities.
The structure in accordance with the present invention can be connected in a "daisy chain" fashion. In addition, an instruction is provided to connect, under in-system programming mode, a serial input pin with a serial output pin, thereby to provide a bypass path for rapidly shifting data and/or command to any device in the daisy chain.
The present invention provides reprogramming of ISPLDs at the cost of only one dedicated pin.
The present invention is better understood upon consideration of the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an idealized pin-out diagram of an in-system programmable logic device (ISPLD) having pins mode, SCLK, SDI and SDO pins dedicated for reprogramming purpose in the prior art.
FIG. 2a is a pin-out of an embodiment of the present showing multiplexing of four input pins (I 0 -I 3 ) for in-system programming functions when the signal on the ISP pin is enabled, in accordance with the present invention.
FIG. 2b'-2b" is a schematic diagram showing the circuit 250, which implements the ISP input pins mode, SDI, and SCLK of the embodiment shown in FIG. 2a.
FIG. 2c'-2c" is a schematic diagram showing the circuit 200, which implements the ISP output pin SDO of the embodiment shown in FIG. 2a.
FIG. 3 shows the functional programmable logic in the embodiment of the present invention shown in FIG. 2a.
FIG. 4 shows the three states of the state machine 400 controlling the in-system programming operation, in accordance with the present invention.
FIG. 5 is a block diagram of the internal interface to the ISP pins, and the functional units involved in the ISP operation.
FIG. 6 shows a configuration of three devices for ISP operations, these devices each have the ability to multiplex input pins for ISP operations in accordance with the present invention.
DETAILED DESCRIPTION
FIG. 2a shows a pin-out of an embodiment of the present invention in an 84-pin package, having 64 programmable input/output (I/O) pins I/O 0 -I/O 63 , eight input pins I 0 to I 7 , four clock pins Y 0 -Y 3 , two power (VCC) pins, four ground (GND) pins, one reset (RESET) pin and one ISP enable (ISP) pin. In accordance with the present invention, as described below, input pins I 0 -I 3 also serve as in-system programming (ISP) pins when the signal on the ISP pin is asserted. It will be appreciated that, although the present invention is illustrated by a programmable logic device having a specific organization to be described herein, the present invention is applicable to any device providing an ability to be programmed "in-system". The present embodiment includes electrically erasable programmable memory cells, which are programmable using the same 5-volt power supply as the logic circuits on the chip, and does not lose the program upon "power-down."
The programmable logic of the present embodiment is shown in FIG. 3. As shown in FIG. 3, the programmable logic structure comprises a programmable interconnect array 601, four I/O blocks (IOBA-IOBD), each controlling 16 of the 64 I/O pins I/O 0 -I/O 63 , four groups of eight "generic logic blocks" (GLBs), respectively designated GLBA 0 -GLBA 7 , GLBB 0 -GLBB 7 , GLBC 0 -GLBC 7 and GLBD 0 -GLBD 7 . The 32 GLBs, which are programmably interconnected by the programmable interconnect array 601, implement the programmed logic functions. The programmable interconnect array 601 is also called the routing resource pool (RRP) 601.
In FIG. 3, each GLB receives two input signals directly from two of the eight input pins I 0 -I 7 , three clock signals selected from the output signals of another GLB and the clock pins Y 0 -Y 3 , and sixteen input signals from the RRP 601, and provides four output signals. Each group of eight GLBs is associated with two of the eight input pins I 0 -I 7 . For example, the eight GLBA 0 -GLBA 7 each receive the signals on the input pins I 0 and I 1 . The four output signals of each GLB are provided to the RRP 601 for routing to any one of the 32 GLBs. Each GLB is associated with two I/O pins in one of four I/O blocks. Within each GLB are 42 rows by 20 columns of memory cells. Of the 42 rows of memory cells, six rows are "architectural" cells for configurating structures such as non inverted signals or inverted signals. The remaining 36 rows are "array" cells for programming the logic array. In sixteen of the GLBs, each GLB is provided an extra row of twenty memory cells, called the "electronic signature row" (ESR) which allows the user to store a "signature" bit-pattern for identification purpose. ESR can be used, for example, to identify the program stored in the associated GLB. A security cell, which when enabled, prevents the stored program to be read from the external pins. The RRP 601 can be programmed to route up to sixteen signals as input to each GLB from the pool of 64 I/O pins I/O 0 -I/O 63 , and the 128 output signals from all the GLBs. Each of the 64 I/O pins I/O 0 -I/O 63 can be independently programmed to be an input, an output or a bidirection pin.
When the signal on the ISP pin is asserted (in this embodiment, the signal on the ISP pin is brought to a logic low state), I/O pins I/O 0 -I/O 63 each go into a high-impedance state, and the present embodiment goes into ISP mode. In ISP mode, the input pins I 0 , I 1 , I 2 and I 3 become, respectively, SDI (serial data in), mode, SDO (serial data out), and SCLK (Shift clock) by appropriately setting internal multiplexers which enable the signals received on these pins to be provided to the ISP logic. Of course, other pin assignments for the ISP pins are possible. In fact, other than the ISP pin, which is required to be a dedicated pin, there is no restriction on how the ISP pins can be assigned.
FIG. 2b is a schematic diagram of a circuit 250 which implements the ISP input pins. As shown in FIG. 2b, the ISP, the mode, the SCLK, and the SDI pins are represented by the terminals 231-234 respectively. If the ISP pin 231 is left floating, the depletion mode transistor 251 and the NMOS transistor 252 pull the ISP pin 231 to a logic high state. Transistors 253 and 254 protect ISP logic circuits receiving the signal on the ISP pin against electrostatic discharge damage caused by improper handling of the integrated circuit package.
The signal on the signal ISP pin is inverted by an inverter (i.e. the combination of transistors 255 and 256), and then amplified by inverters 257 and 258 before being provided respectively to transistor pairs 259-262, 268-265 and 271-272 to enable the SCLK pin 232, the mode pin 233 and the SDI pin 234. Transistors 259, 268, 271 are each part of a NAND gate, which provides the inverted signal of the corresponding pin to the ISP logic. For example, when the NAND gate formed by transistors 259, 260, 261 and 262 is enabled by the signal received on the gate terminal of transistor 259 (i.e. the signal on the ISP pin inverted), the signal on the SCLK pin is inverted and provided on the NAND gate's output terminal 274. When ISP is disabled, the pull-up transistors (e.g. transistors 262 and 265 on the SCLK pin 232) cause a logic low state at each of the terminals 235, 236 and 238. This condition can also be accomplished by setting the ISP pin to logic high. Terminals 235, 236 and 238 are respectively the terminals at which the ISP logic receives the signal on the SDI, the mode and the SCLK pins. In this manner, as will be discussed below, the state machine of the current embodiment is locked in a known state.
FIG. 2c is a schematic diagram of a circuit 200, which implements the output ISP pin SDO. As shown in FIG. 2c, circuit 200 receives input data on any one of the leads 202a-202f, or the data on lead 210, which is provided by the ISP input pin SDI. Each of the leads 202a-202f receives the serial output data stream from one of the ISP registers, which are shown in FIG. 5 and discussed below. Respectively, leads 202a-202f receive data from the ID register 501, command register 502, address register 509, data register 510, GLB register 511, and IO register 512. At any given time, circuit 200 receives at most one of the serial output data stream from these registers on leads 202a-202f. That is, only one of the transistors 201a-201f will pass the data stream on the corresponding leads 202a-202f for output on ISP pin SDO. Transistors 201a-201f each receive an enable signal at its gate terminal, which is indicated respectively by leads 203a-203f. At any given time, at most one of the enable signals 203a-203f is activated by the decoding logic 503 (FIG. 5) to render the corresponding transistor in transistors 201a-201f conducting. Transistor 208 pulls to power supply voltage the data transferred over one of the transistors 201a-201f.
Both the FLOWTHRU command (to be described below) and the logic high state signal on the ISP input pin mode provide that the data on the ISP input pin SDI to be transferred to the ISP output pin SDO. Transfer gates 206 and 207, formed by transistor pairs 206a-206b and 207a-207b, multiplex the data going to the ISP output pin SDO between one of the register output data and the data on the ISP input pin SDI. An output flip-flop 212, formed by the cross-coupled NOR gates 212a and 212b, receives and stores the selected output data from one of the transfer gates 206 and 207. Output flip-flop 212 is enabled by the signal on lead 205, which is logically the signal received on the ISP enable pin ISP. When enabled, the content of flip-flop 212 is buffered by inverter 213 (formed by transistors 213a and 213b) and provided on ISP pin SDO.
The operation of the ISP mode is next described with reference to FIG. 4 and 5. The ISP mode is controlled by an instruction-based state machine 400 shown in FIG. 4. FIG. 5 is a block diagram of the internal interface to the ISP pins and the functional units involved in the ISP operation. As shown in FIG. 4, the state machine 400 comprises three states 401, 402 and 403, corresponding respectively to the ID/NORMAL, command and execute states. Timing of the state machine 400 is provided by the clock signal on the SCLK pin. In this embodiment, every state change is effective at the next clock period after the signals on the SDI and mode pins are provided. When the ISP mode is entered, the state machine is in the ID/NORMAL state 401. During functional mode of the embodiment's operation, the state machine 400 stays locked in the ID/NORMAL state 401, which is unlocked when a logic low signal is received at the ISP enable pin ISP.
The id state 401 can be entered during ISP mode at any time from any state after one shift clock SCLK transition by bringing the signal on the mode pin to logic high and the signal on the SDI pin logic low. A state transition from the ID/NORMAL state 401 to the command state 402, from the command state 402 to the execute state 403, or from the execute state 403 back to the command state 402 can be accomplished by bringing both the mode and the SDI pins to logic high. When the mode pin is at logic low, the SDI pin is a data input pin, and the current state is held.
After entering the ID/NORMAL state 401, if the mode pin is then provided a logic high signal and the SDI pin is at the same time provided a logic low signal the state machine is instructed to load into the ID register 501 an 8-bit "ID", which identifies the embodiment's device type. The ID information associates the device with such parametric values as the number of GLBs on the chip, the number of I/O pins available etc. In the successive clock periods, after the mode pin goes to logic low, the ID information in ID register 501 is shifted out of the SDO pin through multiplexer 506 serially while the value of the signal at the SDI pin is shifted into the ID register 501 through multiplexer 505. Therefore, if the present embodiment is daisy-chained with a number of similar devices, i.e. the output signal on the SDO pin is provided to the SDI pin of the next device etc., the ID of each device can be examined after the appropriate clock periods. In this manner, the device information of each device in the daisy chain can be examined before programming begins.
As mentioned above, the command state 402 is entered from the ID/NORMAL state 401 by bringing to logic high both the mode and the SDI pins. In the command state 402, a 5-bit command is shifted serially into the command register 502. This command is decoded by the instruction decode PLA 503, and provided for execution in the program control circuitry 504 during the execution state 403. As in the ID state 401, the signal on the SDI pin is shifted serially into the current register and the content of the current register (i.e. the command register 502, when in command state 402) is simultaneously shifted out on the SDO pin. This arrangement allows a number of ISP devices to be chained in a daisy chain. Execution of the command in the command register 502 is effectuated by bringing the state machine to the execution state 403, which is entered from the command state 402 by bringing both mode and SDI pins to logic high. Using 5-bit commands, a possible thirty two (5 bits) commands can be defined. For example, the commands provided in Table 1 below can be implemented.
TABLE 1______________________________________In Circuit Programming instructions CMD______________________________________0. NOP No operation 000001. ADDSHFT Address register shift 000012. DATASHFT Data register shift 000103. GBE Global bulk erase 00011 Erase pia, array, architecture and security cells4. PIABE PIA bulk erase 00100 Erase pia cells5. ARRBE Array bulk erase 00101 Erase array cells6. ARCHBE Architecture bulk erase 00110 Erase architecture cells7. PROGEVEN Program even columns 00111 Program even columns of array, pia and architecture cells at the rows selected by Address SR8. PROGODD Program odd columns 01000 Program odd columns of array, pia and architecture cells at the rows selected by Address SR9. SFPRG Program security cell 0100110. VERIFYEVEN Verify even columns pro- 01010 grammed cells Verify even columns of array, pia and arch- itecture programmed cells. Only one row can be selected for each verification11. VERIFYODD Verify odd columns pro- 01011 grammed cells Verify odd columns of array, pia and arch- itecture programmed cells. Only one row can be selected for each verification12. GLCPRELD Preload GLB registers 0110013. IOPRELD Preload I/O Cell registers 0110114. FLOWTHRU Flow through 01110 SDI flow through to SDO15. PROGESR Program ESR 01111 Address SR is automatically cleared to 016. ERAALL Erase all 10000 Erase pia, array, architecture, ES and security cells17. VERESR Verify ESR 10001 Address SR is automatically cleared to 018. VEREVENH Verify even columns erased cells 10010 Verify even columns pia, array and architecture erased cells. Only one row can be selected for each verification19. VERODDH Verify odd columns erased cells 10011 Verify odd columns pia, array and architecture erased cells. Only one row can be selected for each verification20. NOP No operation 10100 . . . . . .31. INIT Initialize 11111______________________________________
In the execution state 403, the command stored in command register 502 and decoded by the instruction decode PLA 503 is executed. If the instruction is to load data into the data register 510 (i.e. the command DATASHFT), for example, the appropriate number of bits are shifted into the data register 510 from the SDI pin after the mode pin goes to logic low, while the same number of bits in data register 510 are shifted out to the SDO pin. The data path from SDI to SDO is set up by the four multiplexers 505-508. As shown in FIG. 5, data are received for the 108-bit address register 509, 160-bit data register 510, 128-bit GLB register 511 (4 bits for each GLB), and 64-bit I/O register 512 (1 bit for each I/O pin). A command "FLOWTHRU" allows the signal on the SDI pin to be provided immediately to the SDO pin. The FLOWTHRU command is executed in execute state 403 to allow quick serial data transfer over the daisy chain, bypassing the registers 509-512 (i.e. the FLOWTHRU command shifts data through a 0-bit register). The FLOWTHRU effect can also be accomplished in the ISP mode by holding the mode pin at logic high. The state machine 400 can be returned to the command state 402 from the execution state 403 by bringing both the mode and SDI pins to logic high. Alternatively, the state machine 400 can be returned to the ID state 401 from any state by bring the mode pin to logic high, and the SDI pin to logic low.
Since the instruction-based state machine has only three states 401, 402 and 403, and programming in the ISP mode is accomplished using commands of an instruction set, programming is much more structured and simplified over the prior art, which employs a state machine having numerous states.
FIG. 6 shows a system 750 including three chips 751, 752 and 753 each having ISP capability daisy chained in accordance with the present invention. As shown in FIG. 6, the pins of chips 751-753 are connected in common. Likewise, the SCLK and mode pins of each chip 751-753 are connected in common. The SDI and SDO pins of each chip are, however, connected in a daisy chain fashion. Yet, this configuration does not restrict the same in-system programming to be applied to all three chips 751-753 simultaneously. In order to program chip 752, for example, the ISP is placed in logic low, thereby placing all three chips 751-753 in ISP mode. However, the FLOWTHRU command is shifted into both the command registers of chips 751 and 753 to allow in-system programming to be applied only to chip 752.
The above detailed description is provided to illustrate the specific embodiments of the present invention described herein. It is appreciated the skilled person will be able to provide numerous modifications and variations within the scope of the present invention upon consideration of the detailed description and the accompanying drawings. The present invention is defined by the following claims. | A structure and method for in-system programming of a programmable logic device are provided. The in-system programming structure provides one dedicated pin for in-system programming function, additional in-system programming pins are multiplexed with programmable input/output pins used in functional operations. When an enable signal is received at the dedicated pin, the multiplexed pins relinquish their roles as programmable input/output pin to become in-system programming pins. A state machine controls the programming steps. The in-system programming structure can be cascaded in a "daisy chain" fashion. | 6 |
FIELD OF INVENTION
The present invention relates to inorganic fillers for phosphate-bonded investments and refractory die materials upon which dental porcelains and/or alloy powders can be sintered.
BACKGROUND OF THE INVENTION
Current phosphate-bonded investments and refractory die materials utilize fillers selected from quartz, tridymite and cristobalite to provide a degree of thermal expansion which is acceptable for sintering conventional porcelains having percent thermal expansion values lower than 0.65% in the temperature range of 20°-500° C. These fillers are combined with binders containing magnesium oxide, mono- or di-ammonium phosphate and colloidal-silica suspensions which provide physical expansion and strength. Trace amounts of surfactants are also added to control dispersion and surface properties of the fillers and binders. Problems exist, however, when such filler and binder combinations are used in developing phosphate-bonded investments and refractory die materials for higher expansion dental porcelains.
The primary difference between investments and refractory die materials lies in the selection of the particle size distribution of the fillers. Investments usually have a coarser particle size distribution. Investments are primarily used as the mold materials for the casting of dental alloys using lost wax processes. Refractory die materials are conventionally utilized as substrates for sintering dental porcelains and alloy powders and thus are subjected to high temperature firing cycles. Both investments and refractory die materials are formulated to provide proper setting, thermal and net positive physical expansion.
Although the silica-based fillers are inexpensive, they suffer from phase transformations at their transformation temperatures. These phase transformations cause sudden and large changes in the thermal expansion of the fillers. FIG. 1 is a graph showing thermal expansion verse temperature profiles for some of the industrial filler materials. It is apparent that the three forms of silica--quartz, tridymite and cristobalite--undergo phase transformation from an alpha form to a beta form. The profiles indicate that each transformation is accompanied by a large change in thermal expansion at the transformation temperature. For example, alpha-quartz converts to beta-quartz at about 573° C. with a thermal expansion change of about 0.5%. Similarly, alpha-cristobalite transforms to a beta-form at a temperature between about 200° C. and about 270° C., and produces a thermal expansion change of about 1.0%. The beta forms are stable only above the transformation temperatures. Upon cooling each composition, an inversion back to the lower alpha-form occurs.
Usually, a proper proportioning of these allotropes is controlled to arrive at the desired thermal expansion verse temperature profile to match the intended application. The addition of binders has only a minor influence on the thermal expansion behavior.
Low temperature phase transformation associated with the use of alpha-cristobalite, in most instances, does not pose problems in investments used for obtaining dense casting of dental alloys using the lost-wax technique. However, phosphate-bonded refractory die materials containing these different allotropes of silica as fillers exhibit the sudden and large changes (referred to herein as spikes) at the phase transformation temperatures. When used as a die (substrate) for sintering dental porcelain and alloy powders, compositions containing such fillers are prone to the formation of micro and macro-defects in the overlaid green (unsintered) products. These defects, if not repaired during sintering, get carried into the final sintered products.
The above phenomena is especially prevalent where the overlaid layers differ considerably in their thermal expansion values when compared to the thermal expansion of the die-material. The use of alpha-quartz alone as a filler appears to be acceptable for dental porcelains having low thermal expansions, e.g.<0.65% in the 25°-500° C. range. However, many of today's dental porcelains exhibit thermal expansions of greater than 0.80%. In fact, many of the dental porcelains currently being used have thermal expansions of between 0.84 and 0.87%. One such class of porcelains is Optec® porcelains, available from Jeneric/Pentron, Wallingford, Conn. Due to the strength of some of these porcelains, crowns and bridges have been produced without the need for metal substrates.
In order to accommodate the sintering of higher expanding dental porcelain and alloy powders, efforts have been made to replace part of the alpha-quartz filler with an alpha-cristobalite filler. These attempts have been unsuccessful though since the presence of cristobalite produces a spike in the thermal-expansion verse temperature profile in the range of 200° to 270° C. The spike produces interfacial tensile stresses between the substrate and the green overlay which is inevitably detrimental to the integrity of the final restoration. Theoretically, it is preferred to have a compressive mode of stress at the interface of the die material and the overlaid material to eliminate defects in the final restoration. This is accomplished by having a refractory die material which has higher thermal expansion values than those of the materials being sintered thereon.
SUMMARY OF THE INVENTION
The present invention provides phosphate-bonded investments and refractory die materials upon which dental porcelains and/or alloy powders can be sintered. According to the present invention, inorganic fillers are mixed with appropriate binders to produce die materials which exhibit very high thermal expansion properties without exhibiting any large or sudden changes in their thermal expansion verse temperature profile. The compositions of the present invention may also preferably be formulated so that their profiles are very similar to the profiles of the overlaid materials to be used in conjunction therewith.
The present invention eliminates the problem of abrupt discontinuous changes in thermal expansion while offering higher thermal expansion values. Investments and refractory die materials having thermal expansions of greater than 0.80% in the range of 25° to 500° C. are provided according to the present invention by incorporating leucite (KAlSi 2 O 6 ) or calcium difluoride (CaF 2 ), or both, as fillers for investments and refractory die materials. In accordance with the present invention, it has been found that leucite and CaF 2 possess high thermal expansion characteristics.
The invention may be more fully understood with reference to the accompanying drawings and the following description of the embodiments shown in those drawings. The invention is not limited to the exemplary embodiments but should be recognized as contemplating all modifications within the skill of an ordinary artisan.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the thermal expansion of four forms of silica currently used as fillers for investments and refractory die materials;
FIG. 2 is a graph showing a comparison of the thermal expansion percentage verse temperature curves for investments and refractory die materials of the prior art and for investments and refractory die materials according to the present invention;
FIG. 3 is an expanded view of the graph of FIG. 2 taken over the temperature range of 350° C. to 700° C.; and
FIG. 4 is an expanded view of the graph of FIG. 2 taken over the temperature range of 0° C. to 350° C.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, leucite or calcium difluoride, or both, are used as fillers for investments and refractory die materials, especially those used for casting alloys, and sintering dental porcelains and alloy powders, respectively. The investments and refractory die materials of the present invention exhibit thermal expansions which equal or exceed the thermal expansion of today's high expanding dental porcelains. In a particular embodiment, investment and refractory die materials according to the present invention exhibit a thermal expansion of greater than 0.80% at 500° C. without exhibiting a spike in the thermal expansion verse temperature profile.
The preparation of leucite and CaF 2 powders are well known in the art. Leucite may be produced using pure oxides (SiO 2 , K 2 O, Al 2 O 3 ) as starting ingredients or by modifying potash-feldspar mineral. The use of potash feldspar, in most instances, may introduce small amounts of other oxides (such as Na 2 O, CaO, MgO, etc.), however, these oxides in small amounts usually do not significantly affect the thermal expansion behavior of the leucite.
The fillers according to the present invention are preferably used alone but may be combined with small amounts of silica fillers, particularly quartz. If combined, preferably 50% by weight, or less, of the silica filler is added. Most preferably, the filler comprises only leucite, only calcium difluoride, or a combination of only leucite or calcium difluoride. Investment and refractory die material powder blends containing leucite mixed with colloidal silica are easier to pour than those containing calcium difluoride and are thus somewhat preferred for most applications.
Along with the fillers, a portion of the solid binders is added to the investments and refractory die materials of the present invention. The fillers usually comprise about 50 to about 80% by weight of the investment or refractory die material. More preferably, the filler comprises between about 60 and about 70% by weight. In the Examples below, the filler comprises about 65.5% by weight of the investment or refractory die material.
The binders of the investments and refractory die materials of the present invention comprise about 20 to about 50% by weight of the material. More preferably, the binders make up about 30 to about 40% by weight. In the Examples below, the binders comprise about 34.4% by weight of the investment and refractory die material.
The binders may comprise, but are not limited to, magnesium oxide, mono- or di-ammonium phosphate, and colloidal silica in a liquid form. Other binders known to those of skill in the art may also be used.
One particularly useful binder is colloidal silica in a liquid form which is used to improve the processibility of the material so that it is easily poured into a mold. The silica liquid further enhances the setting process of the material. The silica concentration can be adjusted to adjust the setting expansion of the investment or refractory die material. Preferred concentrations of silica in colloidal silica binders are between about 30 and about 40% by weight, more preferably between about 30 and about 35% by weight.
Surfactants may also be used in trace amounts and are added to control the dispersion and surface properties of the fillers and binders. Some surfactants may include anionic, cationic and non-ionic surfactants that are well known to those of ordinary skill in the art.
According to an embodiment of the present invention, the oxide blends, or modified feldspar blends, are subjected to a fritting process above 1150° C. so as to crystallize the leucite. The fritted boule is then ground to a proper size to be used as a filler for an investment or refractory die material. CaF 2 having the proper particle size can be directly purchased from manufacturers or distributors or it may be ground down to an adequate size.
Once ground, the filler is added to a mixture of the binders and surfactants, and other fillers, if used. The resultant mixture is allowed to set at room temperature. When mono- or di-ammonium phosphate is used as a binder, the mixture is heated to remove the ammonium which would otherwise discolor the pigments present in the shaded porcelains. The resultant mass is subjected to a high temperature treatment process at about 1030° C.
EXAMPLES
Table I below shows the compositions of the investment and die-materials of Examples 1-5. As can be seen, the investments and refractory die materials of the present invention, shown in Examples 1-3, exhibit high thermal expansions and no sudden or large increase in thermal expansion over the temperature range of 0° to 700° C.
TABLE I______________________________________Ingredients Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5______________________________________Leucite 16.4 8.2 8.2 -- --CaF.sub.2 -- 8.2 -- -- --Quartz -- -- 8.2 13.6 16.4Cristobalite -- -- -- 2.8 --MgO solids 2.0 2.0 2.0 2.0 2.0MaP Monoammo- 1.6 1.6 1.6 1.6 1.6nium PhosphateColloidal Silica 5.0 5.0 5.0 5.0 5.0Liquid-30% silica______________________________________
The thermal expansion verse temperature profiles for Examples 1-5 are shown FIG. 2. FIGS. 3 and 4 are expanded portions of the graph of FIG. 2 which have been enlarged for the purpose of clarity. It is clear from these curves that leucite and CaF 2 when used as fillers, alone or in combination, offer higher thermal expansion values without the presence of spikes in their thermal expansion verse temperature profiles.
Although the present invention has been described in connection with preferred embodiments, it will be appreciated by those skilled in the art that additions, modifications, substitutions and deletions not specifically described herein may be made without departing from the spirit and scope of the invention as defined in the appended claims. | Phosphate-bonded investments and refractory die materials are provided upon which dental porcelains and/or alloy powders can be sintered. Inorganic fillers are mixed with appropriate binders to produce mold materials which exhibit very high thermal expansion properties without exhibiting any large or sudden change in their thermal expansion verse temperature profile. Investments and refractory die materials having thermal expansions of greater than 0.80% in the range of 25°-500° C. are provided by incorporating leucite (KAlSi 2 O 6 ) or calcium difluoride (CaF 2 ), or both, as fillers for investments and refractory die materials. | 1 |
BACKGROUND OF INVENTION
[0001] This invention relates to a starter motor for an engine for a vehicle such as a motorcycle or the like and to a method for starting such engines and reducing starter noise at the time of the starting operation.
[0002] In an engine for a vehicle such as a motorcycle, a starter motor is used at the time of engine starting to rotate an engine shaft under battery power. The starter motor is generally a DC motor driven through a relay by operation of a manual switch such as main switch or a starter switch of the vehicle. In this case, the switch is first turned ON to rotate the starter motor, for cranking. When the engine is started after the starter motor load drops to zero, resulting in a maximum rotational speed. At this moment, the switch is turned OFF to stop the power supply to the starter motor. As a result, the starter motor output shaft is disconnected from the engine shaft by a one way clutch type of device and it rotates idly by its inertia and stops after gradually reducing its rotational speed.
[0003] At the time of the engine starting described above, during the time while the starter motor is stopping its rotation after the power supply to the starter motor is OFF it generates an abnormal and unpleasant noise. The cause of this phenomenon may be understood by reference to FIG. 1. In this figure the horizontal axis represents time and the vertical axis represents both starter motor rotational speed and noise level.
[0004] The power source of the starter motor is turned ON at a time t 0 and begins to rotate for cranking. When the engine is started, the starter motor load drops to zero and the rotational speed increases to a maximum. At a time t 1 when this state is reached, the starter switch is turned OFF by hand.
[0005] As a result, the starter motor rotates idly as a result of its inertia, decreasing its rotational speed gradually and stopping eventually at a time t 2 . Between the times t 1 and t 2 , an abnormally high noise is generated. The noise at this point is an abnormal and unpleasant one and unusually is louder than the engine noise or even that of the starter motor during the actual starting operation.
[0006] This abnormal noise is caused by the starter motor yoke of its stator resonating when the natural frequency of the yoke coincides with the number of times of cogging reaction at a specific motor speed. This resonance frequency corresponds to a frequency determined by the least common multiple of the number of slots of an armature and the number of magnetic poles of magnets, or the cogging number/rotation, and the cogging reaction produced at a specific motor speed. In an actual measurement shown in FIG. 1, the cogging number is the least common multiple of 28 for a motor with fourteen slots and four-pole magnets. An abnormal noise is generated at the time of the rotational speed of 5100 rpm. In this case, the resonance frequency is expressed as follows:
(28×5100/60)×2=4760 Hz.
[0007] More specifically, an armature connected to the output shaft of the starter motor is formed of a plurality of radially disposed cores. Electrical coils are wound on these cores and face a plurality of magnets on the inside surface of the starter motor yoke.
[0008] The armature is rotated through successive attractions of magnetic forces of the magnets.
[0009] When the cores of the armature pass across the magnets and its polarities are changed, the armature changes its rotational torque, generating cogging with a perturbed movement. Therefore, the larger the magnetic forces are, the greater cogging is generated, resulting in an abnormal noise due to the reaction.
[0010] Normally the material of the permanent magnets is a ferrite-based magnetic material. However, neodymium-based magnets made from a magnetic material containing Nd of a rare metal element or its compound known as high-energy magnets are preferred because they permit a higher output starter motor for a given size. If such neodymium-based magnets are used, since the magnetic forces are great, the problem of an abnormal noise due to the cogging reaction is amplified.
[0011] It is therefore a principle object of this invention to provide an improved starter motor arrangement and method of starting an internal combustion engine that reduces noise during the starting operation.
SUMMARY OF INVENTION
[0012] A first feature of this invention is adapted to be embodied in a starter arrangement for an internal combustion engine. The starter arrangement comprises a DC electrical motor having an output shaft in starting arrangement with a shaft of the engine for starting the engine. A battery is provided for selectively energizing terminals of the DC electrical motor for driving the engine shaft to start the engine. A braking arrangement brakes the rotation of the starter motor output shaft when the engine starts.
[0013] In a preferred embodiment of this first feature, the braking arrangement comprises a switching arrangement that connects the terminals of the DC electrical motor to the battery to charge the battery upon the deenergization of the terminals for stopping the driving of the DC electrical motor by regeneratively braking the rotation of said DC electrical motor.
[0014] Another feature of the invention is adapted to be embodied in a method for starting an engine with a DC electrical motor and reducing starter motor noise. A DC electrical motor has an output shaft in starting arrangement with a shaft of the engine for starting the engine. A battery is also provided. The method comprises the steps of selectively energizing terminals of the DC electrical motor for driving the engine shaft to start the engine upon operator demand and the rotation of the starter motor output shaft is braked when the engine starts.
[0015] In a preferred embodiment of this other feature the starter motor output shaft is braked by connecting the terminals of the DC electrical motor to the battery to charge the battery upon starting of the engine to regeneratively brake the rotation of the DC electrical motor.
BRIEF DESCRIPTION OF DRAWINGS
[0016] [0016]FIG. 1 is a graphical view showing the noise and speed of a prior art type of starter motor during engine starting operation.
[0017] [0017]FIG. 2 is a cross sectional view of a starter motor constructed and operated in accordance with the invention.
[0018] [0018]FIG. 3 is a cross sectional view taken along the line 3 - 3 in FIG. 2.
[0019] [0019]FIG. 4 is a cross sectional view taken along the line 4 - 4 in FIG. 2.
[0020] [0020]FIG. 5 is a circuit diagram of the starter motor.
DETAILED DESCRIPTION
[0021] Referring now in detail to the drawings and initially primarily to FIGS. 2 - 4 , a starter motor for an internal combustion engine (not shown) is indicated generally by the reference numeral 11 . The starter motor 11 is comprised of a stator 12 formed of a cylindrical yoke 13 and four permanent magnets 14 , of arc-shaped cross section, bonded on the inside surface of the yoke. The permanent magnets 14 are preferably formed from a neodymium (Nd)-based magnetic material that is magnetized after being bonded to the yoke 13 .
[0022] An armature or rotor, indicated generally at 15 rotatably mounted inside the stator 12 in a manner to be described shortly. The armature 15 is comprised of a core 16 facing the magnets 14 and fixed to a starter motor output shaft 17 . A commutator 18 is fixed adjacent to the core 16 on one end of the starter motor output shaft 17 .
[0023] The core 16 , as shown in FIGS. 2 and 3, is formed of a plurality of radially disposed core teeth 19 . In the illustrated embodiment there are 14 core teeth 19 . Electrical coils (not shown) are wound around the core pieces 19 . The commutator 18 is formed of a plurality of contact pieces 21 corresponding in number to the core pieces 19 and that are electrically connected to the coil ends, as is well known in the art. Two sets of two brushes 22 and 23 (FIG. 4) held by respective brush holders 24 and 25 are juxtaposed to the commutator 18 at its outside circumference. The brushes 22 and 23 are pressed against the contact pieces 21 of the commutator 18 by coil springs 26 .
[0024] Fitted to the opposite ends sides of the cylindrical yoke 13 are a front cover 27 (FIG. 2) covering the left side of the yoke 13 as seen in the figure and a rear cover 28 covering the right side of the yoke. on the figure, collectively forming, with the yoke 13 , a motor case indicated generally by the reference numeral 29 . The starter motor output shaft 17 is journalled for rotation on the front cover 27 and the rear cover 28 , respectively by bearings 31 .
[0025] On the rear cover 28 (FIGS. 2 and 4) is provided a positive terminal 32 for power supply from the positive electrode of a battery (described later by reference to FIG. 5 mounted on the vehicle. The positive terminal 32 is suitably connected to the brushes 22 on the positive electrode side. The brushes 23 on the negative electrode side (ground side) are connected to the end closure 28 by grounding fasteners 33 . The motor case 29 is grounded to the associated engine by a mounting bracket 34 that fixes the starter motor 11 to the engine thus acting as a negative terminal.
[0026] On the front cover 27 is mounted an oil seal 35 (FIG. 2) for preventing ingress of oil into the motor case 29 from the associated engine, and an O-ring 36 for sealing the mounting portion to the engine. On the starter motor output shaft 17 at the engine side end is provided a pinion gear 37 meshing with an flywheel gear (not shown) to rotate the engine shaft for starting. Some form of one way device such as a one way clutch is provided in this connection to permit the engine shaft from driving the starter motor once the engine has started to run under its own power, as is well known in this art.
[0027] Inside the rear cover 28 covering the commutator 18 at the end of the starter motor output shaft 17 is fixed a disk-like brush carrier 38 . The brush holders 24 and 25 are affixed to the brush carrier 38 at four positions spaced radially at right angles to hold the opposing two positive electrode brushes 22 and opposing two negative electrode (grounding) brushes 23 . As has been noted, the brushes 22 , 23 are biased radially inwardly toward the commutator 18 by the coil springs 26 . The positive electrode brushes 22 are connected to the positive terminal 32 , and the negative electrode brushes 23 to the negative (grounding) terminal 34 .
[0028] [0028]FIG. 5 is a diagram of a circuit for driving the starter motor 11 . The starter motor 11 is connected to the aforementioned battery 39 through a relay 41 . Power supply from the battery 39 to the motor is switched ON/OFF through operation of a main or starter switch 42 .
[0029] The relay 41 is comprised of a solenoid winding 43 . The winding 43 encircles an armature that carries a contact plate 44 .The relay 41 further comprises first and second contacts 45 , 46 with which the contact plate 44 comes in contact.
[0030] When the switch 42 is closed, the magnetic force of the solenoid 43 causes the contact plate 44 to move toward the right as shown in FIG. 5, closing the first contact 45 . Thus power supply from the battery 39 is ON for energization of the starter motor 11 . As a result, the starter motor 11 is rotated to rotate the engine.
[0031] After the engine is started by this cranking, the switch 42 is opened. Then, the solenoid 43 is disconnected from the battery 39 , and the contact plate 44 is returned to the left on the figure by a spring (not shown) and comes in contact with the second contact 46 to close it (the state shown in FIG. 5).
[0032] As a result of the second contact 46 being closed, the positive and the negative electrodes of the starter motor 11 are connected. Thus, power supply from the battery 39 to the starter motor 11 is OFF, energization of the starter motor 11 is stopped, and the motor begins to rotate idly by inertia. At this moment, the positive and the negative electrode of the motor are connected, so that the starter motor 11 acts as a generator, producing regenerative electromotive force. Whereby, the function of regenerative braking is effected and the starter motor 11 is stopped quickly. The starter noise caused by the prior art as described by reference to FIG. 1 is thus substantially reduced if not totally eliminated.
[0033] Thus it should be readily apparent that the described apparatus and starting method achieves the goals set out above in a low cost and highly effective manner. Of course those skilled in the art will understand that the embodiment described is only a preferred embodiment of the invention and various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims. | An improved DC electrical starting motor and method for starting internal combustion engines that reduces starter motor noise in the period after the engine starts by effecting breaking of the starter motor shaft at that time. Preferably the braking is accomplished by regenerative braking. | 5 |
This is a continuation of application Ser. No. 07/814,871, filed 24 Dec. 1991, now allowed, the contents of which are incorporated by reference.
This invention was made with government support under Grant Numbers DK35083 and CA50676 from the National Institutes of Health. The U.S. Government has certain rights in this invention.
Throughout this application various publications are referenced. Full citations for these publications may be found at the end of the specification immediately preceding the claims. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains.
BACKGROUND TO THE INVENTION
Thyroid hormones, as well as retinoic acid (RA) function through multiple nuclear receptors that belong to the steroid/thyroid hormone receptor superfamily (reviewed by Evans 1988; Green and Chambon, 1988). The thyroid hormone receptors (TR) are encoded by two genes (Weinberger et al., 1986; Jansson et al., 1983), referred to as TRα and TRβ from which multiple isoforms are generated (Benbrook and Pfahl, 1987; Nakai et al., 1988; Mitsuhashi et al., 1988; Lazar et al., 1989; Koenig et al., 1989; Sakurai et al., 1989; Hodin et al., 1989). The known TRα subtypes are generated by alternative mRNA splicing yielding several isoforms with distinct carboxyterminal regions (Sap et al., 1986; Benbrook and Pfahl, 1987; Thompson et al., 1987; Mitsuhashi et al, 1988; Nakai et al., 1988). Only one of these isoforms, TRα-1, is a classical ligand dependent transcriptional activator, while for the other splicing variants (TRα-2 and TRα-2V) a function as transcriptional activator could not be demonstrated (Mitsuhashi et al, 1988; Lazar et al., 1989; Koenig et al., 1989; Schueler et al., 1990; Hermann et al., 1991). Although TRα-2 has been shown to exhibit weak repressor activity (Lazar et al., 1989; Koenig et al., 1989; Hermann et al., 1991), the biological functions of the carboxyterminal TRα variants are not well understood. Two TRβ forms have been described (Weinberger et al., 1986; Hodin et al., 1989) that differ in their amino terminal regions and both are transcriptional activators. Besides their classical roles as ligand dependent enhancer proteins, TRα-1 and TRβ-1 function as transcriptional repressors and/or silencer proteins in the absence of ligand (Graupner et al., 1989; Damm et al., 1989; Zhang et al., 1991b; Brent et al., 1989; Graupner et al., 1991; Baniahmad et al., 1990).
Retinoic acid receptors (RAR) are encoded by three genes RARα, β, and γ (Petkovich et al., 1987; Giguere et al., 1987; Benbrook et al., 1988; Krust et al., 1989) from which multiple isoforms that differ in their amino terminal regions, are generated by a combination of alternative promoter usage and alternative splicing (Zelent et al., 1991; Lehmann et al., 1991; Leroy et al., 1991). All RAR isoforms can antagonize each other's activity (Husmann et al., 1991). A second type of RA receptor was more recently described that is only activated by high concentrations of RA and does not show significant homology in its ligand binding domain with RAR but has significant homology in its DNA binding domain (Mangelsdorf et al., 1990). It has been proposed that this receptor may be activated by an unknown RA metabolite derivative (Mangelsdorf et al., 1990) and it has been designated retinoid x receptor (RXRα). This receptor is highly homologous to a previously isolated orphan receptor H-2 RIIBP (Hamada et al., 1989) now usually referred to as RXRβ.
TRs as well as the retinoid receptors are believed to function as dimeric or multimeric proteins since they recognize and bind specifically to dimeric or multimeric response elements, that are either direct repeats or palindromic repeats. Certain response elements like the palindromic TRE, are activated by all three types of receptors, TRs, RARs, and RXRs (Umesono et al., 1988; Graupner et al., 1989; Mangelsdorf et al., 1990) while other response elements are receptor specific (Hoffmann et al., 1990; Umesono et al., 1991; Näär et al., 1991). A direct repeat of the sequence TGACCT can function as a specific response element for TRs, RARs and vitamin D receptors depending on whether the repeats are separated by 4, 5 or 3 spacer nucleotides, respectively (Umesono et al., 1991). However, spacing between half-sites of response elements does not solely determine receptor specificity (Näär et al., 1991; our unpublished results).
Although a large set of data appears to suggest that TRs and RARs function as homodimers, there exists no convincing experimental evidence yet that these proteins interact with their responsive elements in vivo or in vitro specifically as homodimers. To the contrary, an increasing volume of data suggests that TRs as well as RARs require accessory nuclear proteins for efficient DNA binding (Lazar and Berrodin, 1990; Glass et al., 1990; Murray and Towle, 1989; Burnside et al., 1990; Zhang et al., 1991a), consistent with recent data from others (Forman and Samuels, 1991). Deletion of a portion of the TRα carboxyterminal region appears to increase DNA binding and greatly enhances dimerization and/or oligomerization, suggesting that one dimerization domain of TRα is located in the “DNA binding domain” (DBD). This concept is supported by structural data on the glucocorticoid (GR) (Härd et al., 1990; Luisi et al., 1991) and estrogen (ER) receptors (Schwabe et al., 1990). A second dimerization/oligomerization domain was found to be located in the “ligand binding domain” (LBD), a region that has been suggested to form a leucine zipper type structure (Forman et al., 1989). Part of the carboxyterminal region appears to inhibit the dimerization function of TRα such that homodimers with a palindromic TRE are not efficiently formed (Zhang et al., 1991a). Enhancement of DNA binding and the formation of a slow electrophoretic mobility complex required the presence of a protein present in nuclear extracts from a number of cell lines including F9 cells, CV-1 cells, and GC cells (Zhang et al., 1991a).
The nature of this protein could not be determined, however it is reasonable to hypothesize that this protein(s) and/or the proteins that interact with TRs and RARs, as described by others (Lazar and Berrodin, 1990; Glass et al., 1990; Murray and Towle, 1989; Burnside et al., 1990; Rosen et al., 1991) are important components for these nuclear receptors that regulate their activity. Whether the protein(s) are members of the nuclear receptor family is not yet known, however we present data in this publication that one of the retinoid receptors, RXRα, strongly enhances binding of TRs and RARs to several response elements. Studies of the enhanced and upshifted TR or RAR complexes by antibodies and receptor mutants demonstrate that RXRα can form a heterodimer with TRs and RARs. The interaction can occur in the absence of DNA and requires both DNA and ligand binding domains of RXRα and the ligand binding domain of TRs or RARs. In cotransfection experiments, RXRα greatly enhances TR and RAR transcriptional activation activity at retinoic acid concentrations where RXRα itself is not significantly activated. Our data suggest that RXRα belongs to a novel class of nuclear receptors that we would like to term “booster receptors” (B-receptors) that at low ligand concentrations greatly enhance the activity of other receptors by heterodimer formation while, when by themselves, can not dimerize efficiently and have only low affinity for their ligands.
SUMMARY OF THE INVENTION
This invention provides a purified heterodimer comprising an RXR and a hormone receptor. The invention also provides a method of screening ligands for their effect on the activity of an RXR-containing hormone receptor heterodimer comprising combining the heterodimer with the ligand and determining the effect on activity. Also provided is a method of amplifying the activity of a hormone receptor comprising forming a heterodimer with another hormone receptor.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1A–1D . Enhancement of TRα and RAR DNA binding by RXRα
(a) In vitro synthesized TRα, TRβ, RARα, RARβ, RARγ and TRα2 receptor proteins were preincubated either with (+) or without (−) equal amount of in vitro synthesized RXRα protein at room temperature for 10 minutes. Following this preincubation, the reaction mixtures were incubated with 32 p-labelled palindromic TRE (for 1 sequence see FIG. 2 a ) and analyzed by gel retardation assay as described in Experimental Procedures. Lane 1 represents binding of unprogrammed reticulocyte lysate. The nonspecific band observed with unprogrammed reticulocyte lysate is indicated by the open triangle. Complexes migrating below or above the nonspecific band are the specific comlexes of TRs in the absence of RXRα and the complexes formed by TRs and RARs in the presence of RXRα. As a control, equal amounts of TRα and RARα proteins were also mixed and inclubated with labelled TRE.
(b) Effect of estrogen receptor. To analyze whether ER could also enhance TRα binding to the TRE, or whether RXRα would enhance ER binding to the ERE, equal amounts of in vitro synthesized ER protein were incubated with TRα or RXRα proteins and the reaction mixtures were analyzed by gel retardation using either 32 p-labelled palindromic TRE or palindromic ERE as indicated. Control represents the binding of the unprogrammed reticulocyte to ERE. The nonspecific bands observed with unprogrammed lysate are indicated by the open triangles.
(c) Effect of CV-1 cell extract on TRαDNA binding. Cell extract was prepared from CV-1 cells as described in the Experimental Procedures and the different amounts of cell extract (in microgram) were incubated either with in vitro synthesized TRα protein or the same volume of unprogrammed reticulocyte lysate. The reaction mixtures were then analyzed by gel retardation using 32 p-labelled palindromic TRE.
Open triangle, solid arrow, and solid diamond indicate the nonspecific binding of the reticulocyte lysate, specific TRα binding, and the upshifted TRα complex, respectively.
(d) Interaction of RXRα with TR and RAR is ligand independent. The effect of T 3 (10- 7 M) or RA (10- 7 M) on the interaction between RXRα and TRα or RARα was analyzed by gel retardation as described in FIG. 1 a . Open triangle indicates the nonspecific binding of the unprogrammed reticulocyte lysate.
FIGS. 2A–2C . RXRα forms a complex with TRs and RARs.
(a) Effect of anti-Flag-RXRα on the slow migrating complex. In vitro synthesized Flag-RXRα (F-RXRα) protein was incubated with in vitro synthesized TRα, TRβ, RARα RARβ and RARγ as indicated, in the presence of anti-Flag antibody (α-Flag). After incubation at room temperature for 45 minutes, the effect of antibody on slow migrating complexes was analyzed by gel retardation using 32 p-labelled palindromic TRE as a probe. As a control, receptor mixtures were also incubated with preimmune serum (NI). The effect of anti-Flag antibody on Flag-RXRα, TRα, TRβ, RARα, RARβ and RARγ was also shown. Empty triangle represents the binding of unprogrammed reticulocyte lysate (lane 1). Solid triangle represents the binding of antibody-shifted Flag-RXRα protein. Arrow represents the binding of antibody-shifted Flag-RXRα-TRβheterodimer.
(b) Effect of anti-Flag-TRα antibody on binding of the slow migrating complex. In vitro synthesized Flag-TRα (F-TRα) protein was incubated with in vitro synthesized RXRα protein in the presence or absence of anti-Flag antibody. The effect of antibody on DNA binding of the slow migrating complex was analyzed as described in FIG. 2 a . For control, the receptor mixture was also incubated with preimmune serum (NI). The effect of anti-Flag antibody on DNA binding of Flag-RXRα, RXRα, Flag-TRα, and TRα was also analyzed. For comparison, anti-Flag antibody/Flag-RXRα-TRα interaction was run on the same gel (lanes 7–10). Open triangle represents the nonspecific binding of the unprogrammed reticulocyte lysate. Solid triangle represents the binding of the antibody-shifted RXRα protein. Arrow indicates the binding of antibody-upshifted Flag-TRα protein.
(c) Effect of anti-Flag-RARγ antibody on the slow migrating complex. The assay was carried out as described in FIG. 2 b . Open triangle represents the binding of the unprogrammed reticulocyte lysate. Solid triangle indicates the binding of antibody-upshifted Flag-RXRα protein.
FIGS. 3A and 3B . Interaction of TRα and RXRα on different DNA response sequences.
(a) Sequences of oligonucleotides used for the gel retardation assays. TRE (SEQ. ID NO: 9) is the perfect palindromic T3/RA response element (Glass et al., 1988; Graupner et al., 1989). TRE/OP (SEQ. ID NO: 10) is an oligonucleotide consisting of two TRE half-site (as indicated by the arrows) in the opposite orientation separated by 4 bp. βRARE (SEQ ID NO:11) is a RA response element present in the RARβ promoter (Hoffmann et al., 1990). TRE/half (SEQ ID NO:12) is the half-site of TRE. ERE (SEQ ID NO:13) is the perfect palindromic ER response element (Klein-Hitpass et al., 1986). These oligonucleotides were synthesized with appropriate restriction sites at both ends as indicated by the small letters.
(b) Gel retardation analysis of RXRα-TRα interaction using different DNA response elements. Gel retardation assays were carried out essentially as described in FIG. 1 a but using different response elements. (−) represents the binding of unprogrammed reticulocyte lysate. Specific binding of TRα to each response element is indicated by the solid arrows. Non specific bands observed with unprogrammed reticulocyte lysate are indicated by open triangles. Binding TRα to βRARE or RXRα to all response elements was not visible under the conditions used. The heterodimer formation (TRα/RXRα) was clearly observed on the TRE, the TRE/OP and the βRARE (as indicated by the diamonds) but not on TRE/half and the ERE.
FIGS. 4A–4D . Ligand binding domains of TR and RAR are essential for the interaction of RXRα.
(a) Schematic representations of the TRα and c) RARγ deletion mutants. Numbers above the bars indicate the amino acids positions. DNA binding domain (DBD) and the ligand binding domain (LBD) are shown. A leucine-Zipper-like motif (Foreman et al., 1990) in the LBD of the TRα and RARγ containing 9 heptad repeats is indicated by the black bars.
Interaction of RXRα with the TRα and d) RARγ deletion mutants. TR and RAR deletion mutant proteins were synthesized in vitro as described in the Experimental Procedures. Equal amounts of TR and RAR proteins and the mutant proteins were analyzed for their interaction with RXRα using the gel retardation assay with the palindromic TRE as described in FIG. 1 a . The nonspecific binding of the unprogrammed reticulocyte lysate is indicated by the open triangles.
FIGS. 5A–5C . Both DNA and ligand binding domains of RXRα are required for interaction with TR and RAR.
(a) Schematic representation of the RXRα deletion mutants. RXRα deletion mutants were constructed and proteins were prepared as described in the Experimental Procedures. Numbers above the bars indicate the amino acid positions. DNA binding domain (DBD) and ligand binding domain (LBD) are indicated. Single lines mark the deleted portions of the receptor. Deletion mutants RXRαm3, RXRαm4 and RXRαm5 are truncated cDNA clones of RXRα isolated from screening the human placenta λgt11 cDNA library. These clones were sequenced and show identical nucleotide sequence as the wild type RXRα. The proteins of these cDNA clones were translated in vitro using existing Met codons for amino acid 28, 61 and 198, respectively, as determined by SDS-PAGE. The black bars indicate the untranslated portions of these three mutants.
Interaction of RXRα deletion mutants with b) TRα and c) RARγ. Interaction of RXRα deletion mutants with TRα and RARγ was analyzed by the gel retardation assay essentially as described in FIG. 1 a . The first lane represents the binding of the unprogrammed reticulocyte lysate. The nonspecific binding is indicated by the open triangles. The specific binding of TRα migrates faster than the nonspecific band. RARγ by itself shows no visible binding to TRE under the condition used. Arrows indicate the migration positions of complexes formed with RXRαm3 and RXRαm4.
FIGS. 6A and 6B . RXRα enhances the transcriptional activation of RAR.
(a) CV-1 cells were cotransfected with 100 ng of TRE 2 -CAT and the indicated amounts of the receptor expression vector. Cells were treated with 100 nM RA (▪) or no hormone (□), and 24 h later assayed for CAT activity. The mean of duplicate cultures is shown.
(b) The TRE-tk-CAT reporter was cotransfected into CV-1 cells with 5 ng RXRα, or 5 ng RARγ, or 5 ng of each receptor expression vector. Cells were treated with indicated concentrations of RA and assayed for CAT activity as described in the Experimental Procedures. The activity of RXRα on the reporter gene in the absence of either hormone was chosen as reference value, and CAT activities were normalized accordingly. The mean of duplicate experiments is shown.
FIGS. 7A and 7B . Induction curves of RXRα in the presence and absence of TRα.
The single palindromic TRE reporter gene ( 7 a ) or the double TRE reporter ( 7 b ) (100 ng/well) were transfected into CV-1 cells together with 5 ng RXRα, 100 ng reporter gene, 150 ng β-galactosidase plasmid, 25 ng TRα (or no TRα) and Bluescript up to 1000 ng. Cells were grown in 24 well plates with the indicated amounts of RA and a constant amount of 10- 7 M T 3 . CAT activities were corrected for transfection efficiency by β-gal values. As control, reporter constructs were transfected alone, and CAT activities were analyzed after the same hormone treatment as described above. The activity of RXRα on the reporter gene in the absence of either hormone was chosen as reference value, and CAT activities were normalized accordingly. The mean values from 4 to 6 independent transfection experiments as shown. Note that CAT activities elicited by T3 after cotransfection of TRα and RXRα or TRα alone correspond to 5-fold induction from the single TRE and 10–15-fold induction from the double TRE, respectively.
FIGS. 8A and 8B . Direct interaction of RXRα with TR or with RAR.
(a) Affinity column chromatography. To analyze whether RXRα directly interacts with TRs and with RARs in the absence of DNA, TRα and RARγ proteins were synthesized in bacteria using PGEX-2T expression vector (Pharmacia). Purified glutathione S-transferase-TRα or RARγ fusion proteins was also bound to a column (−). 35 S-labelled RXRα and the mutant RXRαm4 synthesized in vitro were then loaded on columns that contained bound glutatione transferase-TRα or -RARγ or glutatione transferase. As a control, in vitro synthesized 35 S-labelled ER was also loaded on a column containing bound glutathione transferase-TRα or -RARγ. After extensive washing with PBS, the bound proteins were eluted with 5 mM reduced glutathione. The elutes were concentrated using centricon 10 and analyzed on a 10% SDS-PAGE. The right panel represents in vitro translation products of RXRα, RXRαm4, and ER. Molecular weight markers (in kd) are also shown.
(b) Immuno-coprecipitation of RXRα by antibody against TR or RAR. 35 S-labelled in vitro synthesized RXRα protein was incubated with partially purified bacterially expressed Flag-TRα, or Flag-RARγ (+) or similarly prepared glutathione transferase control protein (−) either in the absence or presence of cross-linker DSP as indicated on the top of the figure. After incubation, either anti-Flag antibody (F) or preimmune serum (NI) was added. The immune complexes were washed, boiled in SDS sample buffer and separated on a 10% SDS-PAGE. The labelled, in vitro synthesized RXRα protein is shown in the right panel together with the molecular weight marker (in kd).
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on the core discovery that an RXR can form a heterodimer with other hormone receptors to increase the activity of the receptors. This increase can be in either the hormone receptors' activity or RXR's activity. Since RXRα and β are very closely related, RXRβhas a similar activity to RXRα. Methods employing RXRβutilize the same methods, conditions etc. as set forth hereinbelow for RXRα.
By “activity” is meant any activity which is affected by the heterodimer formation. Generally, this activity is activation or enhancement of transcription. Generally, the ligand of one or both hormone receptors of the heterodimer enhance the activity.
By “hormone receptor” is meant a receptor of the steroid/thyroid hormone receptor superfamily which forms a heterodimer with an RXR. However, oligodimers are also covered herein. Oligodimers can be tested by the methods set forth hereinbelow. Moreover, any additional receptors not tested can be tested using the methods set forth herein. Proteins having substantially the same sequence and activity of the receptors, such as “RXR”, are also included in the definition of hormone receptor. Thus, minor substitutions, deletions and additions can readily be made and tested. Moreover, any receptor consisting essentially of the amino acids of the hormone receptors are included in the definition.
Additionally, since heterodimer formation can be attributed to certain portions of the hormone receptors, molecules containing only those portions are also contemplated. Also, since only certain regions of the receptor may be necessary for activity, i.e., ligand or hormone binding region, heterodimers containing only these portions of the receptors are contemplated.
The activities of the heterodimers can be applied to affect transcription in an in vivo system. Thus, many therapeutic applications, including enhancement or inhibition of transcription, can readily be obtained.
These methods can easily by adapted to use the heterodimers to screen further ligands for their effect on activity. In this way, more effective ligands can be determined. The well known methods used to screen ligands using a single receptor can readily be applied to screen using heterodimers.
A key discovery set forth herein is that different receptors can form heterodimers with selective enhancement or reduction in activity. Thereby specific genes can be regulated using the teachings herein.
The following experimental procedures and results are set forth to exemplify and not limit the invention.
EXPERIMENTAL PROCEDURES
Plasmid Constructions
The construction of reporter plasmids, TRE-tk-CAT and TRE 2 -tk-CAT has been described previously (Zhang et al., 1991b). The coding sequences of TRα, TRβ, RARβ, and RARγ were inserted into the multiple cloning sites of the eukaryotic expression vector pECE or pBluescript (Stratagene). The construction of these plasmids has been described (Graupner et al., 1989; Zhang et al., 1991b). RARα cDNA was amplified from poly(A) RNA prepared from the squamous cell carcinoma line, SCC-13, by polymerase chain reaction (PCR). The PCR products were cloned into both pECE and pBluescript. Two primers (SEQ. ID NO:1 and SEQ. ID NO:2) (5′-CGCAGACATGGACACCAAACAT-3′; 5′-CCTCTCCACCGGCATGTCCTCG-3′) were used to amplify the N-terminal half of RXRα cDNA from SCC-13 by PCR technique. The Smal-Sall fragment from PCR product (530 bp) containing the DNA binding domain of the RXRα was used as a probe to isolate RXRα cDNA by screening a λgt11 human placenta cDNA library (obtained from J. Millán; Millán, 1986). Several positive clones were obtained, including full length receptor and the truncated clones, RXRαm3, RXRαm4 and RXRαm5 which were sequenced and show identical sequences as the wild type RXRα. The cDNA clones were subsequently subcloned into the EcoRI site of pBluescript and pECE.
To obtain TRα and RARγ deletion mutants, existing restriction enzyme sites on receptors were used to digest receptor cDNAs. The resulting cDNA fragments were purified and cloned into pBluescript. TRαm1 and TRαm2 were generated by digesting TRα cDNA with Xhol (1530) and Stul (964), respectively. RARγm1, RARγm2, and RARγm3 were generated by digesting RARγ cDNA with Pst 1 (1469), DraIII (1066), and Sac I (976), respectively (Numbers in brackets indicate the nucleotide position).
RXRα deletion mutants were obtained as following: RXRαm1 and RXRαm2 were generated by digesting RXRα cDNA with Stul (1463) and XmaIII (1231), respectively. RXRαm6 and RXRαm7 were generated by internal deletion using NcoI and Ba1I, respectively.
The construction of Flag-containing receptors (Flag-RXRα, Flag-TRα, and Flag-RARγ) was described previously (Hermann et al., 1991; Zhang, et al., 1991a). Briefly, they were constructed by ligating a double-stranded oligonucleotide containing an ATG codon and a DNA sequence encoding Flag (SEQ ID NO: 3) (Arg Tyr Lys Asp Asp Asp Asp Lys) (Hopp et al., 1988) to the N-terminus of receptors. The fusion products were then cloned into pBluescript.
Tissue Culture, Transient Transfection, and CAT Assay
CV-1 cells were grown in DME medium supplemented with 10% fetal calf serum (FCS). Cells were plated at 1.0×10 5 per well in a 24 well plate 16 to 24 hours prior to transfection as described previously (Husmann et al., 1991). A modified calcium phosphate precipitation procedure was used for transient transfection and is described elsewhere (Pfahl et al., 1990). In general, 100 ng of reporter plasmid, 150 ng of β-galactosidase (β-gal) expression vector (pCH 110, Pharmacia), and variable amounts of receptor expression vector were mixed with carrier DNA (Bluescript) to 1000 ng of total DNA per plate. CAT activity was normalized for transfection efficiency by the corresponding β-galactosidase activity (Pfahl et al., 1990).
Preparation of Receptor Proteins
cDNAs for RXRα, RARα, RARβ, RARγ, TRα, TRβ, Flag-RXRα, Flag-TRα, Flag-RARγ and the deletion mutants cloned into pBluescript were transcribed by using T7 and T3 RNA polymerases, and the transcripts were translated in the rabbit reticulocyte lysate system (Promega) as described (Pfahl et al., 1990: Zhang et al., 1991b). The relative amounts of the translated proteins was determined by separating the 35 S-methionine labelled proteins on SDS-polyacrylamide gels, quantitating the amount of incorporated radioactivity and normalizing it relative to the content of methionine residues in each protein. In vitro synthesized Flag-containing receptor proteins were checked for corrected sizes and antigenic specificity by immunoprecipitation with anit-Flag antibody (obtained from M. Leahy, Immunex, Seattle, Wash.) followed by SDS-polyacrylamide gel electrophoresis.
cDNAs for RXRαm3, RXRαm4 and RXRαm5 cloned into pBluescript were also translated in vitro. The translation start sites of these clones used the internal ATG sequences at 28, 61 and 198 amino acid position, respectively, as determined by the SDS-PAGE analysis of the 35 S-labelled translation products.
To prepare TRα and RARγ fusion proteins, Flag-TRα and 1 Flag-RARγ cDNAs were cloned in frame into the expression vector pGex-2T (Pharmacia). The proteins were expressed in bacteria using the procedure provided by the manufacturer. Proteins were purified on a prepacked glutathione sepharose 4B column (Pharmacia), and checked by gel retardation assays and western blot with anit-Flag antibody.
Preparation of Specific DNA Fragments
The TRE used in the experiments was a 16-bp perfect palindromic TRE (SEQ. ID NO:4) (TCAGGTCATGACCTGA) (Glass et al., 1988). An oligonucleotide flanked by a Bg1II adaptor sequence was synthesized (Applied Biosystems DNA Synthesizer) and purified by polyacrylamide gel electrophoresis. Oligonucleotides were annealed and were radioactively labeled using the Klenow fragment of DNA polymerase. TRE/OP is an oligonucleotide consisting of two TRE half-sites with a 4 bp spacer (SEQ ID NO: 5) (GATCCTGACCTGAGATCTCAGGTCAG). TRE/half is an oligonucleotide consisting of one TRE half-site (SEQ ID NO: 6) (GATCTCAGGTCA). βRARE is the direct repeat of RA response element present in RARβ promoter (SEQ ID NO:7) (AGGGTTCAGGCAAAGTTCAC). ERE is the perfect palindromic ER response element (SEQ ID NO:8) (TCAGGTCACTGTGACCTGA). These oligonucleotides are all synthesized with a Bg1II adaptor sequence. Labeled DNA probes were purified by gel electrophoresis and used for the gel retardation assay.
Preparation of Cell Extracts
Cell extracts were prepared from CV-1 cells in a buffer containing 20 mM Hepes, pH 7.9, 0.4 M KCl, 2 mM DTT and 20% glycerol as described (Zhang et al., 1991a).
Gel Retardation Assays
In vitro translated receptor protein (1 to 5 μl depending on the translation efficiency) was incubated with the 32 P-labeled oligonucleotides in a 20-μl reaction mixture containing 10 mM hepes buffer, pH 7.9, 50 mM KCl, 1 mM DTT, 2.5 mM MgCl, 10% glycerol, and 1 μg of poly(dI-dC) at 25° C. for 20 minutes. In general, relative low receptor concentration was used to obtain the clear effect of heterodimer formation. The reaction mixture was then loaded on a 5% nondenaturing ployacrylamide gel containing 0.5×TBE (1×TBE=0.089 M Tris-borate, 0.089 M boric acid, and 0.002 M EDTA). To analyze the effect of RXRα or the nuclear proteins on receptor DNA binding activity, RXRα or the cell extracts were preincubated with receptor protein at room temperature for 10 minutes before performing the DNA binding assay. When antibody was used, 1 μl of the antiserum was incubated with the specific translation products at room temperature for 45 minutes before performing the experiments described above.
Affinity Column Chromatography
To analyze the interaction between RXRα and TRα or and RARγ, purified Flag-TRα or Flag-RARγ fusion proteins were loaded on the prepacked glutathione sepharose 4B columns. For control, the vector protein (glutathione S-transferase) prepared under the same conditions was also loaded on the separate columns. The columns were washed extensively with PBS with 1% Tritonx-100. 35 S-labelled in vitro synthesized RXRα, RXRαm4 and ER proteins were applied to the columns. Columns were then washed extensively with 3 times of 10 ml PBS. The bound protein was eluted with 50 μM Tris pH 8 containing 50 μM Tris pH 8 containing 5 μM glutathione. Elutes were than concentrated by using a Centricon 10 microconcentrator, and analyzed by denaturing polyacrylamide gels.
Immunoprecipitation
Twenty microliters of reticulocyte lysate containing in vitro translated 35 S-labelled RXRα were incubated with 5 μl (approximately 0.2 μg) of partially purified bacterially expressed Flag-TRα or Flag-RARγ fusion proteins or similarly prepared glutathione transferase control protein in 100 μl buffer (containing 50 mM KCl and 10% glycerol) for 15 min. at room temperature. When cross-linker was used, we added 2 μl of 100 mM DSP and continued the incubation at room temperature for 10 min. The reactions were then incubated with 1 μl of anti-Flag antibody or preimmune serum for 2 hrs. on ice. Immunocomplexes were precipitated by adding 60 μl of protein-A-sepharose slurry and mixing continuously in the cold room for 1 hr. Protein-A-sepharose was saturated in TBS buffer (Tris-buffered saline) or in RIPA buffer when cross-linker was used. The immunocomplexes were washed four times with NET-N buffer (20 mM Tris, pH 8.0, 100 mM NaCl, 1 mM DTT, 0.5% NP-40) or five times with RIPA buffer when DSP was used, and resuspended in SDS sample buffer containing 15% β-mercaptoethanol, boiled and resolved by SDS-polyacrylamide gel electrophoresis. The gels were fixed, dryed and visualized by autoradiography.
Results
RXRα Enhances DNA Binding of TRs and RARs
Previous data from us (Zhang et al., 1991a) and others (Lazar and Berrodin, 1990; Glass et al., 1990; Murray and Towle, 1989; Burnside et al., 1990; Rosen et al., 1991) suggested that TRs and RARs bind more efficiently to their response elements by binding as heterodimers or heterooligomers. Since proteins from nuclear extracts that enhance TR and/or RAR DNA binding have not been defined, we investigated the possibility that TRs can bind with increased efficiency to the palindromic TRE when complexed with other nuclear receptor proteins, in particular those that bind and activate the same or related response elements. Using the gel retardation assay, we observed that TRα bound to the TRE as one major complex which migrates faster than the nonspecific band seen with unprogrammed reticulocyte lysate ( FIG. 1 a ). This specific complex has been previously demonstrated to represent the binding of a TRα monomer (Zhang et al., 1991a; Forman and Samuels, 1991). When TRα was mixed with RXRα, a dramatic increase in DNA binding was seen. A prominent complex which migrated slower than the nonspecific complex was observed while the faster migrating TRα complex disappeared ( FIG. 1 a ). The strong binding complex was observed at concentrations at which RXRα by itself did not form visible complexes with the TRE ( FIG. 1 d ). The effect of RXRα was specific since no significant increase in TRα binding to the TRE or change of TRα binding pattern could be observed when it was mixed with RARα ( FIG. 1 a ) or estrogen receptor (ER) ( FIG. 1 b ). In addition, when RXRα was mixed with ER and labelled ERE ( FIG. 1 b ), no increased binding or slow electrophoretic mobility complex was seen. Interestingly, when TRα isoform TRα-2 was used, the formation of a low electrophoretic mobility complex was not observed either ( FIG. 1 a ). These data suggest that TRα and RXRα bind as heterodimers at least by an order of magnitude more effectively to the palindromic TRE than by themselves. To investigate whether RXRα can also affect the binding of other nuclear receptors, RXRα was mixed with in vitro synthesized TRβ, RARα, RARβand RARγ receptor proteins ( FIG. 1 a ). Similar to TRα, the complex formed between TRβ and TRE was upshifted by RXRα. In the case of RARα, RARβ and RARγ, specific protein-DNA complexes which migrated slower than the nonspecific complex were observed only in the presence of RXRα, while by themselves RARs did not form detectable complexes with the TRE under the conditions used. Very similar results were also obtained with bacterially produced TRα and RARγ (data not shown). The mobility of the slow migrating complexes formed between RXRα and TRα was very similar to that formed between TRα and nuclear protein(s) ( FIG. 1 c ) from CV-1 cells previously reported by us (Zhang et al., 1991a). This suggests that the protein(s) found in CV-1 cells might be RXRα or related protein(s). Next, we investigated the effect of T3 or RA on the interaction between RXRα and TRs or RARs ( FIG. 1 d ). We observed no clear influence of these hormones on the formation of the slow migrating complexes when TRα and RARα were studied although T 3 slightly increases the migration rate of the TRα complex. Similar results were also obtained when TRβ, RARβ and RARγ were analyzed (data not shown).
RXRα Forms a Complex with TRs and RARs
The observation that TR is upshifted by RXRα but not by RAR and ER and the fact that RAR binds to the TRE strongly only in the presence of RXRα but not of TR, strongly suggested that RXRα interacts with TRs and RARs to form heterodimers or larger complexes which interact very effectively with the palindromic TRE. It is unlikely that RXRα catalyzed formation of TR and RAR homodimers since at high TRα concentrations, we have observed a TRα dimer complex (Zhang et al., 1991a) which comigrates with the nonspecific band of the reticulocyte lysate, and which is at a different position from the complex we observed here in the presence of RXRα. The slow migrating complex observed here cannot represent the binding of RXRα homodimers either, since the migration of the complex is different depending on which receptor is mixed with RXRα ( FIG. 1 a ).
To examine more directly the components of the prominent upshifted complexes, we used RXRα, TRα and RARγ derivatives that contained an eight-amino-acid epitope (Flag) at the amino-terminal end of these receptors (Flag-RXRα, Flag-TRα and Flag-RARγ, respectively) which can be recognized by a specific monoclonal antibody (Hermann et al., 1991; Zhang et al., 1991a). The behavior of these receptor derivatives was indistinguishable from that of the wild-type receptor in both transcriptional activation (Zhang et al., 1991c; data not shown) and DNA binding activity ( FIG. 2 ). When Flag-RXRα was incubated with anti-Flag antibody, we observed a specific complex ( FIG. 2 a , lanes 14 and 23; FIG. 2 b , lane 11; FIG. 2 c , lane 13) which was not observed when preimmune serum was used ( FIG. 2 b , lane 12). The complex may represent the binding of the antibody-catalyzed Flag-RXRα homodimer or homooligomers. These data therefore suggest that RXRα by itself can not efficiently dimerize and bind to DNA. Similar antibody-induced dimerization has been observed for other receptors (Hermann et al., 1991; Zhang et al., 1991a). When Flag-RXRα was incubated with TRs and RARs, it behaved essentially like RXRα, forming prominent slow migrating complexes ( FIG. 2 a , lane 3, 7, 11, 16 and 20). These complexes were strongly reduced when anti-Flag antibody was added ( FIG. 2 a , lanes 4, 8, 12, 17 and 21). At the same time a higher molecular weight complex (indicated by the solid triangle) appeared. The reduction of the slow migrating complexes was observed when antibody was added either before or after both receptors were mixed (data not shown). The effect of antibody was specific in that the binding of these complexes was not changed when preimmune serum was used ( FIG. 2 a , lanes 5, 9, 13, 18 and 22), and the nonspecific binding of unprogrammed reticulocyte lysate (indicated by open triangle) was not affected by the antibody. In addition, the effect of anti-Flag antibody was specific towards Flag-RXRα since it did not influence the binding of TRs and RARs ( FIG. 2 a , lanes 24–28) and RXRα ( FIG. 2 b , lane 13). The migration of the faint higher molecular weight complex that appeared in the presence of antibody was dependent on the TR or RAR isoform used. This complex migrated at the same position as the antibody-catalyzed RXRα homodimer ( FIG. 2 a , lanes 14 and 23), suggesting that it may represent the binding of antibody-catalyzed Flag-RXRα homooligomer. However, the intensity of this band was much weaker than the band observed in the absence of antibody. The inhibition of the slow migrating complexes in the presence of anti-Flag antibody suggests that the antibody interacted with RXRα-TRs or RXRα-RARs complexes, resulting in the formation of larger complexes which have strongly reduced or altered affinity to DNA. When TRβ was assayed in the presence of Flag-RXRα and anti-Flag antibody ( FIG. 2 a , lane 8), we clearly observed an additional complex (indicated by arrow). This complex migrated differently from the antibody-catalyzed Flag-RXRα homodimer complex, and therefore may represent the binding of the antibody-upshifted Flag-RXRα/TRβ heterodimer. Together, these data provide strong support for the assumption that the slow migrating complexes contain RXRα. More direct evidence comes from RXRα deletion mutant studies in which we show that the migration rate of the complexes depends on the size of the RXRα protein ( FIG. 5 ).
We show in FIG. 1 that the slow migrating complexes migrate differently depending on which TR or RAR isoform is mixed with RXRα, suggesting that the slow migrating complexes contain TR or RAR. To directly test this, we used Flag-TRα and Flag-RARγ ( FIGS. 2 b and 2 c ). For comparison, the effect of anti-Flag antibody on Flag-RXRα/TRα and Flag-RXRα/RARγ binding is shown on the same gel ( FIG. 2 b , lanes 7–12; FIG. 2 c , lane 8–13). The Flag-TRα behaved essentially as TRα, forming one specific complex ( FIG. 2 b , compare lane 1 and lane 7), which now can be upshifted by anti-Flag antibody ( FIG. 2 b , lane 5; indicated by arrow) but not by preimmune serum (lane 6). When Flag-TRα mixed with RXRα a slow migrating complex appeared (lane 2) which is similar to the complex formed by TRα and Flag-RXRα (lane 8). The appearance of this slow migrating complex was inhibited when anti-Flag was added (lane 3). The inhibition was specific since the binding was not affected when preimmune serum was used (lane 4) and the nonspecific binding of unprogrammed reticulocyte lysate (indicated by open triangle) was not changed by the antibody. In addition, the antibody did not influence the binding of wild type RXRα or TRα (lane 13 and 14). Similar to the effect of the antibody with Flag-RXRα and TRs or RARs ( FIG. 2 a ), we also observed the appearance of weak slow mobility complexes when incubating antibody together with Flag-TRα and RXRα. When Flag-TRα was replaced with Flag-RARγ, similar inhibition effect of anti-Flag antibody on Flag-RARγ/RXRα binding was also seen ( FIG. 2 c ). Thus, taken together, these data strongly suggest that slow migrating prominent band observed in the presence of RXRα contain both RXRα and TR or RAR.
A Specific Dimeric Response Element is Required for Heterodimer Interaction
To investigate the DNA sequence requirements for effective heterodimer binding, gel retardation assays were carried out using several TRE related sequences: an inverted repeat of the TRE (TRE/OP); a TRE half-site; the βRARE, a retinoic acid response element (Hoffmann et al., 1990; de Thé et al., 1990); and the estrogen response element (ERE, Klein-hitpass et al, 1986) ( FIG. 3 a ). RXRα alone did not bind to these DNA sequences at the concentration we used. However, when it was mixed with TRα, a specific slow migrating complex was observed on the TRE, TRE/OP, and the βRARE ( FIG. 3 b ). Similar to the palindromic TRE, TRα binds to the inverted repeat of the TRE as one complex which was strongly enhanced and upshifted in the presence of RXRα. In case of the βRARE, TRα alone shows no visible binding but binds strongly when RXRα is present. Binding of TRα to the half-site is approximately as efficient as to the palindromic TRE in the absence of RXRα. However, this binding was abolished in the presence of RXRα, suggesting that a TRα/RXRα complex is formed but that a dimeric response element is required for heterodimer interaction. Interestingly, TRα also binds to the ERE, a response element identical to the palindromic TRE except for the 3 bp spacing in the center ( FIG. 3 a ). However, when RXRα was added, the binding of TRα to ERE was abolished. The inhibition of TRα binding to the ERE by RXRα could also be due to the interaction between TRα and RXRα in solution and formation of a heterodimer which has reduced affinity or does not bind to the ERE. Together these data demonstrate that a dimeric recognition sequence must be present for effective heterodimer binding and that heterodimer binding appears to be restricted to T 3 /RA responsive elements. Our data suggest in addition, that RXRα can enhance receptor binding to quite different dimeric response elements, indicating a broad functional role for RXRα.
The Carboxyterminal End of TR and RAR is Necessary for Interaction with RXRα
To delineate regions of the TRs and RARs required for RXRα interaction, a number of TRα and RARγ deletion mutants were investigated ( FIGS. 4 a , 4 c ). The deletion of 8 amino acids from the TRα carboxyterminus did not affect TRα-RXRα interaction, however, deletion of 197 amino acids (TRαm2) or 243 amino acids (Trαm3) abolished TRα-RXRα complex formation. The TRαm2 and m3 mutants bound effectively to the TRE ( FIG. 4 b ) as reported previously and are able to dimerize or oligomerize since several complexes can be observed (Zhang et al., 1991a). Similar results were also observed with RARγ deletion mutants ( FIGS. 4 c , 4 d ). Wild type RARγ and the mutants do not exhibit visible binding under the conditions used. As shown before, a strong DNA binding complex was observed when RXRα protein was mixed with RARγ ( FIG. 4 d ). However, deletion of 102 amino acid from the carboxyterminus (RARγm1) completely abolished the binding of this complex. Other carboxyterminal deletion mutants behaved similarly to the RARγm1 ( FIGS. 4 c,d ). Our results on the TR mutants are consistent with our observation that TRα-2 which has an altered carboxyterminal region (Benbrook and Pfahl, 1987) also does not form a low electrophoretic mobility complex with the TRE in the presence of RXRα ( FIG. 1 a ). Mutational analysis of other receptors, including TRβ, RARα and RARβ, revealed that the carboxyterminal region of these receptors is also important for their interaction with RXRα (data not shown). These results therefore indicate that the carboxyterminal region TRα and RARγ is critical for interaction with RXRα.
RXRα Regions Required for Nuclear Receptor Interaction
To delineate regions of RXRα required for nuclear receptor interaction, deletion mutants of RXR-α were investigated ( FIG. 5 a ) for their ability to upshift TRα and RARγ ( FIGS. 5 b,c ). Deletion of 60 (RXRαm1) or 75 (RXRαm2) amino acids from the RXRα carboxyterminus abolished enhancement and upshift of the TRα band while deletion of 28 (RXRαm3) or 61 (RXRαm4) amino acids from the amino terminus did not visibly affect interaction with TRα, as analyzed by the gel retardation assay ( FIG. 5 b ). However, a comparison of the complexes observed with RXRαm3 and RXRαm4 (indicated by arrows) clearly indicates that the size of the RXR protein determines migration of the complex. The smaller protein RXRαm4 forms a faster migrating complex than the larger protein (RXRαm3). These data therefore provide direct evidence that RXRα participates in the complex. In addition, we observed that the carboxyterminal but not the aminoterminal end of RXRα is required for interaction with TRα. Interestingly, an internal deletion that spanned the hinge region and the aminoterminal half of the ligand binding domain (RXRαm7) also abolished interaction with TRα ( FIG. 5 b ). Thus both TRs as well as RXRα require the carboxyterminal domain for heterodimer formation. In addition, however, a truncated RXRα form (RXRαm5) in which the aminoterminal 198 amino acids were deleted (including the DNA binding domain) also failed to form a complex with TRα. A second mutant lacking the DNA binding domain, RXRαm6, was also unable to upshift TRα. The absence of a complex and the fact that TRαDNA binding was not inhibited, suggest that portions of the DNA binding region of RXRα are required for interaction with TRα. When we replaced TRα with RARγ identical results were obtained with the RXRα mutants ( FIG. 5 c ). In this experiment, RXRαm4 also forms a complex with RARγ which migrates faster than the complex formed by RXRαm3 and RARγ, as indicated by arrows. Similar results were also obtained when TRβ, RARα and RARβ were used (data not shown). These data thus support the hypothesis that interaction of RXRα with TRs and RARs is mediated by the same structural determinants.
RXRα Enhances Gene Activation by RARs
The ability of RXRα to enhance RAR and TR DNA binding could also allow enhancement of transcriptional activation of these receptors on the TRE, a known RA response element (Graupner et al., 1989; Umesono et al., 1988). When low concentrations of RXRα expression vector were cotransfected with RARα and the TRE 2 -tk-CAT reporter construct, a strong enhancement of the RARα activity was observed ( FIG. 6 a ). Most interestingly, this strong enhancing activity by RXRα was seen at RA concentrations (10- 7 M) at which RXRα by itself was only slightly activated ( FIG. 6 b ). The increased activation of the reporter gene in the presence of both retinoid receptors is clearly more than additive at certain receptor concentrations as shown. For instance, when 25 ng of RARα and 25 ng of RXRα expression vectors were used, a strong synergistic effect was observed. A very similar enhancing effect was also observed with RARγ ( FIG. 6 b ). In this study, we analyzed the effect of RXRα on RARγ activity under several RA concentrations using the TRE-tk-CAT construct as reporter. At the concentrations used, neither RXRα by itself nor RARγ by itself could elicit any significant transcriptional response at RA concentrations between 10- 9 M and 10- 7 M ( FIG. 6 b ). However, when they were transfected together, a synergistic effect (2 to 4 fold induction) was observed over this RA concentration range. Thus, the ability of RXRα to enhance RAR DNA binding in vitro correlates with an enhanced transcriptional activation capacity of RXRα-RAR complexes in vivo.
Dual Ligand Requirements of the TRα/RXRα Complex
The above experiment did not allow to determine whether RXRα itself requires ligand binding to boost transcriptional activation with RARα or RARγ. When we cotransfected RXRα with TRα, we also observed synergism between both receptors on \TRE-tk-CAT reporter constructs ( FIG. 7 ). Some synergism was observed when only thyroid hormone (T 3 ) was added, while optimal synergism required the presence of both ligands, T 3 and RA. Remarkably, only low amounts of RXRα as well as TRα were required to observe a strong activation of the reporter genes.
To examine in detail the ligand requirements for the putative RXRα/TRα complex, we compared the RA concentrations required to activate RXRα alone or in combination with TRα. RXRα expression vector alone or together with TRα expression vector were cotransfected into CV-1 cells with reporter constructs that contain either a single (TRE-tk-CAT) or double (TRE 2 -tk-CAT) response element. Cells were grown in the presence of a constant amount of T 3 (10- 7 M) and various amounts of RA (10- 10 to 10- 5 M). We observed a dramatic shift of the RA responsiveness of RXRα in the presence of TRα. In cases of both the single TRE and the double TRE reporter, the RXRα sensitivity to RA appeared to be increased by at least 2 orders of magnitude ( FIGS. 7 a,b ). This enhanced ligand sensitivity is not due to the activation of endogenous RARs by TRα since no effect of CAT activity was observed when TRα was transfected alone ( FIGS. 7 a,b ) consistent with previous observations (Graupner et al., 1989). TRα alone at his low concentration did not induce the reporter gene to a high degree in the presence of T 3 , although an approximately 10 fold induction was observed (this is difficult to see on the scale used in FIG. 7 ). Thus, while RXRα boosts DNA binding and transcriptional activation of other receptors, by forming a complex with TRα, its own ligand affinity is also dramatically increased in the heterodimer complex. Our observation that RXRα exerts its effect on RARα and RARγ transcriptional activity in the presence of less than 10- 7 M RA, suggests that complex formation between RXRα and RARα or RARγ also boosts the ligand sensitivity of RXRα and that RA may be a natural ligand for RXRα.
Heterodimer Formation Occurs in the Absence of DNA
An important question is whether RXRα can form heterodimers with the other receptors in solution or whether the heterodimeric complexes are only formed in the presence of specific DNA sequences. The ability of RXRα to interact with other receptors in the absence of DNA could be expected to largely enhance the efficacy of RXRα as a regulator of heterologous receptor activity. To investigate interaction between RXRα and TR or RAR in the absence of DNA, we took advantage of a unique affinity column containing glutathione coupled to sepharose to which bacterially produced receptor-glutathione transferase fusion protein binds specifically and can be eluted with free glutathione (Smith and Johnson, 1988). TRα or RARγcDNA were cloned into the prokaryotic expression vector pGEX-2T, and expressed as TRα- or RARγ-glutathione transferase fusion proteins in bacteria. The fusion proteins were able to interact with in vitro synthesized RXRα as determined by gel retardation (data not shown). We used bacterially produced TRα- or RARγ-glutathione transferase bound to the affinity resin and mixed this with in vitro synthesized 35 S labelled receptors. After extensive washing, labelled RXRα could be specifically eluted with glutathione from a column that contained bound TRα or RARγ fusion protein, but RXRα was not retained on a column that contained only bound glutathione transferase ( FIG. 8 ). Labelled ER was not retained on by the TRα or RARγ fusion proteins, while the mutant RXRαm4 that lacked 61 amino acids at the amino terminus and was able to upshift TRα and RARγ, was retained.
To further document the physical interaction between RXRα and TR or RAR, we incubated labelled RXRα protein, produced by cell-free translation, with or without bacterially produced Flag-TRα or Flag-RARγ proteins. Anti-Flag antibody was used to examine whether RXRα could be precipitated together with Flag-TRα or Flag-RARγ. As shown in FIG. 8 b , precipitation of Flag-TRα or Flag-RARγ resulted in a significant coprecipitation of labelled RXRα protein. The coprecipitation occurred even in the absence of cross-linker while it was largely enhanced when cross-linker (DSP) was used. The coprecipitation is specific since no significant amount of labelled RXRα was precipitated when preimmune serum was used or when RXRα was incubated with nonspecific control protein together with the anit-Flag antibody. The observation that RXRα could be coprecipitated in the absence of cross-linker and the results obtained with the affinity column strongly suggest that RXRα forms a stable complex with either TR or RAR in solution, and supports our interpretation of the gel retardation results shown in FIG. 2 .
Discussion
Heterodimer Formation Between RXRα and TRs or RARs
Several lines of evidence are provided here for the direct interaction between RXRα and TRs or RARs, which result in the formation of heterodimers which exhibit strong DNA binding to a number of T3/RA dimeric response elements. First, when RXRα was mixed with TRα, TRβ, RARα, RARβ or RARγ, a prominent slow migrating complex was formed which migrated at different positions depending on which TR or RAR was used ( FIG. 1 a ). Second, using antibodies against RXRα, TR and RAR, we demonstrate that the binding of these slow migrating complexes can be dramatically altered by these antibodies ( FIG. 2 ). Third, RXRα mutational analysis shows that the migration of these complexes depended on the size of the RXRα protein ( FIG. 5 ). Finally, a study using affinity column chromatography and immuno-coprecipitation results demonstrate that RXRα can interact with TR and RAR in the absence of DNA ( FIG. 8 ).
The enhancement of DNA binding and the characteristic upshift observed for all receptors in the presence of RXRα are very similar to the enhanced DNA binding and upshifts of TRα observed in the presence of nuclear extract from several cell lines ( FIG. 1 c ; Zhang et al., 1991a). In addition, all TRα mutants investigated behave virtually identical with RXRα and nuclear extract protein ( FIG. 4 ; Zhang et al., 1991a). It is therefore quite possible that RXRα is identical or closely related to the cellular protein previously described (Lazar and Berrodin, 1990; Murray and Towle, 1989; Burnside et al., 1990). According to its enhancing effects on TR DNA binding, the nuclear protein or proteins that enhance TR DNA binding have been termed TR auxiliary proteins—TRAP (reviewed by Rosen et al., 1991). However, if these proteins are identical with RXRα or a related isoform, this nomenclature is insufficient to describe their function. RXRα, as an example of this new receptor subclass, can not dimerize by itself efficiently but can interact with TRs or RARs to form heterodimers with strong DNA binding activity.
TR and RAR as well as RXRα require regions near the carboxyterminal end for interaction ( FIG. 4 and FIG. 5 ). Interestingly, these regions are also required for TR interaction with cJun, a component of the transcription factor AP-1 that has recently been shown by us to regulate TR and RAR activities (Zhang et al., 1991c; Yang-Yen et al., 1991). Thus, this carboxyterminal region may be viewed as a domain that can interfere with other active protein regions in possibly both cis and trans locations. The ligand binding domain of TRs and RARs was shown to possess 9 heptad repeats of hydrophobic amino acids which are structurally similar to the Leucine-Zipper dimerization domain (Forman et al., 1990). These Leucine-Zipper like motifs are thought to mediate the receptor dimerization activity by a coiled-coil α helix in which a hydrophobic surface along one side of the helix could act as a dimerization interface. Similar heptad repeats are also present in the ligand binding domain of RXRα. The requirement of the ligand binding domain of both RXRα and TR or RAR for heterodimer formation implicates these Leucine-Zipper like motifs in the direct interaction between both receptors. However, RXRα may possess some other special structural features which are not present in TR or RAR since we could not observe clear interaction between TR and RAR when they were mixed together and were assayed under the same conditions ( FIG. 1 a ). These special structural features may not allow RXRα homodimer formation, but allow RXRα to efficiently interact with TR and RAR. A detailed mutational analysis of RXRα receptor protein is therefore important in order to understand the mechanism of interaction between RXRα and TR or RAR. While the heptad repeats in the ligand binding domain of RAR, TR and RXRα may effectively interact with each other, and thereby allow receptor contact, at the same time the interaction may be extended through the dimerization domain embedded in the DNA binding region of nuclear receptors (Zhang et al., 1991a; Härd et al., 1990; Luisi et al., 1991; Schwabe et al., 1990). This is supported by our observation that the DNA binding domain of RXRα is also important for efficient interaction with TR or RAR ( FIG. 5 ).
TRs and RARs are important mediators of cellular development and differentiation processes. The observation that RXRα can interact with TRs and RARs in the absence of DNA ( FIG. 8 ) and the fact that the heterodimer can bind to a number of T3/RA specific response elements ( FIG. 3 ) point to the profound role of RXRα in regulating these cellular processes. Although interaction between RXRα and TR or RAR occurs in solution, the outcome of this interaction may depend on the sequence of the response element in particular genes. In other words, the specificity and the extent of transcriptional regulation, either positively or negatively, by receptor interactions maybe largely determined by the nature of the response elements and the receptors (and their concentrations) with which RXRα interacts.
Transcriptional Activity of RXRα
Synergistic transcriptional activity of RAR and TR on the palindromic TRE was observed when they were cotransfected with RXRα ( FIG. 6 and FIG. 7 ). These in vivo observations correlate very well with the strong DNA binding of heterodimers formed between RXRα and TR or RXRα and RAR. Interestingly, considerable enhancing activity of RXRα is observed in the absence of RA while optimal enhancement occurs already at low RA concentrations (less than 10- 7 M), whereas higher RA concentrations are required to activate RXRα alone (more than 10- 6 M; FIG. 6 , FIG. 7 ; Mangelsdorf et al., 1990). Thus, while RXRα boosts very efficiently the activity of TRs and RARs in terms of DNA binding and transcriptional activation, its own ligand responsiveness is also boosted by the heterodimerization, i.e. mutual enhancement is occurring. This is most likely one of the major roles of RXR. We like to call this novel activity a “booster receptor” (B-receptor), in contrast to activator receptors (A-receptors). In addition to its enhancer activity, RXR forms a complex with TRα (and TRβ, data not shown) that appears to require two distinct hormones for full activation. This novel type of receptor complex allows direct cross-talk between two different hormonal signals at the receptor level. The palindromic TRE analyzed here is derived from the growth hormone (GH) TRE. Two years ago, Bedo et al. (1989) reported that the GH gene can be induced by RA and that the presence of T 3 increases the effectivity of RA by close to 3 orders of magnitude (from 10- 6 M to 10- 9 M for optimal induction). This type of in vivo observation is very similar to ours, where 10- 5 M RA are required for RXR activation while 10- 8 M is sufficient for activation of RXRα in the presence of TRα and T 3 . A comparable synergistic effect has recently also been reported for the induction of granulocyte differentiation in leukemic cells including HL60 (Ballerini et al., 1991). Because low concentrations of RXRα are sufficient for boosting RARα and TRα activity, an extremely sensitive regulatory mechanism is created that can respond very efficiently to small changes in the concentrations of individual components. Our data suggest that, contrary to earlier suggestions (Mangelsdorf et al., 1990), RA is an important natural ligand for RXRα; whether other natural retinoids exist that effectively activate RXRα homodimers at physiological concentrations remains to be determined.
At present it appears that more than one RXR subtype exists (RXRα and RXRβ) that may have distinct booster specificities. Even the same RXR subtype may show considerable selectivity depending on the response element ( FIG. 3 ), interacting receptor and receptor concentration ( FIG. 6 a ). We have provided evidence here that the booster capacity for RXRα towards TRα is much higher than towards RARγ ( FIG. 6 and FIG. 7 ), and effective over a wider receptor concentration range as well (data not shown).
The subfamily of B-receptors may also include a substantial number of orphan receptors for which no specific ligands could be detected so far or other receptors that require very high ligand concentrations for efficient activation. Since RXRs appears to be encoded by more than one gene (Mangelsdorf et al., 1990; Hamada et al., 1989(, RXRβ whose DNA and ligand binding domains are almost identical to those of RXRα is an equally good candidate. In general, the mechanisms of heterodimer formation is widely used by transcription factors, the most well known examples being AP-1 (reviewed by Karin, 1990) and the more recently described myc-max heterodimeric (Blackwood and Eisenman, 1991). Because of the obvious advantage of heterodimeric and booster receptors in many systems, our studies presented here may be the tip of the iceberg of a large field of receptor action not yet explored.
REFERENCES
Ballerini P., Lenoble, M., Balitrand, N., Schaison, G., Najean, Y., and Chomienne, C. (1991). Stimulatory effect of thyroid hormone on RA-induced granulocytic differentiation in leukemic cells. Leukemia 5, 383–385.
Baniahmad, A., Steiner, C., Kohne, A. C., and Renkawitz, R. (1990). Modular structure of a chicken lysozyme silencer: involvement of an unusual thyroid hormone receptor binding site. Cell 61, 505–514.
Bedo, G., Santisteban, P., and Aranda, A. (1989). Retinoic acid regulates growth hormone gene expression. Nature 339, 231–233.
Benbrook, D., and Pfahl, M. (1987). A novel thyroid hormone receptor encoded by a cDNA clone from a human testis library. Science 238, 788–791.
Benbrook, D., Lernhardt, E., and Pfahl, M. (1988). A new retinoic acid receptor identified from a hepatocellular carcinoma. Nature 333, 669–672.
Blackwood, E. M., and Eisenman, R. N. (1991). Max: a helix-loop-helix zipper protein that forms a sequence-specific DNA-binding complex with myc. Nature 251, 1211–1217.
Brent, G. A., Dunn, M. K., Harney, J. W., Gulick, T., Larsen, P. R., and Moore, D. D. (1989). Thyroid hormone aporeceptor represses T 3 -inducible promoters and blocks activity of the retinoic acid receptors. New Biol 1,329–336.
Burnside, J., Darling, D. S., and Chin, W. W. (1990). A nuclear factor that enhances binding of thyroid hormone receptors to thyroid response elements. J Biol Chem 265, 2500–2504.
Damm, K., Thompson, C. C., and Evans, R. M. (1989) Protein encoded by v-erbA functions as a thyroid-hormone receptor antagonist. Nature 339, 593–597.
de The, H., Vivanco-Ruiz, M. M., Tiollais, P., Stunnenberg, M., and Dejean, A. (1990). Identification of a retinoic acid response element in the retinoic acid receptor β gene. Nature 343, 177–180.
Evans, R. M. (1988). The steroid and thyroid hormone receptor family. Science 240, 889–895.
Forman, B. M., and Samuels, H. H. (1990). Interactions among a subfamily of nuclear hormone receptors: the regulatory zipper model. Mol. Endocrinol. 4, 1293–1301.
Forman, B. M., and Samuels, H. H. (1991). p EXPRESS: a family of novel expression vectors containing a single transcription unit that is active in vitro, in prokaryotes and in eukaryotes. (in press).
Forman, B. M., Yang, C-r., Au, M., Casanova, J., Ghysdael, J., and Samuels, H. H. (1989). A domain containing leucine-zipper-like motifs between the thyroid hormone and retinoic acid receptors. Mol Endocrinol 3, 1610–1626.
Giguere, V., Ong, E. S., Seigi, P., and Evans, R. M. (1987). Identification of a receptor for the morphogen retinoic acid. Nature, 330, 624–629.
Glass, C. K., Holloway, J. M., Devary, O. V., and Rosenfeld, M. G. (1988). The thyroid hormone receptor binds with opposite transcriptional effects to a common sequence motif in thyroid hormone and estrogen response elements. Cell 54, 313–323.
Glass, C. K., Devary, O. V., and Rosenfeld, M. G. (1990). Multiple cell type-specific proteins differentially regulate target sequence recognition by the α retinoic acid receptor Cell 63, 729–738.
Graupner, G., Wills, K. N., Tzukerman, M., Zhang, X-K., and Pfahl, M. (1989). Dual regulatory role for thyroid-hormone receptors allows control of retinoic-acid receptor activity. Nature 340, 653–656.
Graupner, G., Zhang X-k., Tzukerman, M., Wills, K., Hermann, T., and Pfahl, M. (1991). Thyroid hormone receptors repress estrogen receptor activation of a TRE. Mol. Endocrinol. 5, 365–372.
Green, S., and Chambon, P. (1988). Nuclear receptors enhance our understanding of transcription regulation. Trends Genet 4, 309–314.
Hamada, K., Gleason, S. L., Levi, B-Z., Hirschfeld, S., Appella, E., and Ozato, K. (1989). H-2RIIBP, a member of the nuclear hormone receptor superfamily that binds to both the regulatory element of major histocompatibility class I genes and the estrogen response element. Proc. Natl. Acad. Sci., USA 86, 8289–8293.
Härd, T., Kellenbach, E., Boelens, R., Maler, B. A., Dahlman, K., Freeman, L. P., Carlstedt-Duke, J., Yamamoto, K. R., Gustafsson, J-Å., and Kaptein, R. (1990). Solution structure of the glucocorticoid receptor DNA-binding domain. Science 249, 157–160.
Hermann, T., Zhang, X-k., Tzukerman, M., Wills, K. N., Graupner, G., and Pfahl, M. (1991). Regulatory functions of a non-ligand binding thyroid hormone receptor isoform. Cell Regulation 2, 565–574.
Hodin, R. A., Lazar, M. A., Wintman, B. I., Darling, D. S., Koenig, R. J., Larsen, P. R., Moore, D., and Chin, W. W. (1989). Identification of a thyroid hormone receptor that is pituitary-specific. Science 244, 76–78.
Hoffmann, B., Lehmann, J. M., Zhang, X-k., Hermann, T., Husmann, M., Graupner, G., and Pfahl, M. (1990). A retinoic acid receptor-specific element controls the retinoic acid receptors-β promoter. Mol. Endocrinol. 4, 1727–1736.
Hopp, T. P., Prickett, K. S., Price, V. L., Libby, R. T., March C. J., Cerretti, D. P., Urdal, D. L., and Conlon, P. J. (1988). A short polypeptide marker sequence useful for recombinant protein identification and purification. Bio-Technology 6, 1204–1210.
Husmann, M., Lehmann, J., Hoffmann, B., Hermann, T., Tzukerman, M., and Pfahl, M. (1991). Antagonism between retinoic acid receptors. Mol. Cell. Biol. 11, 4097–4103.
Jansson, M., Philipson, L., and Vennstrom, B. (1983). Isolation and characterization of multiple human genes homologous to the oncogenes of avian erythroblastosis virus. EMBO J. 2, 561–565.
Karin, M. (1990). The AP-1 complex and its role in transcriptional control by protein kinase C. Molecular Aspects of Cellular Regulation 6, 143–161.
Klein-Hitpass, L., Schorpp, M., Wagner, U., and Ryffel, G. U. (1986). An estrogen-responsive element derived from the 5′ flanking region of the Xenopus vitellogenin A2 functions in transfected human cells. Cell 46, 1053–1061.
Koenig, R. J., Lazar, M. A., Hodin, R. A., Brent, G. A., Larsen. P. R., Chin, W. W., and Moore, D. D. (1989). Inhibition of thyroid hormone action by a non-hormone binding c-erbA protein generated by alternative mRNA splicing. Nature 337, 659–660.
Krust, A., Kastner, P. H., Petkovich, M., Zelent, A., and Chambon, P. (1989). A third human retinoic acid receptor, hRAR-γ. Proc. Natl. Acad. Sci. USA 86, 5310–5314.
Lazar, M. A., and Berrodin, T. J. (1990). Thyroid hormone receptors form distinct nuclear protein-dependent and independent complexes with a thyroid hormone response element.
Mol Endocrinol 4, 1627–1635.
Lazar, M. A., Hodin, R. A., and Chin, W. W. (1989). Human carboxyl-terminal variant of α-type c-erbA inhibits trans-activation by thyroid hormone receptors without binding thyroid hormone. Proc Natl Acad Sci USA 86, 7771–7774.
Lehmann, J. M., Hoffmann, B., and Pfahl, M. (1991a). Genomic organization of the retinoic acid receptor gamma gene. Nucleic Acids Research 19, 573–578.
Leroy, P., Krust, A., Zelent, A., Mendelsohn, C., Garnier, J-M., Kastner, P., Dierich, A., and Chambon, P. (1991). Multiple isoforms of the mouse retinoic acid receptor α are generated by alternative splicing and differential induction by retinoic acid. EMBO Journal 10, 59–69.
Luisi, B. F., Xu, W. X., Otwinowski, Z., Freedman, L. P., Yamamoto, K. R., and Sigler, P. B. Crystallographic analysis of the interaction of glucocorticoid receptor with DNA. Nature 352, 497–505.
Mangelsdorf, D. J., Ong, E. S., Dyck, J. A., and Evans, R. M. (1990). Nuclear receptor that identifies a novel retinoic acid response pathway. Nature 345, 224–229.
Millán, J. L. (1986). Molecular cloning and sequence analysis of human placental alkaline phosphatase. J. Biol. Chem. 261, 3112–3115.
Mitsuhashi, T., Tennyson, G. E., and Nikodem, V. M. (1988). Alternative splicing generates messages encoding rat c-erbA proteins that do not bind thyroid hormone. Proc Natl Acad Sci USA 85, 5804–5808.
Murray, M. B., and Towle, H. C. (1989). Identification of nuclear factors that enhance binding of the thyroid hormone receptor to a thyroid hormone response element. Mol Endocrinol 3, 1434–1442.
Näär, A. M., Boutin, J-M., Lipkin, S. M., Yu, V. C., Holloway, J. M., Glass, C. K., and Rosenfeld, M. G. (1991). The orientation and spacing of core DNA-binding motifs dictate selective transcriptional responses to three nuclear receptors. Cell 65, 1267–1279.
Nakai, A., Sakurai, A., Bell, G. I., and DeGroot, L. J. (1988a). Characterization of a third human thyroid hormone receptor co-expressed with other thyroid hormone receptors in several tissues. Mol Endo 2, 1087–1092.
Petkovich, M., Brand, N. J., Krust, A., and Chambon, P. (1987). A human retinoic acid receptor which belongs to the family of nuclear receptors. Nature 330, 444–540.
Pfahl, M. and Benbrook, D. (1987). Nucleotide sequence of cDNA encoding a novel thyroid hormone receptor. Nucl. Acids. Res. 15, 9613.
Pfahl, M., Tzukerman, M., Zhang, X-k., Lehmann, J. M., Hermann, T., Wills, K. N., and Graupner, G. (1990). Rapid procedures for nuclear retinoic acid receptor cloning and their analysis. Methods Enzymol. 18, 256–270.
Rosen, E. D., O'Donnell, A. L., and Koenig, R. J. (1991). Protein-protein interactions involving erbA superfamily receptors: through the TRAP door. Mol Cell Endocrinol 78, C83–C88.
Sakurai, A., Nakai, A., and DeGroot, L. J. (1989a). Expression of three forms of thyroid hormone receptor in human tissues. Mol Endocrinol 3, 392–399.
Sap, J., Mu{hacek over (n)}oz, A., Damm, K., Goldberg, Y., Ghysdael, J., Leutz, A., Beug, H., and Vennstrom, B. (1986). The c-erb-A protein is a high-affinity receptor for thyroid hormone. Nature 324, 635–640.
Schueler, P. A., Schwartz, H. L., Strait, K. A., Mariash, C. N., and Oppenheimer, J. H. (1990). Binding of 3,5,3′-Triiodothryonine (T 3 ) and its analogs to the in vitro translation produces of c-erbA protooncogenes: differences in the affinity of the α- and β-forms for the acetic acid analog and failure of human testis and kidney α-2 products to bind T 23 . Mol. Endocrinol 4, 227–234.
Schwabe, J. W. R., Neuhaus, D., and Rhodes, D. (1990). Solution structure of the DNA-binding domain of the estrogen receptor. Nature 348, 458–461.
Smith, D. B., and Johnson, K. S. (1988). Single-step purification of polypeptides expressed in Escherichia coli as fusions with glutathione S-transferase. Gene 67, 31–40.
Thompson, C. C., Weinberger, C., Lebo, R., and Evans, R. M. (1987). Identification of a novel thyroid hormone receptor expressed in the mammalian central nervous system. Science 237, 1610–1613.
Umesono, K., Giguere, V., Glass, C. K., Rosenfeld, M. G., and Evans, R. M. (1988). Retinoic acid and thyroid hormone induce gene expression through a common responsive element. Nature 336, 262–265.
Umesono, K., Murakami, K. K., Thompson, C. C., and Evans, R. M. (1991). Direct repeats as selective response elements for the thyroid hormone, retinoic acid, and vitamin D 3 receptors. Cell 65, 1255–1266.
Weinberger, C., Thompson, C. C., Ong, E. S., Lebo, R., Gruol, D. J., and Evans, R. M. (1986). The c-erb-A gene encodes a thyroid hormone receptor. Nature 324, 641–646.
Yang-Yen, H. F., Zhang, X-k., Graupner, G., Tzukerman, M., Sakamoto, B., Karin, M., and Pfahl, M. (1991). Antagonism between retinoic acid receptors and AP-1: implications for tumor promotion and inflammation. New Biol. (in press).
Zelent, A., Mendelsohn, C., Kastner, P., Krust, A., Garnier, J-M., Ruffenach, F., Leroy, P., and Chambon, P. (1991). Differentially expressed isoforms of the mouse retinoic acid receptor β are generated by usage of two promoters and alternative splicing. EMBO Journal 10, 71–81.
Zhang, X-k., Tram, P., and Pfahl, M. (1991a) DNA binding and dimerization determinants for TRα and its interaction with a nuclear protein. (accepted for publication Mol. Endocrinol.).
Zhang, X-K., Wills, K. N., Graupner, G., Tzukerman, M., Hermann, T., and Pfahl, M. (1991b). Ligand-binding domain of thyroid hormone receptors modulates DNA binding and determines their bifunctional roles. New Biol 3, 1–14.
Zhang, X-k., Wills, K. N., Hermann, T., Husmann, M., and Pfahl, M. (1991c). A novel pathway for thyroid hormone receptor action through interaction with JUN and FOS oncogene activities. Mol. Cell. Biol. (in press). | This invention provides a purified heterodimer comprising an RXR and a hormone receptor. The invention also provides a method of screening ligands for their effect on the activity of an RXR-containing hormone receptor heterodimer comprising combining the heterodimer with the ligand and determining the effect on activity. Also provided is a method of amplifying the activity of a hormone receptor comprising forming a heterodimer with another hormone receptor. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a photometer tube for a microscope. Such tubes, as known up to the present time, may be classified into two types.
Tubes of the first type are those in which, in order to visualize the measuring field stop, the entire observation ray path is conducted through what may be called a bypass loop and is reflected at an obliquely positioned measuring field stop, which is usually developed as a concave mirror. Such instruments are described, for example, in Federal Republic of Germany patent document No. 24 06 415 and its corresponding U.S. Pat. No. 3,887,283 of Merstallinger et al., granted June 3, 1975, and in Fed. Rep. Germany patent document No. 32 03 142 and its corresponding U.S. Pat. No. 4,518,230 of Weber, granted May 21, 1985, and in Fed. Rep. Germany patent document No. 32 13 145 and its corresponding U.S. Pat. No. 4,568,188 of Weber et al., granted Feb. 4, 1986.
In instruments of this first type, it is difficult to make the measuring field stop variable, and difficult to illuminate it. Moreover, instruments with bypass loops have the disadvantage that, because of the length of the observation ray path, there comes into being a post-magnification factor, which results in a darker image. This interferes particularly with the observation of objects which fluoresce with low intensity.
Referring again to the above mentioned two types of instruments, in those of the second type the observation ray path is deflected by a beam splitter directly into the eyepiece tube. The image of a back-illuminated measuring field stop is superimposed on an intermediate image produced in the eyepiece tube because of the fact that the auxiliary ray path for the imaging of the measuring field stop is led coaxially backward to the photometry ray path and, with the help of a retroreflector arranged behind the second outlet of the beam-splitter prism, is reflected into the eyepiece tube. Instruments of this type are described, for example, in Feb. Rep. Germany patent No. 1,215,954 of Weber, granted Nov. 17, 1966, and in Swiss patent No. 615,762 and its corresponding British patent No. 1,582,346 of Leitz, published Jan. 7, 1981, and in Fed. Rep. Germany patent document No. 34 43 728 and its corresponding European patent application No. 85308145.3 of Schindl, published in English on June 4, 1986, as publication No. 0 183 416.
Instruments of this second type have the possibility of making the measuring field stop interchangeable, and of illuminating it in a simple way. However, they also have the disadvantage that the light required for illuminating the measuring field stop gives rise to reflections in the image space, that is, on the tube lens, on the objective, or on other optical elements in the viewing ray path. These reflections are disturbingly superimposed on the image of the object.
Fed. Rep. Germany Auslegeschrift No. 1,813,499 of Voss, published Oct. 11, 1973, discloses a photometer tube in which the viewing ray path is reflected directly into the eyepiece by means of a first beam splitter, and in which the light passing through the measuring field stop is led around a bypass loop and, by means of a second beam splitter, is again superimposed on the viewing ray path. A disadvantage of this solution is that it supplies only a rather dim image of the measuring field stop, because of the arrangement of several beam splitters, one after another, through which the light must travel.
It is the object of the present invention to provide an improved photometer tube for a microscope, which will supply an intermediate image with the measuring field stop visible therein with the greatest brightness possible and with the greatest possible freedom from undesirable reflections.
SUMMARY OF THE INVENTION
This object is achieved in accordance with the invention by providing a prism or a prism slide having means to split the light coming from the microscope objective into a viewing ray path and a photometry ray path, and means for reflecting an image of the measuring field stop into the viewing ray path, the imaging ray path for the back-illuminated measuring field stop extending in part coaxial to the photometry ray path. Also there is a switchable (i.e., movable or shiftable) reflector by means of which the imaging ray path c for the measuring field stop is separated from the photometry ray path b and is led to the second image inlet of the prism or the prism slide, as the case may be. The term "prism means" as used hereafter in this description and in the claims is intended to include either a prism or a prism slide.
By this measure, as in instruments of the above mentioned second type, a flat unsilvered measuring field stop can be employed, arranged perpendicular to the optical axis of the photometry ray path and therefore easily interchangeable. Reflections from the illumination of the measuring field stop are avoided because the auxiliary ray path for the back-illuminated measuring field stop does not enter the splitter prism coaxially to the photometry ray path, but enters a second inlet of the splitter prism after deflection. Moreover, a bright intermediate image is produced, because the viewing ray path is not conducted over bypass loops.
The solution in accordance with the invention thus combines the advantages of both of the above mentioned design types without having their specific disadvantages above pointed out.
It is advisable to provide a further switchable reflector by means of which the back-illumination of the measuring field stop may be selectively reflected into the photometry ray path.
It is also advantageous to use motor means to switch this second reflector, and the switchable first reflector for the reflecting out of the measuring field stop ray path, and the splitter prism, and it is advisable to couple these several motor drives with a control unit which contains a computer memory for the positions of the reflectors or splitter prism which are to be combined with one another in the various switch positions "Observation" and "Photometry" and possibly also "Photography" or "TV."
Further advantageous developments of the invention will become evident from the following description of a preferred examplary embodiment of the invention read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a basic schematic diagram of the entire ray path in a photometer tube according to a preferred embodiment of the invention;
FIG. 1b is a basic schematic diagram of a portion of the illuminating ray path for illuminating the measuring field stop; and
FIG. 2 is a schematic diagram of portions of the apparatus, illustrating especially the drives for the switchable elements.
DETAILED DESCRIPTION
Referring first to FIG. 1a, the tube lens is indicated at 1. Below this lens is the conventional objective (not shown) of a conventional microscope. This tube lens 1 produces an intermediate image of the object on which the microscope objective is focused.
Above the tube lens 1 is a splitter prism 2 which has a first image inlet 31, a second inlet 32, a first image exit surface 34, and a second exit 33. The light coming up from the objective through the tube lens 1 enters the prism 2 at the surface 31 and is split into a viewing ray path a which passes through the first exit 34, and a photometry ray path b which passes through the second exit 33.
The first outlet or exit surface 34 of the splitter prism 2 faces the conventional eyepiece (not shown) of the microscope. In front of this outlet 34 is a pivoted stop 4 which may be swung between a closed position and an open position. In the "Photometry" switched position, this stop 4 is closed and prevents spurious or stray light from penetrating through the eyepiece into the photometer ray path. During the viewing and selection of the region to be subjected to photometry, the stop 4 may be swung aside by an electric motor 24 to the "Observation" position, so that the observation rays may exit through the outlet surface 34 and enter the usual eyepiece of the microscope.
The partial ray path b for photometry, transmitted through the splitter surface 3 of the splitter prism 2, passes out through the second image outlet or exit surface 33 and continues to a mirror 5, where it is deflected toward the measuring field stop 7, which is arranged in an intermediate image plane.
The measuring field stop is followed by a lens system schematically indicated at 8, which serves to image the pupil of the objective on the cathode of a photomultiplier 9 or on the inlet slit of an interposed monochromator.
The prism 2 is arranged on a slide on which is also mounted a second prism 22 (FIG. 2) with a different splitting factor. The slide may be switched, e.g., by operation of an electric motor 23, to bring either one of the two splitter prisms into operative position in the optical axis of the microscope. In the specific example here disclosed, the first prism 2 splits the light coming from the objective in the ratio of 90/10, that is, it reflects 10 percent of the light into the viewing ray path a. This is the prism that is normally in effective operating position during "Photometry" operation. The second prism 22, shifted into operative position in the "Observation" switch setting, has a transmission factor of 0.1 so that it reflects 90 percent of the incident light into the viewing ray path a.
In order to make the measuring field stop 7 visible, there is a light source 10 (FIG. 1b) with a diffusing disk 12 and a collimator lens 13. The light bundle produced by these elements is reflected into the photometry ray path b by means of a swingable mirror 11 arranged between the measuring field stop 7 and the lens system 8. In the "Observation" switch setting, the swingable mirror 11 is in the inclined position shown in broken lines and serves to direct light from the light source to the back of the measuring field stop, which is thus illuminated from behind. Simultaneously, the switchable mirror 5 is shifted from its position shown in full lines to the position shown in broken lines, so that the light passing through the measurinmg field stop 7 reaches a further reflecting mirror 14 which is not utilized during the "Photometry" switch setting. The mirror 14 reflects the light passing through the measuring field stop 7 toward a 90 degree prism 15. From there, the light is led to the second inlet 32 of the splitter prism 2.
There is a lens system schematically indicated at 16 arranged in the partial ray path c between the 90 degree prism 15 and the second inlet 32 of the splitter prism. This lens system images the measuring field stop 7 in the intermediate image plane in the viewing ray path a, that is, in the eyepiece tube. Hence the image of the object which is produced in the eyepiece tube has superimposed on it the image of the brightly illuminated measuring field stop 11. The image of the measuring field stop 7 can be precisely adjusted relative to the object image with the help of a flat plate 36 which is tiltable in two directions and which is located in front of the second image inlet 32 of the prism 2.
Above the switchable mirror 5 there is a closure plate 6 in front of a mounting dovetail 35 on which a television camera or a photographic camera may be mounted. The light transmitted by the splitter layer 3 in the splitter prism (2 or 22, as the case may be) arrives at the television camera or photographic camera mounted on the dovetail mount, when the mirror 5 is swung out to its "Observation" position illustrated in broken lines.
Referring to FIG. 2, the drive 23 for the prism slide, and the drive 24 for the shiftable stop 4 in the viewing path, and the drive 25 for the swingable mirror 5, and the drive 21 for the deflecting mirror 11, and the incandescent bulb 10 for illuminating the measuring field stop, are all jointly connected to a control device or unit 26.
In the "memory" of this control device 26 are stored the corresponding positions or switching states of the five components just mentioned, for the three respective operating modes "Observation" and "Photometry" and "TV/Photography." These three modes can be called up as desired, by actuation of the appropriate one of the three respective buttons or switches 27, 28, and 29. A fourth input button or switch 30 is also provided, with which the user can call up a switch combination appropriate to his needs, which he himself has previously entered or programmed into the memory bank of the control device. A switch combination defined by the user himself might, for example, provide for a TV representation of the object with a reflected measuring field stop in the TV picture.
For ease of understanding, the positions or switching states are summarized in the following table.
______________________________________ Stop Mirror Mirror LampMode Prism 4 5 11 10______________________________________Observation 22 out out in inPhotometry 2 in in out outTV/Photo 2 out out out out(withoutmeasuringfield)TV/Photo 2 out out in in(withmeasuringfield)______________________________________
In the description up to this point, it has been assumed that the mirror 5 is a totally reflecting mirror. When this is the case, it is not possible simultaneously to perform photometry and to depict the object with, for example, a TV camera on the mount 35, because a totally reflecting mirror 5 allows only one or the other mode of operation. However, it is possible to provide simultaneous TV depiction during photometry if the mirror 5 is made as a beam splitting mirror, or if a swingable beam splitter is provided at this point, to be optionally swung into effective position to replace the totally reflective mirror 5 when desired. | A photometer tube for a microscope contains several switchable reflectors (5, 11). By the appropriate use of these, the ray path (c) for the back-illuminated measuring field stop (7) is reflected out of the photometry ray path (b) and is conducted to a second image inlet (32) of a beam splitter prism or prism slide. Various switchable elements (mirrors 5 and 11; stop 4; prism 2/22) in the tube are electrically driven and are centrally actuated from a control unit. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present Invention relates to a device for transferring flat, flexible, non-self-supporting printed products from a line conveyor to a receiving device like a conveyor or a bundler. The present Invention is especially useful for handling newspapers.
2. Art Relating to the Invention
In the graphic arts industry, flat, flexible, non-self-supporting printed products, such as newspapers and magazines, are moved by line conveyors. At some point along their path, the product has to be transferred from the line conveyor to another conveyor, a bundler, or other type of receiving device for further processing a stacker. The bundler/stacker prepares stacks of product for shipment, future binding, handling, or processing.
Typically, a line conveyor, as employed in the graphic arts industry, is a horizontally oriented endless chain which is equipped with a plurality of vertically oriented grippers. The grippers clamp the top edge of the product and transports the product to the receiving device. When the product arrives at the receiving device, the gripper opens its jaws to allow the product to fall from the gripper onto another conveyor, a platform or stack of other products, depending on the type of receiving device to which the product is transferred to at the transfer point.
One of the transfer devices used with bundlers/stackers as taught in U.S. Pat. No. 5,218,813 uses a circular conveyor which transfers the product from the line conveyor to the bundler/stacker. The circular conveyor employs grippers which grip the bottom edge of the product and rotate the product around to the bundler/stacker.
There is a point in time, just prior to release of the product from the line conveyor gripper, when the product is held by both the line conveyor gripper and the circular conveyor gripper. At this point in time, the product is subject to forces in opposite directions which can lead to problems in transferring the product from one conveyor to the other.
Additionally, there are times when the product is intended for a subsequent bundler/stacker and the line conveyor gripper does not release the product. In this situation, the circular conveyor grippers pulls the product out of the jaws of the line conveyor grippers. There is a need to avoid the fight between the line conveyor grippers and the circular conveyor grippers.
SUMMARY OF THE INVENTION
It has now been discovered that, by employing a circular conveyor with each circular conveyor gripper having both radial and circular motion, that a smooth transition of the product occurs between the line conveyor gripper and the circular conveyor gripper. The grippers of the circular conveyor gripper receive the product directly from the jaws of the line conveyor gripper and move the product to deposit it directly to a receiving device. Radial movement is suitably provided by mounting each circular conveyor gripper on a slide which moves the gripper in a radial direction with respect to the rotation of the circular conveyor.
The circular conveyor grippers of the present Invention are conventional grippers wherein the jaws are spring biased in a closed position and cams are used to open the jaws. Opening cams, positioned at the top and bottom of the rotational path of the circular conveyor, are employed for opening the circular conveyor grippers using a conventional cam follower which is mounted on one of the jaws of the circular conveyor gripper. The top opening cams are employed for opening the circular conveyor gripper to receive the product and the bottom opening cam for opening the circular conveyor gripper to deposit the product onto the receiving device.
It has also been discovered that an inhibiting cam device, which controls the closing of the circular conveyor gripperas it receives the product, provides better control for receiving the product and avoids a tug of war between the line conveyor gripper and the circular conveyor gripper when the product is intended to be carried by the line conveyor to a subsequent receiving device more particularly, the inhibiting cam device is a rotatable assembly of a plurality of inhibiting cams which act on the circular conveyor gripper as it closes about the product and starts its downward movement to the stacker/bundler.
Additionally, it has been found that, if the bottom opening cam is adjustable as to the release point of the product, the bottom opening cam allows for a constant point of release of the product regardless of the thickness of the product.
Preferably, a copy stripper is mounted opposite the bundler/stacker so as to remove the product from the jaws of the circular conveyor gripper.
It is also preferred that one or more pans be employed adjacent to the circular conveyor but, downstream of the circular conveyor, so that, as the product is received from the line conveyor gripper, it is controlled during its movement downward to the receiving device
Preferably, the receiving device employed with the transfer device of the present Invention is a bundler/stacker.
When the receiving device is a bundler/stacker, it is preferred that the stacking fork of the bundler/stacker have a homing sensor to permit automatic setting of the stacking fork relative to the circular conveyor.
These and other aspects of the present Invention will be more readily understood by reference to one or more of the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the transfer device of the present Invention employed as a bundler infeed device;
FIG. 2 is a perspective view of the inhibiting cam assembly;
FIG. 3 is a front view of the inhibitor cam assembly and a circular conveyor gripper shown in inhibited position;
FIG. 4 is a side view of FIG. 3 ;
FIG. 5 is a front view of the circular conveyor gripper and inhibited assembly showing the circular conveyor gripper uninhibited;
FIG. 6 is a side view of FIG. 5 ;
FIG. 7 illustrates a side view of the device of FIG. 1 ; and
FIG. 8 illustrates a cross section of the device taken along line A—A of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
In the detailed description of the Invention, reference will be made to newspaper jackets or, more simply, jackets as the flat, flexible, non-self-supporting printed product. Additionally, reference will be made to a bundler/stacker as the receiving device. It will be understood that other receiving devices can be employed with the present Invention and that other products besides newspapers can be handled by the present Invention.
FIG. 1 illustrates a preferred embodiment of the transfer device of the present Invention employed as a bundler infeed device wherein a circular conveyor shown as gripper drum 20 has a plurality of circular conveyor grippers or drum grippers 22 positioned around its periphery. Drum grippers 22 have been numbered 1 through 12 to distinguish each from the other. Gripper drum 20 rotates about center of 24 in the direction of arrow A. Drum grippers 22 follow drum gripper tip path 26 . Drum grippers 22 are mounted on slide 28 which provides the radial movement of drum grippers 22 .
Drum grippers 22 are of a conventional construction having jaws which are spring biased in a closed position as shown by drum gripper No. 11, for example.
Gripper drum 20 is positioned below line conveyor 30 . Line conveyor 30 has a plurality of line conveyor grippers 34 which hold jacket 32 of a newspaper. Conveyor 30 moves in the direction of arrow B.
Below gripper drum 20 is positioned articulating stacking fork 36 and its articulating mechanism 38 . Drum grippers 22 receive jacket 32 and deposits jacket 32 onto fork 36 , all this being accomplished by the rotation of gripper drum 20 in the direction of arrow A.
In order to open drum grippers 22 as they move to the top of the rotation of gripper drum 20 , top opening cam 40 is fixed in position on the outside of gripper drum 20 . As shown in FIG. 1 , top opening cam 40 acts on gripper Nos. 1 , 2 , 3 , and 4 as they rotate towards the top of their path of rotation. Top opening cam 40 operates on drum grippers 22 in a conventional manner by means of cam follower 66 which is part of each of drum grippers 22 .
In order to control the closing and removal of jacket 32 from line conveyor gripper 34 , inhibiting cam assembly 41 is used to control the closing of drum grippers 22 about jacket 32 . Inhibiting cam assembly 41 employs a plurality of inhibiting cams 42 which rotate about center 43 . As shown in FIG. 1 , inhibiting cams 42 have been numbered to correspond with drum grippers 22 upon which they act. In other words, as shown in FIG. 1 , inhibiting cam No. 6 , 12 operates on drum gripper No. 12 and drum gripper No. 6 . Likewise, inhibiting cam No. 5 , 11 operates on drum gripper No. 11 and drum gripper No. 5 . As will be appreciated, the number of inhibiting cams 42 is half the number of drum grippers 22 . As also will be appreciated, inhibiting cam assembly 41 rotates twice around for each rotation of gripper drum 20 .
As jacket 32 is carried to the bottom of the rotational cycle of gripper drum 20 , bottom opening cam 44 operates on cam follower 66 to open drum gripper 22 and allow jacket 32 to be deposited on articulating stacking fork 36 or the stack of jackets 32 which are on stacking fork 36 . Bottom opening cam 44 is adjustable to accommodate different thickness of newspaper and functions in a conventional manner by forcing one of the jaws away from the other.
In order to assist in the depositing jacket 32 under fork 36 , copy stripper 46 is employed. Copy stripper 46 is a conventional piece of equipment which is employed in a conventional manner in order to assist in a speedy removal of jacket 32 onto fork 36 . In FIG. 1 , only one cam follower 51 is illustrated for drum gripper No. 9 in a breakaway portion of FIG. 1 . The non-circular movement of the drum grippers 22 is provided by cam surface 50 a on cam follower 51 . The radial motion of drum gripper 22 is illustrated by drum gripper tip path 26 . As can be seen, this path is somewhat flat at the top of rotation of drum 20 , such that the line of travel of drum gripper 22 is approximately parallel to the line of travel of line conveyor gripper 34 . This aids in avoiding a tug-of-war and aids in a smooth transition of jacket 32 from line conveyor gripper 34 to drum gripper 22 .
The radial motion of drum gripper 22 is also evident in the downward path of drum gripper 22 wherein the downward path of drum gripper 22 is approximately vertically downward as shown in FIG. 1 .
Furthermore, the radial movement of drum gripper 22 is seen at the area of contact between drum gripper 22 and stacking fork 36 . By having the line of travel of drum gripper 22 approximately parallel to the flat surface of fork 36 , a smooth transition between the circular conveyor and the bundler is obtained.
Additionally, by employing radial movement for drum gripper 22 , a space savings is obtained. Obviously, an approximate parallel line of travel between line conveyor 30 and drum gripper 22 , and fork 36 and drum gripper 22 , can be obtained if the diameter of drum 20 is very large. Radial movement of drum gripper 22 allows for a smaller diameter drum while still obtaining relatively parallel movement.
Radial cam 50 is employed to act on a cam follower 51 mounted on each slide 28 to provide radial movement of drum gripper 22 .
In order to control the movement of jacket 32 during its downward decent from line conveyor 30 to fork 36 , upper pan 52 and lower pan 54 are employed. As will be appreciated, drum grippers 22 grabs the bottom edge of jacket 32 while pans 52 and 54 help maintain the top edge of jacket 32 in an upward direction during its downward movement. This assists in preventing inserts, which are in jacket 32 , from escaping. The distance, which pans 52 and 54 are spaced from tip path 26 , depends primarily on the size or dimension of jacket 32 .
As will be appreciated, FIG. 1 does not illustrate the framework which is associated with the various elements. Such framework is conventional and is employed to maintain the relative position of the various elements.
Also, as will be understood, fork 36 and its associated articulated mechanism 38 is movable so as to move the stack of jackets 32 away from gripper drum 20 as the stack grows and to allow an empty fork 36 to be positioned in place. The stack, which is formed on fork 36 , can either be stored for future use or banded in a conventional manner for shipment. Both stacking fork 36 and its associated mechanism 38 , as well as a banding mechanism, are conventional.
Turning to FIG. 2 , details of the inhibitor cam assembly 41 are illustrated in a perspective view. As shown in FIG. 2 , there are six inhibitor cams 42 which are part of assembly 41 . Enabling cam 60 , which is shown in the retracted position in FIG. 2 , is retracted by fluid activation from valve 62 as shown in FIG. 5 . In the retracted position, enabler cam 60 is retracted. Enabling cam 60 is spring loaded to be in an extended state as shown in FIG. 3 without activation from air via fluid valve 62 . When enabling cam 60 is retracted, inhibiting cams 42 are in position to allow closing of drum gripper 22 by acting on cam follower 66 . Thus, opening and closing of drum grippers 22 is controlled via valve 62 .
Turning to FIG. 3 , FIG. 3 illustrates enabling cam 60 in an extended position which, in turn, shows inhibitor cam 42 extended into the path of gripper cam follower 66 . With gripper cam follower 66 acted upon by inhibitor cam 42 , drum gripper 22 is maintained in a slightly open position as shown by drum gripper No. 12 in FIG. 1 .
Reset cam 64 operates on all inhibitor cam 42 to move them to the extended or inhibiting position as shown in FIG. 3 . This is the natural or rest position of inhibitor cam 42 . When inhibitor cam 42 is retracted, it moves to right in FIG. 3 , gripper cam follower 66 is no longer acted upon by inhibitor cam 42 and drum gripper 22 can close on jacket 32 , as shown in FIG. 5 .
FIG. 4 illustrates drum gripper 22 and inhibitor cam assembly 41 , as shown in FIG. 3 , wherein inhibitor cam 42 is operating on cam follower 66 to maintain drum gripper 22 in a slightly open position.
As shown in FIG. 4 , drum gripper 22 follows the rotation as indicated by arrow A while inhibitor cam 42 rotates about center 43 and moves in the direction of arrow C. As will be appreciated, inhibitor cam assembly 41 is operated by belt 68 which is operated upon the axle that drives gripper drum 20 . As will be appreciated by one of skill in the art, inhibitor cam assembly 41 can be independently driven, however, it is suitable that a standard servo drive be employed so as to coordinate, not only the movement of gripper drum 20 with respect to conveyor 30 , but also to coordinate the movement of inhibitor assembly 41 and gripper drum 20 .
Turning to FIG. 5 , enable cam 60 is shown in the retracted state which, in turn, allows inhibitor cam 42 to be in the retracted state and out of the path of cam follower 66 . In such an arrangement, drum gripper 22 closes so as to hold jacket 32 tightly between its jaws. Referring back to FIG. 1 , this is the position of gripper No. 10 which is shown leaving the area of operation of inhibiting cam assembly 41 on its downward movement towards fork 36 .
By controlling the opening and closing of drum grippers 22 with inhibitor cam assembly 41 , selected jackets 32 can bypass one device of the present Invention and pass to a subsequent transfer device.
While only a limited number of specific embodiments of the present Invention have been expressly disclosed, it is, nonetheless, to be broadly construed and not to be limited except by the claims appended hereto. | The transfer device is a circular conveyor having a plurality of radially moveable grippers. The grippers receive a non-self-supporting package, such as a newspaper jacket, on its bottom edge from an overhead line conveyor and rotate the newspaper down onto a receiving device such as a bundler at the bottom of the drum's rotation. The transfer device controls the gripping of the newspaper from the line conveyor with an inhibitor cam to provide a controlled bypass mechanism. The radial moveable grippers allow for smoother transistion and decrease space needs. | 1 |
TECHNICAL FIELD
The present invention relates generally to a portable liquid reservoir and, more specifically, to a portable water reservoir for fire fighting.
BACKGROUND OF THE INVENTION
In rural and remote areas which lack an adequate and accessible water supply, or in areas where water pressure is low, an extra water supply is often necessary when fighting fires. In such situations, a portable water reservoir is useful for storing and delivering water at the scene of the fire.
Upon arrival at the scene of a fire, the portable reservoir is assembled and positioned in proximity to the fire. Water is transported by land and emptied into the reservoir. Depending on the construction of the reservoir, water may be dumped into the top of the reservoir, known as a "dump tank", or may be pumped in through inlet hoses. After filling, fire hoses from a pumper truck are attached to the reservoir and water is pumped directly from the reservoir onto the fire. As the reservoir is emptied, the water is replenished by the water transport system. When the fire has been extinguished, the apparatus is removed from the scene of the fire.
A variety of factors affect the utility and efficiency of a portable liquid reservoir. These factors include the speed with which the portable reservoir can be transported to a desired location, positioned properly, and assembled for use; the rate at which the reservoir can be filled with liquid; the volume of liquid the reservoir can hold; the rate at which the reservoir can be drained of liquid; and, the volume of liquid which can be efficiently removed form the reservoir.
The speed with which a portable reservoir can be transported, assembled and positioned at a desired location depends on its construction and the steps necessary to ready it for use. In the past, portable reservoirs have been constructed as free-standing canvas tanks which require assembly prior to use, or as trailer tanks which require no assembly. The free-standing dump tanks are comprised of a metal or plastic frame and a canvas lining into which large volumes of liquid may be dumped. The free-standing dump tanks are brought to the scene of the fire disassembled or collapsed and are then manually assembled by the fire fighters. The trailer tanks are towed to a desired location, either empty or full depending on their particular construction, and are then positioned as convenient.
The fill rate of a reservoir depends on the size of the opening through which the liquid is to be delivered into the reservoir. This, in turn, depends on whether the tank is of open or closed construction. The fill rate of enclosed reservoirs is slower due to the build up of air pressure within the tank and the limitations on fill rate imposed by the diameter of the fill openings.
The volume of the reservoir obviously depends on its size. Reservoirs may be designed in a variety of shapes and sizes to accommodate the individual fire fighting needs of a fire department.
The rate at which liquid is drained from a reservoir depends on the diameter of the pipes through which the liquid can be drained, the number and size of the openings through which the liquid can be drained, the pumping capacity of the pumper truck, and whether the reservoir is of open or closed construction. The air pressure in an enclosed tank may be somewhat reduced as liquid is rapidly pumped from the tank, thereby reducing the rate at which liquid may be removed.
Finally, the efficiency of a particular reservoir design depends greatly on the volume of the stored liquid which can actually be removed from the reservoir. When liquid is being drained from a reservoir, suction loss is created by the development of whirlpools at the drainage site. When the bottom of the whirlpool contacts the drainage site, suction is interrupted and no more liquid can be removed from the reservoir. The rate of draining liquid from the tank also affects the formation of whirlpools. With many types of reservoirs, a specific volume of liquid contained therein may not be extracted because of the whirlpool phenomenon. This reduces the efficiency of a particular reservoir because it must be refilled more often.
A variety of dump-tanks or other portable reservoirs have been developed to address the considerations enumerated above. U.S. Pat. No. 2,192,593 to Bradley et al., discloses a trailer tank in which the trailer frame itself has been incorporated into the body of the tank. The particular tank disclosed in the patent is a cylindrical enclosed tank designed for land distribution of liquid commodities, similar to tanks used to transport fuels or milk.
U.S. Pat. No. 4,482,017 to Morris, discloses a portable, enclosed liquid supply tank designed to correct the disadvantages of earlier enclosed tanks by including an overflow relief valve and a fill valve. The fill valves or "air holes" are designed to stabilize the pressure between the inside and the outside of the tank when filling or draining. A drain pipe extends from the rear of the tank to allow removal of the liquid. Despite the presence of fill valves and air holes, the rate at which liquid may be removed from the tank is limited by the diameter of the fill valves and the number of air holes. Additionally, the apparatus disclosed in the Morris patent does not provide a method for preventing the development of suction whirlpools, thereby allowing more efficient use of the liquid contained in the tank.
Vinyl of canvas tanks which are assembled at the scene of the fire are also common portable reservoirs. However, these tanks are cumbersome and difficult to assemble. They also have no devices which aid in the prevention of whirlpools, and suction hoses placed in such tanks must have a whirlpool-inhibiting device fitted into the inlet end of the hose. Furthermore, experience indicates that the materials composing these devices are subject to decay if not dried prior to disassembly, and that the tanks must be treated carefully prior to storage and reuse.
Thus, what is needed in the art is a portable liquid reservoir which is formed of a durable material, is easy and quick to assemble, is easily positioned and maneuvered, and allows more efficient use of the liquid contained therein by preventing the development of whirlpools. The present invention solves these problems in the art by providing a portable liquid reservoir that contains anti-whirlpool devices which enable a pumper truck to withdraw virtually every gallon of water before breaking suction; which can be assembled and positioned by one person in less time than supply tanks currently available; and, which can be immediately stored after use without taking any precautions to dry the material and without damage to the tank material.
SUMMARY OF THE INVENTION
The present invention is directed to an improved portable reservoir in the form of a trailer to be towed empty to the scene of a fire. Once at the fire scene, the open-top reservoir becomes available for storing and delivering liquid. A drain pipe runs along the bottom of the reservoir and contains one or more openings of varying sizes for withdrawing liquid from the reservoir and venting air. These openings are covered by anti-whirlpool devices which reduce the formation of whirlpools and increase the volume of water which may be extracted from the reservoir before breaking suction, thus improving the efficiency and utility of the reservoir during fire fighting.
The anti-whirlpool devices comprise one or more baffles which are staggered along the length of the drain pipe such that the baffles break up of diffuse the most direct paths from the openings to the surface of liquid in the tank. The baffles are designed to contain a plurality of irregular openings and are positioned in close spaced-apart relation to the drain pipe. The baffles may be layered on top of one another to enhance their anti-whirlpool activity. Thus, the numerous openings present in the baffles break up the laminarity of the flow of the liquid and prevent whirlpools from forming.
Described somewhat more particularly, the present invention provides a container similar to an open trailer formed of a suitable material and having an open top. The container has a built-in axle and wheels but may also be designed as a separate container configured for placement on a mobile trailer frame and attached thereto in any convenient manner.
Described in greater detail, the sides of the container are equipped with a plurality of stabilizing legs which are retracted when the reservoir is being transported. Each stabilizing leg has a stabilizing foot at its bottom to distribute the weight of the reservoir more evenly when the leg is extended. The stabilizing legs are positioned on either side of the container directly opposite from one another to afford maximum support. The legs are locked at a desired height by any convenient mechanism for maintaining an extension at a particular length or height.
A drain pipe is positioned along the bottom of the container such that the pipe runs the length of the container, preferably perpendicular to the axle and midway between the sides of the container. The bottom of the container may slope towards the drain pipe to aid in removing the liquid. The drain pipe extends out the front or the rear of the container, or at both ends, and joins suitable couplings and valves allowing selective connections to the suction hose of at least one pump.
The drain pipe has a series of openings along its length inside the walls of the container. Two types of openings may be found in the drain pipe. The openings along the top of the drain pipe are vents. They are narrow slits which serve to vent air when the reservoir is being filled or liquid is being removed. Because of their small size, their utility for draining the reservoir is limited. The openings along the sides of the drain pipe are intake holes. They serve to drain liquid from the reservoir when the pumper truck is engaged. The intake holes increase in size towards the center of the drain pipe. Thus, those intake holes in the drain pipe nearest the walls of the container are smaller than the intake holes near the center of the drain pipe. The openings are sized to allow a maximum amount of liquid to be withdrawn from the container.
The vents and intake holes along the length of the drain pipe are enclosed by anti-whirlpool baffles designed to break up the flow of the liquid through the openings and thereby prevent the formation of whirlpools. The anti-whirlpool baffles are designed to shelter or partially shelter the intake holes and vents, but do not block the intake holes or vents. The anti-whirlpool baffles may have various sizes and shapes so long as the baffles are sized and located relative to the openings in the drain pipe to function as barriers interposed between the openings and the surface of liquid in the tank. Two or more anti-whirlpool baffles may be layered one on top of another to enhance their anti-whirlpool activity. The baffles impede the nominal straight path to the liquid surface and may induce liquid flow through several streams each of which has less flow than the total flow into the particular drain hole in the pipe, thereby reducing whirlpool formation in the streams.
Thus, it is an object of the present invention to provide a portable liquid reservoir for storing and delivering liquids.
It is a further object of the present invention to provide a portable liquid reservoir from which nearly all stored liquid can be withdrawn before suction is broken.
It is another object of the present invention to provide a portable liquid reservoir which can be quickly positioned and readied for receiving liquid.
It is a further object of the present invention to provide a portable liquid reservoir which can immediately be stored without damage to the materials from which it is constructed.
It is another object of the present invention to provide an apparatus and method for preventing the formation of whirlpools when liquid is being extracted from a container.
Other objects, features and advantages of the present invention will become apparent upon review of the following detailed description of a preferred embodiment and the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a preferred embodiment of the present invention, including several alternative embodiment of the anti-whirlpool device of the present invention.
FIG. 2 is a top plan view of the embodiment shown in FIG. 1.
FIG. 2A is a cut away view of a preferred embodiment of an anti-whirlpool device.
FIGS. 3-6 are perspective views of several alternative embodiments of the anti-whirlpool device.
FIG. 7 is a front end view of the embodiment shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in more detail to the drawings, in which like numbers refer to like elements throughout the several views, FIG. 1 shows a portable liquid reservoir 10 according to the present invention. The portable liquid reservoir 10 comprises a container 20 similar to an open trailer and including a drainage system 30 located within the container; and a transport and frame subassembly comprising a pair of wheels 50, an axle 51, and a hitch 40 located on the frame members 41 extending forwardly from the front end of the reservoir 10.
The container 20 is rectangular in plan view, having two pairs of parallel sides. Two sides 25 extend the length of the container and are spaced apart and parallel to each other but perpendicular to the axle 51. The other two sides 26 traverse the width of the container and are spaced apart and parallel to each other and to the axle 51.
Wheelwells 24 are built into two sides 25 of the container 20. Also built into the container are leg pockets 22 for retaining the stabilizing legs 26 when the container 20 is not in use or is being transported. The stabilizing legs 26 may be withdrawn from the leg pockets 22 to stabilize the container 20 when in use. The stabilizing legs 26 rest upon feet 27 which serve to distribute the weight of the container 20 on the ground so that the stabilizing legs 26 do not become embedded in the surface upon which they rest, and to afford the best distribution of the weight of the container 20. FIG. 7 illustrates a method for maintaining the stabilizing legs 26 at a desired height by inserting a pin 28 into one of a series of holes 29 along the length of the stabilizing leg 26, the pin also extending through a rotating hole in the left pocket 22 so as to retain the leg at the selected elevation.
FIG. 2 illustrates the drainage system 30 comprising a drain pipe 31 running the length of the container 20 along the bottom of the container 20 parallel to and midway between two sides 25. The ends of the drain pipe 31 extend through the sides 26 of the container 20 at the front and back ends of the container 20. In the interior of the container 20, the drain pipe 31 contains a multitude of openings 32 for removing liquid from the container. The openings 32 comprise vents 39 and intake holes 38 (depicted in FIG. 2A) and are sized such that a maximum amount of liquid can be extracted through the intake holes 38.
Where the drain pipe 31 extends through the front wall 26 of the container 20, the drain pipe is coupled to a traverse header pipe 33 which distributes the liquid to two hose couplings 35 at the downstream sides of the corresponding outlet valves 34. Each outlet valve 34 may be closed or opened by a control handle. Air bleed risers 36 are positioned on the header pipe 33 in front of the outlet valves 34 to allow bleeding air from the drain pipe 31 and the header 33 before instituting pumping through one or more hoses (not shown) connecting a pumper to the couplings 35. Where the drain pipe 31 extends out the rear side 26 of the container 20, there is also an outlet valve 34 connected to a hose coupling 35. This allows for three sources from which to pump liquid from the container 20.
FIG. 2 illustrates the position of the several different embodiments of whirlpool prevention devices, numbered here as 60, 70, 80, and 90. The anti-whirlpool baffles are placed along the drain pipe 31 so that the baffles confront or surround the openings 32 as depicted in FIG. 2A. FIG. 2A also serves to illustrate the relative sizes of the intake holes 38 and the vents 39 found along the length of the drain pipe 31.
FIG. 3 depicts a co-preferred embodiment of an anti-whirlpool baffle 60 comprising a plurality of inverted V-shaped members 61 spaced apart and connected in sequence to one another by perpendicular supporting rods 62 attached perpendicular to and spaced apart along the length of one arm of each V-shaped member 61.
FIG. 4 depicts a co-preferred embodiment of an anti-whirlpool baffle 70 having a V-shaped trough 74 at its apex, from which extend a plurality of flat bars 71 spaced apart and connected to the underside of the trough. The bars 71 are connected to and spaced apart from one another by perpendicular supporting rods 73 which are parallel to the trough 74 and spaced apart along the length of the bars 71. As seen in FIG. 2, the anti-whirlpool baffle 70 is mounted along side the drain pipe 30 with the trough 74 disposed in radial spaced relation to a intake hole 38 in the pipe 31. The trough 74 thus acts as a barrier interposed between the intake hole 38 in the drain pipe and the surface of liquid in the container 20. This barrier, together with the plurality of suction paths defined between the flat sides of the bars 71, inhibit or prevent whirlpools from forming between the intake hole 38 and the liquid surface. The anti-whirlpool baffle 70 may be layered over a second anti-whirlpool baffle of smaller proportions.
FIG. 5 depicts the anti-whirlpool device 80 comprising a pair of elongate C-shaped members 81 having a plurality of openings 82 extending through the member approximately midway along their length. As seen in FIG. 2, the C-shaped members 81 are located on opposite sides of the pipe 31 in radial spaced relation to the pipe, and at least one opening 32 is formed in the pipe behind each C-shaped member. These openings 32 are offset longitudinally behind the C-shaped members 81 from the openings 82 in the C-shaped members, so as to preclude a whirlpool-conducive straight path from the suction openings 32 to the surface of liquid in the container 20. Liquid thus flows to each opening 32 along paths through the openings 82 in the C-shaped member 81, and through the open spaces 83 between the pipe 31 and each of the members, neither path being a straight-line flow to the suction opening.
FIG. 6 depicts a fourth co-preferred embodiment of an anti-whirlpool baffle 90 layered over a second anti-whirlpool baffle 60. The anti-whirlpool baffle 90 comprises an inverted U-shaped member 91 having a plurality of openings 92. The device 90 is placed over the drain pipe 31 so that the openings 32 are covered by the device 90 however, the device 90 is spaced apart from the drain pipe 31.
The portable liquid reservoir 10 is transported by attaching it to a vehicle via a hitch 40. Upon arrival at a desired location, the reservoir 10 is disconnected from the towing vehicle and maneuvered to a desired location. The stabilizing legs 26 are then withdrawn from the leg pockets 22 to a height such that the feet 27 are in contact with the surface upon which the reservoir 10 rests, with the bottom of the container 20 preferably being substantially level. The legs 26 are then locked into position by means of removable pegs 28 inserted into holes 29 through the legs 26. Liquid is then dumped into the container 20 via tanker or another available source, through the open top of the container.
When the liquid is to be drained from the container 20, hoses are coupled to the header pipe 33 via the couplings 35. The air bleed risers 36 are momentarily opened to allow any trapped air to escape, and the pumper truck may begin pumping liquid from the reservoir 10.
While this invention has been described in detail with particular reference to a preferred embodiment thereof, it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described herein before and as defined in the appended claims. | A portable liquid reservoir comprising an open container mounted on a moveable frame. The reservoir is intended for fire fighting and has a liquid drain in which whirlpool prevention devices are incorporated to prevent the formation of whirlpools and allow water to be removed from the reservoir at a relatively high rate. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This continuation-in-part application claims the benefit of U.S. patent application Ser. No. 11/468,180, now U.S. Pat. No. 8,249,132, filed 29 Aug. 2006 entitled “ROTATIONALLY DEPENDENT INFORMATION IN A THREE DIMENSIONAL GRAPHICAL USER INTERFACE. The entire contents of U.S. application Ser. No. 11/468,180 (U.S. Pat. No. 8,249,132) are incorporated by reference herein.
BACKGROUND
The present invention relates to the field of information data set navigation and rotational objects.
The presentation of information is a crucial component of business that is often underappreciated. Most software applications present information visually, sometimes supplemented with or alternatively presented as an audio presentation. A variety of graphical user interface (GUI) tools and input devices have been developed to present information and allow a user to manipulate the presentation. For example, conventional interface tools include hot-keys, menus, toolbars, pop-up command lists, mouse clicks, and the like; conventional input devices include a mouse, a keypad, a keyboard, a remote control device, touch screens, and the like. Together, these components facilitate user interaction with the information in an electronic space. However, the majority of existing software tools are limited to navigating a dataset in a logically-linear manner using a conventional input mechanism.
That is, the GUI elements of conventional software tools act in a way that is consistent with a physical reality and a linear logic. For example, selecting the forward-facing or “next” button in a GUI for a digital book displays the next page, which follows a linear numeric sequence. In essence, conventional software tools mimic the user interactions that are performed with a corresponding physical object (i.e., opening the book, closing the book, and turning pages).
While such software tools are sufficient for repeating manual manipulations within an electronic space, they do not fully utilize and interconnect the vast amount of information available. The amount of information contained in a physical book is limited by the number of pages it contains and each page displays two sets of information, one on each side. Additionally, a book typically has a variety of related information (e.g., book reviews, author's notes, essays, etc.) written about it contained in other sources (e.g., literary journals, magazines, newspapers, etc.).
In the electronic space of the GUI taught in U.S. Pat. No. 8,249,132 titled “ROTATIONALLY DEPENDENT INFORMATION IN A THREE DIMENSIONAL GRAPHICAL USER INTERFACE”, a digital representation is able to disregard the limitations of its physical counterpart. For example, pages containing author's notes could be dynamically added to the content of a book, exceeding the number of pages in its physical counterpart. Further, three-dimensional rotation of the digital representation of the book can be used to present related information acquired from other sources, which is impossible with a physical book. For example, rotating the front cover of the book towards the user (i.e., perpendicular to the book's spine) could present the user with book review information instead of the expected edge-view of the book's pages
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings, embodiments which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a flowchart of a method describing the use of a three-dimensional data handling system to navigate a rotationally-dependent dataset in accordance with embodiments of the inventive arrangements disclosed herein.
FIG. 2 is a schematic diagram of a system for utilizing a three-dimensional data handling system in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3A is an example embodiment of a three-dimensional data handling system that utilizes rotation of a physical analog input device to control selections in a visual user interface in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3B is an example embodiment of a three-dimensional data handling system that utilizes rotation of a digital object to control the selector 325 in a visual user interface in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3C is an example embodiment of a three-dimensional data handling system utilizing selection preview windows within a visual user interface to provide selection assistance for the rotation of a digital object in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3D is an example embodiment of a three-dimensional data handling system that utilizes an auxiliary input device that presents the digital object for controlling selections in a visual user interface in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3E is an example embodiment of a three-dimensional data handling system that utilizes a remote control to control rotation of a digital object in a visual user interface in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3F is an example embodiment for a physical analog input device and the correspondence of physical side rotations to selections made in a visual user interface in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 3G is an example embodiment of a three-dimensional data handling system that utilizes a physical analog input device paired with a digital object to control selections in a visual user interface in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 4 is a collection of example graphical user interfaces (GUIs) for the three-dimensional data handling system illustrating navigation through a rotationally-dependent dataset by hyper-rotation of a physical analog input device in accordance with an embodiment of the inventive arrangements disclosed herein.
FIG. 5 is a flowchart of a method describing the handling of hyper-rotation of a physical analog input device by a three-dimensional data handling system to navigate a rotationally-dependent dataset in accordance with embodiments of the inventive arrangements disclosed herein.
DETAILED DESCRIPTION
The present invention discloses a solution for controlling navigation through a rotationally-dependent dataset within a graphical user interface of a three-dimensional data handling system by manipulating a physical analog input device. The physical analog input device can be manipulated along its directional axes to control navigation through the data elements of a rotationally-dependent dataset. The rotationally-dependent dataset can be a multi-dimensional relational data structure. When the quantity of data elements of a branch of the rotationally-dependent dataset is greater than the number of faces the physical analog input device has along the directional axis, the physical analog input device can be hyper-rotated to continue navigation within the graphical user interface.
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing. Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
FIG. 1 is a flowchart of a method 100 describing the use of a three-dimensional data handling system to navigate a rotationally-dependent dataset in accordance with embodiments of the inventive arrangements disclosed herein. The three-dimensional data handling system can represent one of the many possible embodiments described within U.S. Pat. No. 8,249,132 titled “ROTATIONALLY DEPENDENT INFORMATION IN A THREE DIMENSIONAL GRAPHICAL USER INTERFACE”.
Method 100 can begin in step 105 where the user can initiate use of the three-dimensional data handling system via the visual user interface. The user can navigate through the branches of a rotationally-dependent dataset by rotating a physical analog input device or a digital object around a rotational axis in step 110 .
In step 115 , the user can access a branch of the rotationally-dependent dataset whose quantity of members, M, is greater than the number of faces, N, that the physical analog input device or digital object has in that direction. For example, a cube physical analog input device or digital object can have three rotational axes (x, y, and z) and four distinct or unrepeated faces in each rotational direction (N=4). Step 115 can be applicable to any branch of the rotationally-dependent dataset having more than four data elements.
To access members of the rotationally-dependent dataset whose position is greater than N, the user can hyper-rotate (i.e., continue rotation past a full revolution) the physical analog input device or digital object, in step 120 . Essentially, the faces of the physical analog input device/digital object can be reused to represent the additional data elements; a one-to-one relationship need not exist between each face of the physical analog input device/digital object and a member of the rotationally-dependent dataset.
FIG. 2 is a schematic diagram of a system 200 for utilizing a three-dimensional data handling system 235 in accordance with an embodiment of the inventive arrangements disclosed herein. System 200 can be utilized for the performance of method 100 .
In system 200 , the user 205 can interact with a three-dimensional data handling system 235 via a visual user interface 215 . As used herein, the terms “visual user interface” and “graphical user interface” can be used interchangeably to refer to user interface of the three-dimensional data handling system 235 and/or a software application being presented to the user 205 whose operation is supported by the three-dimensional data handling system 235 . The three-dimensional data handling system 235 , including the visual user interface 215 , can be a specific embodiment of the three-dimensional graphical user interface (GUI) described in U.S. Pat. No. 8,249,132 titled “ROTATIONALLY DEPENDENT INFORMATION IN A THREE DIMENSIONAL GRAPHICAL USER INTERFACE”.
As such, the three-dimensional data handling system 235 can represent the hardware and/or software required to support the presentation of a rotationally-dependent dataset 245 with the visual user interface 215 . The architecture (e.g., client/server, Web 2.0, etc.) and/or configuration (e.g., distributed, centralized, etc.) of the three-dimensional data handling system 235 can vary based upon the requirements for the specific embodiment.
The rotationally-dependent dataset 245 can be a collection of data elements and/or data groups arranged according to a predetermined relational model and/or hierarchical structure where the presentation of different branches of the relational model is dependent upon the rotation of a digital object within the visual user interface 215 . In essence, a rotationally-dependent dataset 245 can be similar to a typical relational set of data with the exception of having defined three-dimensional parameters for presentation.
Take, for example, data arranged in a typical hierarchical tree structure like folders having sub-folders that contain files. To make such a tree structure a rotationally-dependent dataset 245 can require defining three-dimensional presentation parameters that relate the data's presentation to the rotational path of a digital object in the user interface 215 that represents the rotationally-dependent dataset 245 .
In another contemplated embodiment, the three-dimensional data handling system 235 can interpret the three-dimensional presentation parameters from the relationships expressed in the rotationally-dependent dataset 245 .
The rotationally-dependent datasets 245 can be stored in a data store 240 of the three-dimensional data handling system 235 . In another embodiment, the rotationally-dependent dataset 245 can be stored remote from, but accessible by the three-dimensional data handling system 235 , such as in a data store of the client device 210 .
In yet another contemplated embodiment, the rotationally-dependent dataset 245 can be dynamically aggregated by the three-dimensional data handling system 235 from various accessible data sources (not shown) when the rotationally-dependent dataset 245 is selected by the user 205 .
The visual user interface 215 can be a graphical means in which the user 205 can access the functionality of the three-dimensional data handling system 235 , as described in U.S. Pat. No. 8,249,132 titled “ROTATIONALLY DEPENDENT INFORMATION IN A THREE DIMENSIONAL GRAPHICAL USER INTERFACE” and further detailed herein. The visual user interface 215 can run on a client device 210 . The client device 210 can represent a variety of computing devices capable of supporting operation of the visual user interface 215 and communicating with the three-dimensional data handling system 235 over the network 250 .
The client device 210 shown in system 200 can utilize a physical analog input device 220 , in addition to or in lieu of one or more conventional input mechanisms (e.g., keyboard, mouse, etc.). The physical analog input device 220 can represent a physical object that is able to be rotated around predefined rotational axes, providing the rotational data as input data for the three-dimensional data handling system 235 .
The physical analog input device 220 can include one or more motion detection components 225 and a data handler 230 . A motion detection component 225 can be configured to determine when the physical analog input device 220 is moved in a specified direction. Since the three-dimensional data handling system 235 is concerned with how the physical analog input device 220 is rotated, the motion detection components 225 can be aligned such as to indicate when the physical analog input device 220 is rotated around a rotational axis. The data handler 230 can be the component that collects and communicates the input data to the client device 210 using a physical (e.g., cable) or wireless connection.
It should be noted that the three-dimensional geometry of the physical analog input device 220 can affect the quantity of rotational axes, the number of distinct faces along each axis, and the navigation behavior of the three-dimensional data handling system 235 . For example, a regular quadrilateral-faced physical analog input device 220 like a cube can have three rotation axes and four distinct faces along each axis; a regular dodecahedron physical analog input device 220 (e.g., a 12 -sided die comprised of regular pentagonal faces) can have upwards of six rotational axes with a variable number of faces along each axis. For the sake of simplicity, a cubic geometry is used in the following Figures.
Additionally, the physical analog input device 220 can include selectors (e.g., buttons or switches) that increase functionality of the physical analog input device 220 , such as for changing the mode of the three-dimensional data handling system 235 as discussed in U.S. Pat. No. 8,249,132 titled “ROTATIONALLY DEPENDENT INFORMATION IN A THREE DIMENSIONAL GRAPHICAL USER INTERFACE”.
Network 250 can include any hardware/software/and firmware necessary to convey data encoded within carrier waves. Data can be contained within analog or digital signals and conveyed though data or voice channels. Network 250 can include local components and data pathways necessary for communications to be exchanged among computing device components and between integrated device components and peripheral devices. Network 250 can also include network equipment, such as routers, data lines, hubs, and intermediary servers which together form a data network, such as the Internet. Network 250 can also include circuit-based communication components and mobile communication components, such as telephony switches, modems, cellular communication towers, and the like. Network 250 can include line based and/or wireless communication pathways.
As used herein, presented data store 240 can be a physical or virtual storage space configured to store digital information. Data store 240 can be physically implemented within any type of hardware including, but not limited to, a magnetic disk, an optical disk, a semiconductor memory, a digitally encoded plastic memory, a holographic memory, or any other recording medium. Data store 240 can be a stand-alone storage unit as well as a storage unit formed from a plurality of physical devices. Additionally, information can be stored within data store 240 in a variety of manners. For example, information can be stored within a database structure or can be stored within one or more files of a file storage system, where each file may or may not be indexed for information searching purposes. Further, data store 240 can utilize one or more encryption mechanisms to protect stored information from unauthorized access.
FIG. 3A is an example embodiment 300 of a three-dimensional data handling system that utilizes rotation of a physical analog input device 310 to control selections in a visual user interface 320 in accordance with an embodiment of the inventive arrangements disclosed herein. Embodiment 300 can be a specific implementation of system 200 .
The example embodiment 300 can illustrate use of the three-dimensional data handling system as a learning tool. In this example, the user 305 , a child, can use a computer 315 to interact with a learning software application that is supported by the three-dimensional data handling system. The visual user interface 320 can be that of the learning software application and can be presented to the user 305 within the display of the computer 315 .
The computer 315 and visual user interface 320 can both be configured to accept input from the user 305 via the physical analog input device 310 . In this example embodiment 300 , the physical analog input device 310 can be an icosahedron (20-sided polyhedron) that wirelessly communicates with the computer 315 . Movement of the physical analog input device 310 can result in a corresponding movement of the selector 325 within the visual user interface 320 .
Use of the physical analog input device 310 in this embodiment 300 can have numerous benefits over conventional computing input devices. Firstly, many conventional computing input devices like a mouse and keyboard are designed as “one-size-fits-most”. Not all users 305 , particularly children, can comfortably and ergonomically use the same conventional computing input device.
For example, a child cannot easily manipulate a mouse or type effectively on a keyboard that were designed for an adult (e.g., fingers are too small to properly rest on keyboard keys, hand is too small to grip and move mouse, etc.). While child-sized computing input devices exist, they incur additional cost and require the adult user 305 to switch out devices or ineffectively use the child-size device, which then poses a similar and opposite problem for the adult user 305 (e.g., hand is too big to comfortably click mouse buttons, fingers hit too many keys on the keyboard, etc.).
Size need not be a problem for multiple users 305 when using the physical analog input device 310 . Since the three-dimensional data handling system is concerned with rotational movement, not planar motion, the physical analog input device 310 can be of a size that is relatively easy for users 305 of varying hand size and motor skill proficiency to manipulate. That is, most users 305 can “roll” the icosahedron along the floor or other relatively flat surface.
Alternately, the physical analog input device 310 can be mounted in a specialized base or holder for stabilization and/or definition of the rotational axes. For example, a specialized base can limit physical analog input devices 310 of varying geometrical shapes to the X, Y, and Z axes. Such a base can also be beneficial for users 305 who difficulty manipulating conventional computing input devices due to illness and can help to reduce repetitive motion injuries like carpal tunnel syndrome caused by conventional computing input device use.
FIG. 3B is an example embodiment 330 of a three-dimensional data handling system that utilizes rotation of a digital object 335 to control the selector 325 in a visual user interface 320 in accordance with an embodiment of the inventive arrangements disclosed herein. Embodiment 300 can be a specific implementation of system 200 .
Example embodiment 330 can also illustrate use of the three-dimensional data handling system as a learning tool. Example embodiment 330 can be an alternate, but complementary embodiment of example embodiment 300 of FIG. 3A . In this example, the user 305 , a child, can use a computer 315 to interact with a learning software application that is supported by the three-dimensional data handling system. The visual user interface 320 can be that of the learning software application and can be presented to the user 305 within the display of the computer 315 .
In example embodiment 330 , the user 305 can control movement of the selector 325 using the rotational controls 340 for a digital object 335 ; not with a physical analog input device 310 as in embodiment 300 of FIG. 3A . The digital object 335 can be a three-dimensional graphic of a fixed-sided object that is used as a control mechanism for the selector 325 . As shown in the example embodiment 330 , the digital object 335 can be a three-dimensional representation of an icosahedron.
The rotational controls 340 can be the elements (e.g., buttons, slider bars, etc.) of the visual user interface 320 that, when selected by the user 305 , rotate the digital object 335 along a directional axis. The rotational controls 340 can be presented three-dimensionally in alignment with the directional axes or can be presented two-dimensionally, depending upon the specific implementation of the three-dimensional data handling system and/or software application.
Further, the rotational controls 340 can be hidden from the user 305 . That is, the rotational controls 340 need not be overtly presented to the user 305 within the visual user interface 320 . For example, a portion (e.g., edge or face) of the digital object 335 can be clicked upon and the entire digital object 335 rotated. In such an example, the rotational controls 340 , rotating of the digital object 335 , of the visual user interface 320 can be implicitly understood by the user 305 and need not have a visual representation.
The rotational controls 340 can be activated by the user 305 in a manner commensurate with the computer 315 and/or the underlying software application. For example, when using a computer 315 having a touch screen display, the rotational controls 340 can be activated by a touch selection (e.g., touch acts as would a mouse-click) or a touch-directed manipulation of the digital object 335 (e.g., touch and rotate the digital object 335 along a directional axis).
FIG. 3C is an example embodiment 345 of a three-dimensional data handling system utilizing selection preview windows 347 and 349 within a visual user interface 320 to provide selection assistance for the rotation of a digital object 335 in accordance with an embodiment of the inventive arrangements disclosed herein. Embodiment 345 can represent a specific implementation of system 200 .
Example embodiment 345 can be an expansion upon embodiment 330 of FIG. 3B . In embodiment 345 , preview windows 347 and 349 can appear within the visual user interface 320 to show the user 305 the data items to the right and left, respectively, of the data item that is currently highlighted or displayed within the selector 325 as related to the rotation of the digital object 335 .
Unlike in embodiment 330 , the visual user interface 320 of example embodiment 345 can exclude a listing of data items that the selector 325 scrolls through in response to the rotation of the digital object 335 ; displaying large lists of data items can obscure the visual user interface 320 and make it difficult to read the data items easily. The preview windows 347 and 349 can replace the listing of data items by limiting the data items presented to the user 305 to those data items that are within one rotational step of the data item currently displayed by the selector 325 .
As shown in this example, the user 305 can be attempting to spell the word “cat”. The selector 325 can be currently upon the letter ‘t’. The left-rotation preview window 347 can display the letter ‘s’, indicating that a left rotation of the digital object 335 using the rotational controls 340 , assuming a Cartesian set of axes, will move the selector 325 to the letter ‘s’. Likewise, a right rotation of the digital object 335 can result in the movement of the selector 325 to the letter ‘u’, as shown by the right-rotation preview window 349 .
The left and right rotation preview windows 347 and 349 can be configured as such to appear when the selector 325 is in use like a typical pop-up window. Further, the visual user interface 320 can include additional rotation preview windows to display related, selectable data items of the rotationally-dependent dataset that correspond to the directional axes represented by the rotational controls 340 .
FIG. 3D is an example embodiment 350 of a three-dimensional data handling system that utilizes an auxiliary input device 355 that presents the digital object 335 for controlling selections in a visual user interface 320 in accordance with an embodiment of the inventive arrangements disclosed herein. Embodiment 350 can represent a specific implementation of system 200 .
In example embodiment 350 , the user 305 can control movement of the selector 325 within the visual user interface 320 by rotating the digital object 335 displayed upon an auxiliary input device 355 . Like embodiments 330 and 345 , the user 305 can use the rotational controls 340 to rotate the digital object 335 , and, therefore, move the selector 325 to the desired data item.
However, in embodiment 350 , the digital object 335 and rotational controls 340 can be presented to the user 305 upon an auxiliary input device 355 , instead of within the visual user interface 320 . The auxiliary input device 355 can represent a computing device configured to present the user 305 with the control elements for the visual user interface 320 and communicate entered commands to the computer 315 .
Examples of an auxiliary input device 355 can include, but are not limited to, a tablet computer (e.g., iPad), a notebook computer, a smart phone, a portable multi-media device (e.g., iPod Touch), a remote control, a portable gaming console (e.g., PSP), and the like. The auxiliary input device 355 can be physically connected to the computer 315 via a cable or can include wireless communications components to wirelessly exchange data.
As shown in this example embodiment 350 , the auxiliary input device 355 can present the user 305 with the digital object 335 , rotational controls 340 , and rotational preview windows 360 for the data item currently highlighted by the selector 325 . Such a configuration can allow the user 305 to control interaction with the visual user interface 320 at a distance from the computer 315 .
FIG. 3E is an example embodiment 365 of a three-dimensional data handling system that utilizes a remote control 370 to control rotation of a digital object 335 in a visual user interface 320 in accordance with an embodiment of the inventive arrangements disclosed herein. Embodiment 365 can represent a specific implementation of system 200 and/or example embodiment 350 .
In example embodiment 365 , the user 305 can utilize a remote control 370 having rotational controls 340 to control selector 325 movement in the visual user interface 320 . The remote control 370 can be a specialized auxiliary input device 355 of embodiment 350 of FIG. 3D . The rotational controls 340 of the remote control 370 can rotate the digital object 335 , causing the selector 325 to move through the data items and changing the contents presented in the left and right rotational preview windows 347 and 349 .
FIG. 3F is an example embodiment 375 for a physical analog input device 310 and the correspondence of physical side rotations to selections made in a visual user interface 320 in accordance with an embodiment of the inventive arrangements disclosed herein. Embodiment 375 can be utilized within the context of system 200 and/or embodiments 300 .
Physical analog input device 310 can be constructed such that its faces include a graphical display area 380 within which data items can be presented to the user 305 , such as the data item currently selected 325 as well as those data items rotationally-related 347 and 349 to the current data item. The graphical display area 380 can be implemented utilizing a variety of display technologies such as electronic paper, electrophoretic display, electrofluidic display, light-emitting diode (LED) display, organic LED (O-LED) display, and the like.
The graphical display area 380 can be covered and protected by a clear, scratch-resistant material like GORILLA GLASS or DRAGONTRAIL. Such an exterior can serve to protect other sensitive components (e.g., motion sensors, computing elements, etc.) that can be positioned within the physical analog input device 310 .
The data items presented within the graphical display area 380 of the physical analog input device 310 can change based upon the software application being run by the user 305 . For example, different foreign language software applications can each present the corresponding alphabet within the graphical display areas 380 of the physical analog input device 310 ; a software application teaching mathematical skills can display numbers instead of letters.
FIG. 3G is an example embodiment 385 of a three-dimensional data handling system that utilizes a physical analog input device 310 paired with a digital object 335 to control selections in a visual user interface 320 in accordance with an embodiment of the inventive arrangements disclosed herein. Embodiment 385 can represent a specific implementation of system 200 and the physical analog input device 310 described in embodiment 375 of FIG. 3F .
Example embodiment 385 can represent a robust implementation of the three-dimensional data handling system in which the data items presented within the graphical display areas 380 of the physical analog input device 310 can be paired to or synchronized with the orientation of the digital object 335 and the data items displayed in the rotational preview windows 360 . That is, the movement of the physical analog input device 310 can be mirrored by the digital object 335 and vice versa.
Therefore, when the user 305 rolls the physical analog input device 310 to the right, the digital object 335 can also be rotated to the right within the visual user interface 320 and the contents of the selector 325 and the rotational preview windows 360 can be updated to reflect the shift to the appropriate data item. Likewise, when the user 305 utilizes the rotational controls 340 within the visual user interface 320 to rotate the digital object 335 to the left, the contents of the graphical display areas 380 of the physical analog input device 310 , the selector 325 , and the rotational preview windows 360 can also change to match the movement to the new data item.
Thus, the data items displayed within the graphical display areas 380 of the physical analog input device 310 can be synchronized to the data items shown in the selector 325 and rotational preview windows 360 of the visual user interface 320 .
FIG. 4 is a collection 400 of example graphical user interfaces (GUIs) 410 , 430 , and 440 for the three-dimensional data handling system illustrating navigation through a rotationally-dependent dataset by hyper-rotation of a physical analog input device 405 in accordance with an embodiment of the inventive arrangements disclosed herein. The GUIs 410 , 430 , and 440 can be utilized in conjunction with method 100 , system 200 , and/or example embodiment 300 .
The commands for the GUIs 410 , 430 , and 440 of the three-dimensional data handling system can be provided by the user via the physical analog input device 405 . It can be assumed that the physical analog input device 405 is configured to communicate orientation data to the three-dimensional data handling system and that the user understands how to manipulate the physical analog input device 405 to navigate the rotationally-dependent dataset.
In this example, the physical analog input device 405 can be a cube having six distinct faces, numbered 1 through 6 , and three Cartesian rotational axes 407 with four distinct faces, N, when rotated around each rotation axis 407 . As the user rotates the physical analog input device 405 around an axis 407 , some of the faces of the cube can change their orientation in three-dimensional space.
For example, by rotating the current presentation of the physical analog input device 405 around the X-axis 407 , the positions of faces 1 and 3 can remain unchanged (i.e., face 1 is at the front and face 3 is to the rear) while the positions of faces 2 through 5 change places in the XY and XZ planes.
GUI 410 can illustrate the physical analog input device 405 being used to navigate a rotationally-dependent dataset representing an electronic filing system. The GUI 410 can include a display area 412 to render a digital object 414 representing the rotationally-dependent dataset, navigation controls 416 , and data presentation areas 418 , 420 , and 425 .
In GUI 410 , the filing system can be represented as a filing cabinet digital object 414 . The top level elements of the rotationally-dependent dataset, the alphabet, can be shown in a corresponding data presentation area 418 . Since only the top level of the rotationally-dependent dataset is being navigated at this time, data presentation areas 420 and 425 can be inactive at this time.
In another contemplated embodiment, the data presentation areas 418 , 420 , and 425 can be consolidated into a single data presentation area where only the branch of the rotationally-dependent dataset that is currently being navigated through is presented.
Rotation of the physical analog input device 405 around a predefined axis 407 can control movement of a selector 419 through the data elements of the data presentation area 418 . The rotation of the physical analog input device 405 can be mirrored by the digital object 414 or the digital object 414 can remain rotationally-static and present an animation like the drawers of the filing cabinet 414 opening and closing.
For example, as the physical analog input device 405 is rotated around the Z-axis 407 , the filing cabinet 414 can spin accordingly and the selector 419 can move to the left or right, depending on whether the rotation is in the clockwise or counter-clockwise direction.
It should be noted that the physical analog input device 405 can be hyper-rotated through multiple revolutions around a rotational axis 407 in order to move the selector 419 through all of the data elements presented in data presentation area 418 . That is, since the number of data elements, M=28, in the top-level of the example rotationally-dependent dataset is larger than the number of faces, N=4, the physical analog input device 405 has along a rotational axis 407 , the user can continue rotation of the physical analog input device 405 through a maximum of seven revolutions, M divided by N, to continue movement of the selector 419 .
The three-dimensional data handling system can track the number of revolutions performed and adjust movement through the data elements of the rotationally-dependent dataset accordingly. Further, the use of hyper-rotation of the physical analog input device 405 can apply to all rotational axes 407 and any branch of the rotationally-dependent dataset where M is greater than N.
The navigation controls 416 can be used to control the rotation/animation of the digital object 414 and movement of the selector 419 in situations where navigational commands are provided by a conventional computing input device instead of the physical analog input device 405 .
GUI 430 can illustrate the information presented when the user selects a data element of the rotationally-dependent dataset in GUI 410 ; the letter ‘S’, in this example. Selection of a data element in the data presentation area 418 can be performed in a variety of ways commensurate with the specific embodiment of the three-dimensional data handling system and user interface.
For example, the physical analog input device 405 can include a selection button (not shown) that indicates the selection of the data element currently highlighted by the selector 419 . Alternately, ceasing movement of the selector 419 and rotating the physical analog input device 405 around a different rotational axis 407 can also indicate that navigation through the rotationally-dependent dataset is to branch from the last data element upon which the selector 419 stopped.
That is, using the current example, if rotating the physical analog input device 405 around the Z-axis 407 scrolls the selector 419 through the alphabetical listing, stopping the Z-rotation on the letter ‘S’ and then rotating the physical analog input device 405 around the Y-axis 407 can access the next part or branch of the rotationally-dependent dataset that originates from the letter ‘S’, as illustrated in GUI 430 . Since the rotationally-dependent dataset is a filing system, selection of the letter ‘S’ in GUI 410 can be thought of as selecting the filing cabinet drawer of the same letter.
Thus, in GUI 430 , the digital object 414 of the filing cabinet can be replaced in the display area 412 with a digital object 432 of a file drawer, representing navigation to the ‘S’ branch of the rotationally-dependent dataset. Data presentation area 418 can remain unchanged within GUI 430 to remind the user of their navigation history and/or provide an easy means for the user to retrace their steps.
Data presentation area 420 can now become active to display to the user the data elements of the selected branch of the rotationally-dependent dataset; data presentation area 425 can remain inactive, since the user has not yet navigated to its corresponding level of the rotationally-dependent dataset. As shown in this example, rotation of the physical analog input device 405 around the Y-axis 407 can “flip” file cards 435 representing the alphabetical sub-groupings within the data presentation area 420 . Again, selection of a data element in the data presentation area 420 can be performed in a variety of ways commensurate with the specific embodiment of the three-dimensional data handling system and user interface.
GUI 440 can illustrate the data presented when the user has navigated three-levels deep in a rotationally-dependent dataset. Using this example, the first or top level can be the alphabetical designation of a filing cabinet drawer. Selecting a drawer can navigate to the second level of filing cards having alphabetical sub-groupings of the selected alphabetical designation. Lastly, selection of a file card can present the user with file titles associated with the selected alphabetical sub-grouping, as shown in GUI 440 .
In GUI 440 , the digital object 432 of GUI 430 can be replaced with a digital object 442 representing the sub-level of the rotationally-dependent dataset that the user has accessed, file pages in this example. Data presentation areas 418 and 420 can remain unchanged within GUI 440 to remind the user of their navigation history and/or provide an easy means for the user to retrace their steps.
Data presentation area 425 can now present the data elements, file titles 445 , of the rotationally-dependent dataset branch that the user has accessed. Since rotation of the physical analog input device 405 around the Z-axis 407 was used to control selection in data presentation area 418 and the Y-axis 407 for data presentation area 420 , rotation of the physical analog input device 405 around the X-axis 407 can be used to control selector 447 with the data presentation area 425 .
Selection of a file title 445 within the data presentation area 425 by the user can result in the presentation of additional data (not shown) about the file title 445 , within a data presentation area 418 , 420 , or 425 of GUI 440 or within a secondary GUI window.
Additionally, GUIs 410 , 430 , and 440 can be configured to support multiple modes, as taught in U.S. Pat. No. 8,249,132 titled “ROTATIONALLY DEPENDENT INFORMATION IN A THREE DIMENSIONAL GRAPHICAL USER INTERFACE”, where the rotation of the physical analog input device 405 accesses and presents different rotationally-dependent datasets based upon the selected mode.
FIG. 5 is a flowchart of a method 500 describing the handling of hyper-rotation of a physical analog input device by a three-dimensional data handling system to navigate a rotationally-dependent dataset in accordance with embodiments of the inventive arrangements disclosed herein. Method 500 can be performed within the context of method 100 , system 200 , example embodiment 300 , and/or the GUIs 410 , 430 , and 440 of collection 400 .
Method 500 can begin in step 505 where the three-dimensional data handling system can identify the physical analog input device. The quantity, j, and direction for the rotational axes of the physical analog input device can be ascertained in step 510 .
In step 515 , the quantity of faces, N, that the physical analog input device has along each rotational axis, the set {N 1 , N 2 , . . . N j }, can be determined. Alternately, the information determined by the three-dimensional data handling system can be supplied by the physical analog input device as part of step 505 , when the physical analog input device identifies itself, or can be accessed from a static table containing such information for various physical analog input devices.
The user-specified rotationally-dependent dataset can be loaded in step 520 . In step 525 , the size, M, of each branch of the rotationally-dependent dataset can be identified. The three-dimensional data handling system can receive navigation commands for a branch of the rotationally-dependent dataset from the user via rotation of the physical analog input device in step 530 .
In step 535 , it can be determined if the number of face rotations is less than the quantity of faces, N, of the physical analog input device along the rotational axis and the quantity of data elements, M, in the branch of the rotationally-dependent dataset. When the number of face rotations is less than N and M, it can be determined if the next navigation command is along the same rotational axis in step 540 .
When the following navigation command is along the same rotational axis, step 545 can be performed where navigation of the current branch of the rotationally-dependent dataset is continued. From step 545 , method 500 can return to step 530 to continue processing the user's navigation commands.
When the following navigation command is not along the same rotational axis, navigation can be changed to the selected branch of the rotationally-dependent dataset in step 550 . From step 550 , method 500 can return to step 530 to continue processing the user's navigation commands.
When the number of face rotations is not less than N and M, corresponding to a situation where the physical analog input device is past at least one full revolution, the three-dimensional data handling system can adjust the position within the branch of the rotationally-dependent dataset by the number of full rotations of the physical analog input device in step 555 . It should be noted that it can be assumed that navigation using the physical analog input device is only valid when then end of the branch of the rotationally-dependent dataset has not been met; hence, it can be implied that step 555 is not executed once the last data element of the branch has been accessed.
For example, using a cube having N=4, a branch of the rotationally-dependent dataset where M=9 and the number of face rotations is 6, the three-dimensional data handling system can move the selector to M 6 and recognize that the physical analog input device has made one full revolution along the rotational axis and that the second face is “active” or facing the user.
From step 555 , method 500 can proceed to step 540 to determine how to handle the next received navigation command and continue processing subsequent navigation commands. | An initial face of an object having N faces along an axis of rotation is detected. A data set of ordered content items is assessed. An initial one of the ordered content items is visually presented within a field of a user interface shown on a display. The field of the user interface is a displayed graphical element of the user interface distinct from the object. The object being rotated along the axis of rotation is detected so that X number of faces are cycled as the object is rotated from the initial face to a post-rotation face of the N faces. The data set is sequentially advanced by X number of items from the initial one of the content items to a current item of the content items. The field of the user interface is updated to visually present the current content item. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ignition system for internal combustion engines and more particularly to improvements of an ion current detector used for detecting misfiring of internal combustion engines.
2. Prior Art
FIG. 14 shows a conventional ignition system for internal combustion engines.
During operation, an ignition timing control unit 701 receives signals outputted at regular timings from a signal generator 716 and drives a power transistor 702 to turn on and off. That is, the transistor 702 operates as a switch for driving an ignition coil 700. When the coil 700 is driven, a back voltage is developed across the primary winding while a negative high voltage is developed across the secondary winding, so that the air-fuel mixture is ignited by an ignition plug 703. When the air-fuel mixture burns, an ion current i is developed to flow through the ignition plug 703, a diode 706, a resistor 707 and a battery 708 as well as through a capacitor 709 and a resistor 710. Then, a voltage appears across the resistor 710. The voltage across the resistor 710 is then supplied as an ion current signal to a comparator 711 which in turn compares the ion current signal with a reference voltage to detect the occurrence of ion current.
FIG. 15 shows another conventional ignition system. A power transistor 802 is turned on at a given timing in synchronism with the crank angle of an internal combustion engine and is turned off at an ignition timing. When the power transistor 802 is turned off to stop the primary current through the primary winding 1a of ignition coil, a negative high voltage is developed across the secondary winding 1b to cause a spark between the electrodes of an ignition plug 803, by which the air-fuel mixture is ignited. At this time, ions are produced due to the combustion of air-fuel mixture and a positively biasing power supply 808 causes discharge through the electrodes of the ignition plug 803 to form a closed path for an ion current. In this manner, the electrodes serve as an ion-detecting electrode through which an ion current flows. The ion current causes a voltage drop across a resistor 805 which appears at an output terminal 806. The detection of the voltage at the output terminal 806 indicates the combustion of air-fuel mixture.
The conventional ignition system in FIGS. 14-15 require power supplies 708 and 808 of about -200 VDC, which are usually large, heavy, and expensive. These power supplies are disadvantageous in mounting on vehicles.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a small, inexpensive ion current detector used for an ignition system in an internal combustion engine.
An ignition system for an internal combustion engine has an ignition coil having a first winding and a second winding. The second winding supplies a high voltage for ignition to an ignition plug when the ignition coil is energized at the first winding at a predetermined period. A voltage producing circuit produces a voltage on the basis of a signal developed across the first winding when the first winding is energized at a predetermined period. The voltage causes discharge across the electrodes of the ignition plug to form a path for an ion current developed in the cylinder. A comparator or detector detects the ion current to determine the combustion in a cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
Features and other objects of the invention will be more apparent from the description of the preferred embodiments with reference to the accompanying drawings in which:
FIG. 1 shows a first embodiment of an ignition system according to the present invention;
FIGS. 2A, 2B and 2C are waveform diagrams illustrating the operation of the first embodiment;
FIG. 3 shows a second embodiment;
FIGS. 4-6 are waveform diagrams showing the second embodiment;
FIG. 7 shows a third embodiment where a negative high voltage is produced for ignition;
FIGS. 8A-8C show various currents in the third embodiment;
FIGS. 9A, 9B, and 9C are waveform diagrams of the respective currents and voltages in the third embodiment;
FIG. 10 shows a fourth embodiment of an ignition system where a positive high ignition voltage is generated.
FIG. 11 shows a fifth embodiment of an ignition system where two cylinders are fired at the same time;
FIGS. 12-13 show a sixth embodiment of an ignition system where a distributor is used to distribute high voltages to respective cylinders, FIG. 12 showing a system for generating a negative high voltage and FIG. 13 showing a system for generating a positive high voltage.
FIG. 14 shows a conventional ignition system for internal combustion engines; and
FIG. 15 shows another conventional ignition system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
FIG. 1 shows a first embodiment. An ion current detector 120 is provided between a resistor 107 and an ignition coil 100. In the figure, a drive signal from an ignition timing controller 101 drives a transistor 102 to turn on and off. The signal (FIG. 2A) appearing at a point A, the collector of the transistor 102, is supplied to a series circuit of a resistor 123 and a capacitor 122, which serves as a differentiating circuit to a signal inputted thereto so as to output a differentiated waveform shown in FIG. 2B. The differentiated waveform is then rectified by diodes 121 and 124 so that the rectified negative voltage -Vo is held across a capacitor 125. This negative voltage -Vo is used as a d-c power supply for detecting an ion current. That is, the ion current i flows through a diode 106 and then a resistor 107 into the capacitor 125 so that the ion current i is superposed to the negative voltage -Vo. Then, a voltage due to ion current appears across a resistor 110 via a capacitor 109. A comparator 111 compares the voltage across the resistor 110 with a reference voltage to output an ion current signal I.
Second Embodiment
FIG. 3 shows a second embodiment. In the first embodiment, the ion current detector 120 is provided only to a cylinder fired first. Of course, this ion current detector 120 produces a sufficient negative biasing voltage for that first cylinder but the negative biasing voltage will gradually decrease for the rest of cylinders as shown in FIG. 6. Thus, the negative biasing voltage will have decreased to -Vn for an Nth cylinder, not being sufficient for reliable ion current detection of Nth cylinder.
The second embodiment is to supply all the cylinders with the same biasing voltage for ion current detection.
Signals from an ignition timing controller 201 drive respective power transistors 202 to turn on and off so that the respective transistors 202 cause positive voltages similar to that shown in FIG. 2A across the primary winding of an ignition coil 200. The ion current detector 220 receives these positive voltages associated with the respective cylinders from the respective transistors 202. Each of differentiation circuits is formed of a resistor 223 1-n and a capacitor 222 1-n , and differentiates the positive voltage similar to that shown in FIG. 2A and sends the differentiated voltage to a rectifier formed of diodes 224 1-n and 221 1-n . Then, the rectified negative voltage is held across a common capacitor 225.
The operation of the second embodiment will now be described as follows: The power transistors 202 are driven by the signals from the ignition timing controller 201 to turn on and off so as to drive the ignition coils 200. Across the secondary winding of ignition coil 200 is developed a negative high voltage 213 which is fed to an ignition plug 205 via a diode assembly 207 to ignite the air-fuel mixture. The high voltage 213 is a negative voltage and therefore does not affect the operation of a comparator 211. When ions are developed in a cylinder 212, an ion current flows through an ion current path 215 and the comparator 211 outputs an ion current signal I. A signal generator 216 detects the crank angle of the engine and sends it to the ignition controller 201. This crank angle is used to determine whether ignition is effected normally in the respective cylinders.
FIG. 4 shows voltages at lines 218 for the first to Nth cylinders and a negative biasing voltage produced across the capacitor 225. FIG. 5 shows the voltage at 214 when only voltages of the first and third-cylinders of a four-cylinder engine are used to produce an ion detecting biasing voltage across the capacitor 225. The biasing voltage at 214 decreases somewhat but this configuration may be useful if the ion detection characteristics are not seriously affected.
For other engines such as six-cylinder- and eight-cylinder-engines, it is preferred to produce the negative biasing voltage at 214 based on more than two lines 218.
Third embodiment
FIG. 7 shows a third embodiment where a negative high voltage is produced for ignition.
The secondary winding 1b of an ignition coil 300 is connected at one end thereof to an ignition plug 303 and is connected at the other end thereof to the ground via a Zener diode 313. A diode 311 is connected at its cathode to the cathode of the Zener diode 313 and is connected at its anode to an output terminal 312. Between the output terminal 312 and the ground is inserted a series connection of a resistor 310 and a capacitor 307. A resistor 308 and a diode 309 are connected in series between the junction of the resistor 310 and capacitor 307 and one end of the primary winding 1a of ignition coil 300. A transistor 302 is inserted between the junction point of the resistor 308 and the primary winding 1a.
The operation of the third embodiment will now be described with reference to FIGS. 8A-8C and FIGS. 9A-9C. The power transistor 302 is turned on at time t1 in synchronism with the crank angle of an engine so as to run a primary current (FIG. 9A) through the primary winding, and is turned off at time t2. When the primary current through the primary winding 1a is shut off, a back voltage of about -10 to 25 kV is developed as shown in FIG. 9C to cause a spark between the electrodes of plug 303. Thus, a discharge current flows through a path indicated by an arrow as shown in FIG. 8A so that the air-mixture is ignited by the ignition plug 303. The Zener diode 313 serves to restrain the voltage applied to the ignition plug 303. During the combustion of air-fuel mixture, ions are developed and the positive biasing voltage of about 50 to 300 volts discharges through the electrodes of ignition plug to form a closed current path so that an ion current i flows through a path indicated by an arrow as shown in FIG. 8B. The ion current i results in a voltage (ion current signal) at an output terminal 312 from which the combustion of the cylinder is detected.
A back voltage of about 400 volts is developed across the primary winding 1a as shown in FIG. 9B when the primary current is shut off(times t2 to t3 in FIG. 9B), and an induced voltage appears across the primary winding when the discharge current flows(times t3 to t4 in FIG. 9B.) The induced voltage causes a charging current as depicted by an arrow in FIG. 8C to charge the capacitor 307. If the capacitor 307 is charged to a voltage higher than the zener voltage of the diode 313, then the capacitor 307 discharges through the resistor 310, diode 311, and diode 313. Thus, the zener voltage of the zener diode 313 determines a maximum voltage charged across the capacitor 307.
Fourth embodiment
FIG. 10 shows a fourth embodiment, which is a modification of the third embodiment, where a positive high ignition voltage is generated for ignition. The discharge current flows through the second winding 1b--diode 414--ignition plug 403--ground. The ion current i flows through a path as shown in FIG. 10. The other operation of the circuit is the same as that of the third embodiment.
Fifth embodiment
FIG. 11 shows a fifth embodiment, which is another modification of the third embodiment, where two plugs are fired at the same time. The discharge current flows through the second winding 1b--ignition plug 503a--ground--ignition plug 503b--second winding 1b. The ion current i flows through a path as shown in FIG. 11. The ignition timing is set such that when one cylinder is in firing stroke, the other cylinder is in discharge stroke. Thus, although the spark occurs in both the cylinders at the same time, ignition is effected only in a cylinder which is in compression stroke thereof. The other operation is the same as the third embodiment.
Sixth embodiment
FIGS. 12-13 show a sixth embodiment, which is still another modification of the third embodiment, where a distributor is used to distribute the high voltage to the respective cylinders. FIG. 12 shows a circuit for generating a negative high voltage for ignition. The discharge current flows through the secondary winding 1b--resistor 610--capacitor 607--ground--ignition plug 603 --distributor 615--secondary winding 1b. The ion current i flows through the capacitor 607--resistor 610--secondary winding 1b--diode 616--ignition plug 603--ground--capacitor 607. It should be noted that the ion current flows in a direction opposite to the discharge current. Thus, the voltages appearing on the terminal 612 due to the two currents are different in polarity. Using the difference in polarity, the ion current can properly be detected by a subsequent circuit(not shown) connected to the terminal 612. The diode in parallel with the secondary winding 1b is inserted so as to cancel out an unwanted voltage of about 1 to 2 kV developed at a moment when the first winding is energized, whereby the ignition plug 603 is not fired by this induced voltage at a wrong timing. There is a short clearance between the center pole and the each of peripheral poles, and the insulation of the clearance is broken by the voltage across the secondary winding when the discharge current flows. However, when the ion current flows, the insulation resistance is too high for the voltage(about 200-300 V) across the capacitor 607 to break the insulation. The diode 616 is inserted in parallel with the distributor 615 to provide a path for the ion current. The other operation is the same as the third embodiment.
FIG. 13 shows a circuit for generating a positive high voltage for ignition. In FIG. 13, the discharge current flows through the secondary winding 1b--distributor 615--ignition plug 603--ground. The ion current i flows through the capacitor 607--resistor 610--diode 611--ignition plug 603--capacitor 607. It should be noted that the diode 616 in FIG. 12 is not required since the ion current path does not include the clearance between the center pole and peripheral poles of distributor. The other operation is the same as the third embodiment. | An ignition system for internal combustion engines has an ignition coil having a primary winding and a secondary winding. The secondary winding supplies a high voltage for ignition to an ignition plug when the ignition coil is energized at the primary winding at a predetermined period. A voltage producing circuit produces a voltage on the basis of a signal developed across the primary winding when the primary winding is energized at a predetermined period. The voltage causes discharge across the electrodes of the ignition plug to form a path for an ion current developed in the cylinder. A comparator or detector detects the ion current to determine the combustion in a cylinder. | 5 |
FIELD OF THE INVENTION
The invention relates to a valve device for a hydraulic circuit which divides the incoming volumetric flow into at least two predetermined partial flows for the supply of hydraulic consumers of the circuit. The valve device has at least one pressure compensator and at least one orifice.
BACKGROUND OF THE INVENTION
These valve devices are also technically referred to as flow regulators or pressure-compensated flow control valves and allow the incoming volumetric flow to be divided into a regulated and an unregulated residual volumetric flow according to the throttle principle. Ultimately, they are throttle valves with an adjustable orifice (throttle) in which the flow rate remains constant, regardless of changing load pressures, by a combination with a respective pressure compensator. At the same time, the pressure compensator clears a changing cross section that is inversely proportional to the load pressure so that consequently the flow rate remains essentially constant, regardless of the load pressure.
Such a valve device is shown, for example, in DE 10 2006 004 264 A1, relating to a stabilization means or mechanism for a multi-axle vehicle with one hydraulic control circuit each provided for the front and the rear axles. Because in the known solution the incoming volumetric flow of at least one of the axles is controlled by the pressure-compensated flow control valve, and because at a higher capacity of the supply unit, the accompanying excess of volumetric flow can be relayed to at least one of the other axles which is unregulated, in case of an excess of the volumetric flow, the flow is kept constant on the axle controlled by the flow control valve. The excess portion travels to the respective unregulated axle. Among other things, this system causes the desired roll stabilization on the unregulated axle in terms of trigger behavior to be designed to be more highly dynamic. Under actual driving conditions, this operation confers distinct advantages compared to otherwise conventional divisions of amounts with percentage volumetric ratios that are stipulated in a defined manner for the respective partial flow amounts for the supply of the hydraulic consumers in the form of the control circuit for the indicated front and rear axles.
SUMMARY OF THE INVENTION
An object of the invention is to provide a valve device, regardless of how high the power demand is for the respective partial flow of the hydraulic circuit, that supplies the necessary amount of fluid the consumer needs to ensure the power demand for a safety-relevant system of the hydraulic circuit.
This object is basically achieved by a valve device having an orifice outfitted as a variable orifice triggerable by a proportional magnet. Its opening area then can be changed to implement a type of flow regulator switching and/or proportionally setting the controlled volumetric flow in a defined manner. This function is required, in particular, when at least two hydraulic systems are operated with hydraulic consumers that are different in terms of power demand by only one hydraulic pump as a pressure supply source. Their power demand can be at least in part very different. At the same time, one of the two systems comprises the safety-relevant system which must be supplied under all conditions.
Due to the variable orifice implemented by triggering with a proportional magnet, a proportionally variable opening area arises and is made such that for all trigger states a defined passage area remains opened. In any case, the flow through the orifice meets the power demand for the safety-relevant system. Even in the case of a fault, for example, the power for the proportional magnet as a trigger fails, a maximally regulated volumetric flow is supplied to the safety-relevant system and its operation is guaranteed.
The valve device according to the invention designed as a variable pressure-compensated flow control valve, is especially advantageous when used in vehicles of any type (passenger cars, busses, trucks, roadworthy machinery, etc.) where a hydraulic pump driven by the vehicle engine as a pressure supply source supplies both the servo-assisted steering and the roll stabilization for the axles of the vehicles.
For the associated power demands on the individual systems, this ability means the following based on practical circumstances.
When the vehicle is driving at speed, only very little steering deflection (speed) is necessary on the part of the operator, and little servo assistance is necessary. In this case, the volumetric flow in the steering circuit can be ramped down to a minimum value, while at the same time greater roll moments must be corrected. Conversely, when parking, for example, a large steering deflection (speed) with correspondingly high servo assistance is necessary, and roll compensation is less important when parking. For both system requirements, there should never be too little volumetric flow for the steering since otherwise the servo assistance for the steering deflection will fail. Modern vehicles are very difficult to manage with normal expenditure of force without the pertinent servo assistance. With the invention, for this application it is always ensured that steering does not receive too little volumetric flow relative to the indicated servo assistance.
It must also be ensured, in case of a fault, that, for a minimally regulated volumetric flow, servo assistance benefits the steering system. Furthermore, when the power fails, as another possible fault source for the proportional magnet, the magnet should then set the largest opening area on the orifice for the largest regulated volumetric flow available for steering.
Regardless of the described application, the valve device according to the invention can always be used wherever different partial flows of a hydraulic circuit must be set with connected hydraulic consumers having different power requirements and/or which, especially for safety reasons, are not to be supplied beforehand.
In this application, the expression “orifices” is also intended to describe and to cover the use of “throttles.” This usage also applies to the term “metering orifice” used technically below. To the extent that the expression “orifice,” “variable orifice,” “free orifice cross sections,” etc. are used, these terms generally include the terms “throttle,” “variable throttle,” “free throttle cross-sectional area,” etc.
In one especially preferred embodiment of the valve device according to the invention, at least the pressure compensator and the respectively used orifices and proportional magnet are components of a common valve block. This common valve block can also be retrofitted on site onto existing vehicle systems as a modular unit.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure and which are schematic and not to scale:
FIG. 1 is a hydraulic circuit diagram of a valve device according to a first exemplary embodiment of the invention;
FIG. 2 is a side elevational view in section, without the crosshatching, of the proportional magnet used in the valve device of FIG. 1 with a connected valve housing for implementation of a variable orifice and a constant orifice;
FIG. 3 is a side elevational view in section, without the crosshatching, of a valve device according to a second exemplary embodiment of the present invention with a downstream pressure compensator in addition to a damping means;
FIG. 4 is a side elevational view in section, without the crosshatching, of the pressure compensator of FIG. 3 , but without additional vibration damping; and
FIG. 5 is a perspective top view of the valve device of FIG. 3 as a whole.
DETAILED DESCRIPTION OF THE INVENTION
The valve device shown in FIG. 1 as a hydraulic circuit diagram is used to supply a hydraulic circuit 10 with fluid. The hydraulic circuit 10 is supplied with fluid by a pressure supply source 12 . The pressure supply source 12 has a conventional hydraulic pump driven by an engine, for example the internal combustion engine of a motor vehicle. The volumetric fluid flow flowing in via the line 14 from the pressure supply source 12 is divided at the branch site X, one partial flow leading to a hydraulic consumer V 1 (not detailed) and the other partial flow to a hydraulic consumer V 2 . In the specific exemplary embodiment, the consumer V 1 is designed to be formed from the servo-assisted steering system, and the consumer V 2 forms a roll stabilization system for the axles of the vehicle (not shown).
The valve device has a conventional pressure compensator 16 shown in the non-regulating basic position and forming a 4/3-way proportional valve. The pressure compensator spool 20 , guided in the pressure compensator housing 13 , is exposed on its opposite sides to control pressures ST 1 and ST 2 acting in opposite directions. As illustrated in FIG. 1 , the pressure compensator spool 20 has its right side supported on an adjusting spring 22 in the manner of a compression spring. One control pressure ST 2 is connected to the branch site X, which in turn is connected to the fluid inlet E 2 of the pressure compensator 16 to carry fluid via the line 24 . The other control pressure ST 1 is tapped upstream of the inlet E 1 of the pressure compensator 16 in the supplying line 26 . Supplying line 26 leads to branch site X. On the opposite side of pressure compensator 16 , fluid outlets A 1 , A 2 are connected by lines 28 , 30 to the first hydraulic consumer V 1 and second consumer V 2 .
Beginning at the branch site X, a variable orifice 32 is connected in the line 26 and can be triggered by proportional magnet 34 , i.e., the free opening area of the variable orifice 32 can be dictated by the proportional magnet 34 . Parallel to the variable orifice 32 another orifice 36 is connected as a constant orifice, i.e., the free opening area of the other orifice 36 is constant. The parallel arrangement for the other orifice 36 arises from being connected in a line 38 which, viewed in the fluid direction, discharges upstream of the variable orifice 32 into the line 14 and downstream of the variable orifice 32 into the line 26 , specifically, at the connecting site 40 . As shown in FIG. 1 , the line 38 discharges into the branch site X of the line 14 . To obtain the control pressure ST 1 , the pressure compensator 16 is connected by the control line, indicated by the broken line, to the line 26 between the connecting site 40 and the fluid inlet E 1 . The fluid pressure prevailing at E 1 is then present as the control pressure ST 1 , and the control pressure ST 2 is the fluid pressure on the fluid inlet side E 2 of the pressure compensator 16 . This control line for the control pressure ST 2 is also shown in FIG. 1 by the broken line.
To trigger the whole system, the coil winding 42 of the proportional magnet 34 is connected to a computer unit (not detailed) by an electrical plug contact 44 (cf. FIG. 2 ). For example, depending on the driving speed of the vehicle, the computer unit dictates the trigger values of the current for the proportional magnet 34 . Overall, with the solution as shown in FIG. 1 , a valve device in the manner of a flow regulator can proportionally set in a defined manner the regulated partial volumetric flow to the consumer to be regulated. This function is required if, proceeding from the pressure supply source 12 , for example two hydraulic systems with a consumer V 1 (servo-assisted steering system) and a consumer V 2 (roll stabilization system) are operated whose power demands to some extent are distinctly different. At the same time, one of the two systems, specifically the servo-assisted steering system, is a safety-relevant vehicle system and must be supplied with the volumetric flow necessary for safe operation under all conditions. The valve representation as depicted in FIG. 2 shows the energized and therefore connected state for the valve device, yielding a minimum volumetric flow.
Then, in particular, the following applies to the power requirements of the two systems.
When the vehicle is driving at speed, only very little steering deflection (speed) is necessary and little servo assistance is required. In this case, the regulated volumetric flow in the steering circuit can be ramped down for the consumer V 1 to a minimum value, induced by the proportional magnet 34 triggerable depending on the speed. In turn, larger roll moments must be corrected, and the consumer V 2 acquires a larger residual volumetric flow from the branch site X and the pressure compensator 16 . By contrast, when parking, for example, a large steering deflection (speed) with high servo assistance is necessary, so that the hydraulic consumer V 1 requires a large partial volumetric flow. Roll compensation is conversely less relevant during parking, so that the fluid volumetric flow required in this respect can be reduced.
For both described states, however, the steering system, i.e., the hydraulic consumer V 1 , should never receive too little volumetric flow. This requirement is achieved with the valve device shown in FIG. 1 . In the case of a fault, i.e., for example when the power fails, the proportional magnet 34 is no longer energized, and the variable orifice 32 will assume its largest opening cross section, i.e., have the largest opening area. The largest regulated volumetric flow will then continue to travel to the servo-assisted steering system (consumer V 1 ).
In the valve device according to the invention, the arrangement of the proportional magnet 34 with a variable orifice 32 and constant orifice 36 is detailed below. As already described, the proportional magnet 34 has a coil winding 42 which can be triggered via an electrical plug contact 44 by a computer unit (on-board computer), not shown. The computer unit processes the vehicle-side data, such as, for example, the vehicle speed, steering deflection, etc. In a pole tube arrangement 46 with magnetic separation 48 , an armature body 50 with an actuating rod 52 inserted on the end side is guided to be able to move lengthwise. The proportional magnet 34 is made as an attachment part. The magnet housing 54 can be fixed on third components by a flange part 56 , for example in the form of a valve block 58 as shown in FIG. 5 . By the electrical contact or plug 44 , the coil winding 42 can be triggered by the computer unit. Depending on the vehicle speed, the computer unit relays control pulses to the coil winding 42 to advance the armature body 50 with the actuating rod 52 . The structure of these proportional magnets 34 is known so that it need not be described further.
The proportional magnet 34 is connected to a valve housing 60 in which a valve spool or control spool 62 is guided. The control spool 62 on its right side, as viewed in FIG. 2 , is triggered by the actuating rod 52 and is supported with its other left free end on a support spring 64 in the manner of a compression spring supported in the valve housing 60 by a plug 66 . Spring 64 applies a permanent resetting compressive force to the control spool 62 . The control spool 62 has an annular widening 68 and has a conically widening control surface 70 on its left free face side.
The surface of widening 68 is used to trigger passage openings 72 , 74 . The passage openings 72 , 74 are made as passage bores, are arranged in succession to one another and preferably diametrically opposite one another, and extend repeatedly through the valve housing 60 . Furthermore, the passage openings 72 , 74 , viewed in each cross-sectional row, can have different diameters and/or a different number of holes. In particular, FIG. 2 shows a first row of bores with passage openings 72 , 74 arranged in succession viewed in the direction of travel of the control spool 62 , with the first row of passage openings 72 being in concert with the annular widening 68 of the control spool 62 forming the control for the variable volumetric flow portion, and therefore, forming the orifice design for the variable orifice 32 . Conversely, the constant orifice 36 , located in the bypass and in a parallel connection, is formed by the passage opening 74 . The variable orifice 32 is formed by the passage opening 72 , and the constant orifice 36 is formed by the passage opening 74 .
Depending on the position of the control spool 62 , the spool then regulates the variable orifice 32 by the corresponding control edge between the passage opening 72 and the cylindrical constriction 78 in the control spool 62 . FIG. 2 also illustrates that, in the event of a power failure and in the event the coil winding 42 is no longer energized, the support spring 64 is relieved and, as viewed in FIG. 2 , shifts the control spool 62 to the right. This shifting leads to complete opening of the passage openings 72 , 74 . Fluid passage is such that a regulated fluid supply is ensured by the connecting site 40 for the partial fluid circuit relating to the consumer V 1 in the form of the servo-assisted steering. In this way, a fail-safe circuit is achieved for the valve device according to the invention.
With the valve solution as shown in FIG. 2 , a variable metering orifice (throttle) 32 is implemented characterized by triggering with the proportional magnet 34 and consequently with a proportionally variable opening area formed by the passage opening 72 . This variable opening area is designed such that for all trigger states a defined area always remains open by the proportional magnet 34 . Here, it would be fundamentally sufficient in one basic version to provide only one row of passage openings 72 for fluid passage from the outside to the inside, where, to limit the stroke of the control spool 62 , at least part of the hole diameter which is active must then remain free.
As shown in practice, with only one row of bores which are only partially closed, exact adjustment of the volumetric flow in the energized end position of the magnet 34 is difficult to ensure. In particular, tolerances cannot be allowed in production and mounting. Conversely, a reliable and durable system can be achieved with an arrangement in which, in addition to the proportionally adjustable orifice (throttle) 32 , an orifice (throttle) 36 is always open. The constant orifice 36 is connected parallel to the proportionally adjustable orifice 32 so that the overall orifice ratio for the system at the connecting site 40 for the pressure compensator 16 is the product of the sum of the two opening cross sections or opening areas.
To be on the safe side, the control spool 62 for the variable orifice 32 is dimensioned such that it is approximately 0.1 mm in front of the assignable row of passage openings 72 in the unenergized state and, in the fully energized state, as viewed in FIG. 2 , is 0.1 mm to the left following the row of passage openings 72 . This structural design is only exemplary and ensures that, regardless of the production tolerances, the variable orifice 32 can in any case be completely opened or closed. In this respect, defined conditions prevail, and the end values are reliably reached. The permanently open orifice 36 can be implemented in the valve block 58 ( FIG. 1 ) or, as shown in FIG. 2 , as a second row of bores 74 which preferably cannot be crossed in its entirety or even partially by the valve spool or control spool 62 , depending on the application.
The variable orifice 32 always interacts with the pressure compensator 16 connected downstream in the fluid direction. This arrangement is detailed in FIG. 3 . The pressure compensator 16 is designed as a screw-in cartridge solution, and, as shown in FIG. 4 , can be inserted into a valve block 58 (compare the exemplary embodiment as shown in FIG. 5 ). As viewed in FIG. 3 , the compensator on the left side, has a screw-in part 80 and on the opposite right side another screw-in part 82 . The other screw-in part 82 in the housing 18 of the pressure compensator 16 also is used to set the spring pretensioning for the adjusting spring 22 since regulation is to take place exactly to a small Δp. In agreement with the basic circuit diagram shown in FIG. 1 , on the pressure compensator the individual connections are designated as E 1 , E 2 , A 1 , and A 2 . Furthermore, in the embodiment as shown in FIG. 3 , at one other branch site 84 within the lines 24 , 26 in the secondary branch 86 , part of the pertinent partial volumetric flow is routed as the control flow ST 1 , ST 2 from the inlet side E 1 , E 2 of the pressure compensator 16 to the assigned end side 88 of the pressure valve spool 20 . In this respect the pressure compensator spool 20 in each of its positions of travel has a fluid-tight separation between the inlet sides E 1 and E 2 to the spool end sides 88 by the spool ring surfaces 90 adjoining the pressure compensator housing 18 . One identical damping orifice 92 at a time is connected to the indicated secondary branch 86 . With these damping orifices 92 in the bypass, unwanted oscillations in the operation of the pressure compensator 16 can be avoided. The respective damping orifices 92 can also be implemented in the form of damping bores in the pressure compensator housing 18 . Providing only one of the two sides of the pressure compensator 16 with damping is also possible.
As depicted in FIG. 3 , the pressure compensator spool 20 is shown in its middle actuation position in which it partially overlaps the fluid outlets A 1 , A 2 leading to the hydraulic consumers V 1 and V 2 . The fluid inlets E 1 and E 2 conversely are left open by the spool 20 . By radial recesses 96 , a permanent fluid connection is between E 1 and A 1 and between E 2 and A 2 . The fluid outlets A 1 , A 2 respectively are choked by the pressure compensator spool 20 . Depending on the position of travel of the pressure compensator spool 20 , the fundamental switching possibilities for the pressure compensator 16 as shown in FIG. 1 are achieved analogously. Since this pressure compensator structure is inherently known, it will not be described further.
The embodiment shown in FIG. 4 has been altered compared to the other embodiment shown in FIG. 3 , in that the damping orifices 92 are omitted. The pressure compensator spool 20 in this embodiment in each of its positions of travel has spool ring surfaces 90 spaced apart from the pressure compensator housing 18 . Otherwise, in terms of surface ratio, the spool ring surfaces 90 opposite one another correspond to one another for the embodiments shown in FIGS. 3 and 4 . For both embodiments the spool 20 is then essentially symmetrical in design. In the modified embodiment shown in FIG. 4 , the fluid travels via the inlets E 1 , E 2 as well as the radial recesses 96 and the respective annular gap 98 to the active spool ring surface 90 .
The valve block configuration according to FIG. 5 shows that the entire valve device can be combined in one unit. For purposes of a compact arrangement, preferably the proportional magnet 34 projects on the top of the valve block 58 and is fixed there by the flange 56 . Then, the valve housing 60 with the different passage sites to the orifice formation 32 , 36 projects into the valve block 58 . Transversely to this installation arrangement, the pressure compensator 16 , as viewed in FIG. 5 , extends essentially in the horizontal position between the free end sides of the valve block 58 . The screw-in parts 80 , 82 form the housing termination to the outside. The important connecting lines P, A 1 , and A 2 then discharge on the side of the valve block 58 facing the viewer of FIG. 5 . Other block arrangements are possible.
While various embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. | A valve device for a hydraulic circuit ( 10 ) divides the incoming volume flow into at least two pre-determined partial flows for supplying hydraulic consumers (V 1 , V 2 ) of the circuit ( 10 ) and has at least one pressure balance ( 16 ) and at least one orifice. Since the orifice is embodied as a variable orifice ( 32 ) controllable by a proportional magnet ( 34 ), the opening area of the orifice varies. A flow regulator is then realized and can switch the regulated volume flow and/or proportionally adjust the regulated volume flow in a defined manner. | 8 |
This is a continuation of Ser. No. 125,449, filed Feb. 28, 1980, now abandoned.
The present invention relates generally to a vibration damping device and more particularly to a vibration isolator for reducing the transmission of vibrations from a periodically vibrating part to a support connected thereto. The vibration isolator of the invention is of the type wherein, in the case of antiresonance, vibrations are essentially no longer transmitted to the support.
The vibration isolator of the invention can be used in all cases in which a periodic excitation is to be isolated, as is particularly the case in piston engines, such as ship engines, motor vehicle engines, reciprocating or piston compressors, reciprocating pumps and the like, and in helicopters wherein vibrations from the rotary wings are to be prevented from acting on the cell.
As a rule, a plurality of isolators are arranged between the periodically vibrating part and the support in order to isolate against vibrations of several degrees of freedom. The vibrations can also be introduced at the support, and in this case the previously periodically vibrating part will assume the function of the support.
Antiresonance force isolators which can be arranged between the transmission and the cell of a helicopter are known in the art, and the number of isolators depends upon the principal axis directions in which vibrations are transmitted. An antiresonance force isolator consists of a parallel arrangement of a spring and a passive force generator. The arrangement is adjusted in such a manner that dynamic forces are locally cancelled at the fastening point on the cell, so that isolation of the cell from the vibrations of the rotor will be achieved.
A pendulum with a mechanical lever transmission has been used as the passive force generator (U.S. Pat. No. 3,322,379). This purely mechanical force isolator requires a relatively large amount of space, it produces high wear of the lag hinges and the technical realisation is complicated. The finite distance between the spring force and the pendulum bearing force required for operation results in a force couple which occurs, among other places, on the side of the support as a dynamic moment. This moment is undesirable in many applications, particularly when it acts on a helicopter cell.
Furthermore, it is known to arrange a fluid-filled deformable space or chamber between the vibrating part and the support with the chamber being connected to a cylinder in which a weight forming a free piston is arranged on the fluid (see Canadian Pat. No. 781,817 particularly FIG. 6 thereof). This known force isolator has the disadvantage that frictional forces occur between the piston and the cylinder and that flow losses occur due to the conduction of fluid. This requires that a damping element be arranged parallel to the isolator which significantly reduces the isolation efficiency. In addition, when overly high accelerations occur, fluid evaporates in the fluid chamber due to expansion during half of the periodic sequence of movements, thereby further impairing the effectiveness of the isolator.
The invention is directed toward the task of constructing a vibration isolator, particularly an antiresonance force isolator of the type described, which is a practical, compact component and which operates essentially without wear.
SUMMARY OF THE INVENTION
Briefly, the present invention may be described as a vibration isolator for reducing transmission of vibrations between a periodically vibrating member and a support member connected therewith and operative to essentially terminate vibration transmission in the case of antiresonance, said isolator comprising spring means interposed between the vibrating member and the support member, fluid transmission means including primary fluid chamber means and secondary fluid chamber means both deformable in the direction of movement of the vibrations, the secondary fluid chamber means having an effective cross-sectional area which is smaller than the effective cross-sectional area of the primary fluid chamber means, the secondary fluid chamber means being thereby deformed to a greater extent than the primary fluid chamber means as a result of the vibrations, and inertia mass means operatively associated with the second fluid chamber means so as to be displaced as a result of the vibrations, the inertia mass means being thereby accelerated with the resulting inertia force causing fluid pressure change in the fluid transmission means which compensates as a dynamic force, the dynamic portion of the spring force transmitted from the spring means to the support.
In accordance with the invention, the primary fluid chamber means may consist of at least one primary fluid chamber which is deformable in the direction of movement of the vibrations and the second fluid chamber means may also consist of at least one secondary chamber which is also deformable in the direction of movement of the vibrations and whose effective cross section is smaller than that of the primary fluid chamber. As a result, due to the fluid displaced by the deformation of the primary fluid chamber, the secondary chamber is deformed to a greater extent so that the inertia mass means assigned to it is accelerated and the resulting inertia force causes a pressure change in the fluid which compensates as a dynamic force the dynamic portion of the spring force which is transmitted from the spring to the support.
The vibration isolator according to the invention has the advantage that the inertia force and the spring force act in a single line of action and that a compact construction is possible with respect to weight and mounting space. Bearings which are subject to wear are not required. The primary fluid chamber system arranged parallel to the isolator spring also allows relative movement of the spring fastening points which are not situated on the principal axis of action.
In the operation of the antiresonance force isolator according to the invention which is provided with a hydraulic transmission, the stroke of the primary fluid chamber caused by the periodic relative movement of the vibrating part relative to the support creates a stroke of the secondary chamber which is larger in proportion to the ratio between the effective cross sections. The inertia force resulting from the acceleration of the inertia mass causes a pressure change in the fluid which acts as a dynamic force on the vibrating part or on the support. This dynamic force is utilized at the support for cancelling the dynamic portion of the spring force acting from the isolator spring on the support. With a properly adjusted system, and in the ideal case in which it is assumed that there is no friction or damping, at a certain excitation frequency, i.e. the antiresonance frequency, a complete cancellation or isolation of the dynamic forces is achieved at the support of the isolator; to wit, for example, at the fastening point on the cell of a helicopter when the isolator fastening point at the transmission is the vibrating part.
Advantageously, the secondary chamber is filled with fluid and follows the primary fluid chamber in the direction of movement of the vibrations. In this embodiment which requires only a narrow mounting space, to avoid damping in the fluid resulting from flow losses due to sudden changes in the cross section, the transition from the primary fluid chamber to the secondary fluid-filled chamber should be constructed so as to cause low flow losses, i.e., the transition should have a rounded contour.
With the secondary chamber located within the primary fluid chamber in order to reduce the structural length of the vibration insulator, the secondary chamber is connected to the ambient atmosphere. It may also be closed and possibly be filled with a compressible medium having a positive or negative pressure. To further reduce the required space, the primary fluid chamber may have a deformable section and a rigid section which, compared to the deformable section, may also have a smaller cross section and surround at least a portion of the secondary chamber to form a fluid-filled annular chamber.
To avoid a negative pressure in the fluid--which conventionally consists of a liquid of low viscosity, such as a water/alcohol mixture--which negative pressure may result in an increase of the entire volume of the fluid chamber arrangement and thus possibly impair its effectiveness, a spring is provided which acts on the pendulum weight and on the support or the vibrating part and is prestressed to increase the fluid pressure. The initial stress of the spring is dimensioned in such a way that the overall fluid volume is not increased during operation.
In accordance with an alternative measure for avoiding negative pressure, a second system having a primary fluid chamber and a secondary chamber is provided, wherein the primary fluid chambers and the secondary chambers of the first and second systems are rigidly coupled to each other by means of connecting members and jointly accelerate the inertia mass, with the volume of the secondary chamber being reduced while that of the other secondary chamber is increased accordingly, and while the volumes of the primary fluid chambers behave inversely.
In one embodiment of the invention, the connecting member of the secondary chambers can be a rod which supports the inertia mass and extends through the secondary chambers.
The primary fluid chamber and the secondary chamber may be cylindrical, corrugated metal bellows or membrane bellows which are deformable with low friction in the axial direction.
By way of a structural simplification the spring acting between the vibrating part and support may be the primary fluid chamber itself constructed as a metal bellows having the required inherent stiffness.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic sectional view of a first embodiment of an antiresonance force isolator according to the invention;
FIG. 2 is a sectional view showing a modification of this embodiment;
FIG. 3 is a sectional view showing a second embodiment of an antiresonance force isolator;
FIG. 4 is a sectional view showing a modification of the embodiment of FIG. 3.
FIG. 5 is a sectional view showing another modification, and
FIG. 6 is a sectional view showing another modification of the embodiment according to FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals refer to similar parts throughout the various figures thereof, antiresonance force isolators in accordance with the invention illustrated in FIGS. 1 through 5 each have a vibration member 1 introducing vibrations into the assembly. The member 1 may, for example, be the fastening point of the isolator to the transmission of a helicopter. The vibrating member 1 is connected through an isolator spring 2 to a support 4 which, when mounted in a helicopter, is a fastening point on the cell. Of course, vibrations can also be introduced through the support 4. In this case, the member 1 assumes the function of the support.
In the illustrated embodiment, the isolator spring consists of a circular spring of glass fiber-reinforced plastic material. However, leaf or plate springs, helical springs or other spring elements can also be used. The isolator spring can possibly be omitted when the inherent stiffness of the system of deformable chambers, to be described hereinafter, is sufficient.
Primary fluid chamber means comprising a system of one or two primary fluid chambers 3 which consists of cylindrical, corrugated metal bellows which are deformable in the axial direction is arranged parallel to the isolator spring 2. Secondary fluid chamber means comprising a system with one or two secondary deformable chambers 5 which also consist of metal or membrane bellows, partially illustrated in FIG. 1, and whose cross sections are smaller than those of the primary fluid chambers 3, is guided, in FIGS. 1 through 4, in the axial direction by a bearing 8 having a low friction coefficient. The bearing 8 may consist, for example, of a ball box or spherical bushing. At the free end of the secondary bellows system there is fastened an inertia mass 9, which may consist of a plurality of disks to enable adjustment thereof.
In the embodiment illustrated in FIG. 1, the fluid chamber of the primary bellows 3 leads through a rounded annular edge into the interior of the secondary bellows 5 which is also filled with liquid. At its free end, the secondary bellows is connected to a connecting element 6 which consists of a bushing which surrounds the bellows, with play being provided therebetween. A spring 7 bears with one end against the bushing and at its other end acts on an internal flange of the support 4 above the bearing 8 in such a manner that the inertia mass 9 is prestressed in the illustrated position of rest. The initial stress is dimensioned in such a way that the volume in the fluid chamber does not increase during the operation of the isolator.
In the embodiment illustrated in FIG. 2, the secondary bellows 5 is arranged in the interior of the fluid chamber defined by the primary bellows 3. On its end face at the support, the interior of the secondary bellows 5 is connected to the atmosphere. The fluid chamber defined by the primary bellows 3 consists of a first section which is axially deformable, and of a second, rigid section whose cross section is reduced as compared to that of the first deformable section in order to save space. The rigid section surrounds a portion of the secondary bellows 5, wherein the annular chamber remaining therebetween is filled with fluid which is connected to the interior of the primary bellows 3.
The connecting element 6 consists of a rod from which the inertia mass 9 is suspended. The rod is guided in a bearing 8 of the support and it is fastened to that end face of the secondary bellows 5 which is located in the interior of the primary bellows 3. The spring 7 is arranged between the support 4 and a collar of the rod 6 inside the interior of the secondary bellows 5, which is connected to the atmosphere.
In the operation of the embodiments of the antiresonance force isolator illustrated in FIGS. 1 and 2, when the isolator spring is compressed, the volume of the primary bellows 3 is reduced. In the embodiment according to FIG. 1 the secondary bellows 5 is extended and in the embodiment according to FIG. 2 it is compressed. As a result, the inertia mass 9 which is connected through the connecting member 6 to the lower (FIG. 1) or the upper (FIG. 2) end of the secondary bellows 5 is moved downwardly. The closer the inertia mass 9 comes to the lower dead center of the periodic sequence of movements, the stronger the mass 9 is decelerated, i.e. the larger becomes the downwardly directed inertia force acting on the mass. This inertia force causes a pressure reduction within the bellows system. This results in an upwardly directed force on the support 4. The dynamic portion of the force which acts from the isolator spring 2 on the support 4 is directed downwardly at this point in time.
With a proper adjustment of the isolator, for a certain excitation frequency, i.e. the antiresonance frequency, the sum of the dynamic forces acting on the support 4 equals zero, i.e. the support 4 remains at rest. The initial stress of the spring 7 is selected such that the total volume of the bellows system is not increased during the phase of movements under consideration. The spring 7 can be omitted when the occurring inertia forces are sufficiently small.
In the embodiments according to FIGS. 1 and 2, the spring 7 can also be omitted when the function of this spring can be assumed by a compressible medium in the secondary chamber 5 according to FIG. 2 or by a closed jacket (not shown) surrounding the secondary chamber 5 in the device according to FIG. 1.
In the embodiments of the antiresonance force isolator illustrated in FIGS. 3 and 4, a twofold bellows system is provided. Each bellows system of the embodiment according to FIG. 3 corresponds to the bellows system of FIG. 1, and each bellows system of the embodiment according to FIG. 4 corresponds to the bellows system according to FIG. 2. In these embodiments, the primary bellows 3 are rigidly connected to each other through a connecting member 10, while the rigid connection of the secondary bellows 5 consists of a connecting rod 6 extending therethrough on which the inertia mass 9 is mounted.
When the isolator spring 2 of the embodiments according to FIGS. 3 and 4 is compressed, the volume of the upper primary bellows 3 is reduced. Since the upper end of the upper primary bellows 3 is connected through the connecting member 10 with the lower end of the lower primary bellows 3, the volume of the lower primary bellows 3 increases by the same extent. As a result, the upper secondary bellows 5 of the embodiment according to FIG. 3 is extended, and that of the embodiment according to FIG. 4 is compressed, while the lower secondary bellows 5 of the embodiment according to FIG. 3 is compressed and that of the embodiment according to FIG. 4 is extended.
The connecting rod 6 which is connected to the two secondary bellows 5 moves upwardly together with the inertia mass 9. The closer the inertia mass comes to the upper dead center, the stronger it is decelerated. The resulting, upwardly directed inertia force increases. Thus, the pressure in the lower bellows system increases and the pressure in the upper bellows system decreases. These pressure changes result in an upwardly directed force on the support 4. The force acting from the isolator spring 2 on the support 4 is directed downwardly at this point in time.
With the proper adjustment, for a certain excitation frequency, namely the antiresonance frequency, the two forces cancel each other, i.e. the support 4 remains at rest.
The double bellows system ensures that at any point in time of the periodic sequence of movements, a pressure increase takes place in one of the two bellows systems, so that a volume increase cannot occur in either of the two systems. The thermal expansion of the fluid can be compensated, for example, through a choke bore and a small bellows (not shown) connected to the bore.
In the embodiments according to FIGS. 3 and 4, the isolator spring 2 can be omitted when its function is assumed by an appropriate gas spring effected by a compressible medium which, in FIG. 3, is arranged in a closed jacket surrounding at least one of the secondary chambers 5 or which, in FIG. 4, is arranged in at least one of the secondary chambers 5.
In principle, the arrangement illustrated in FIG. 5 operates in a similar manner as the one illustrated in FIGS. 3 and 4. When the isolator spring 2 is compressed, the volume of the upper primary bellows 3 is reduced. Since its upper end is connected through the connecting member 10 to the lower end of the lower primary bellows 3, the volume of this bellows 3 increases by the same extent. Thus, the secondary bellows 5 which is the same for both systems is extended, and the inertia mass 9, which in this case is directly connected to the lower end of the secondary bellows 5, moves downwardly. The closer the inertia mass 9 comes to the lower dead center, the more it is decelerated. The resulting downwardly directed inertia force increases. Further operating procedures correspond to those described in connection with FIGS. 3 and 4. The last-described arrangement (according to FIG. 5) requires one bellows fewer than the arrangement according to FIGS. 3 and 4.
The antiresonance force isolator illustrated in FIG. 6 has a member 1 whereby vibrations are introduced into the system. This member may, for example, be the fastening point of the isolator to the transmission of a helicopter. The vibrating member 1 is connected through a metal bellows 3 to a support 4 which, when arranged in a helicopter, is the fastening point at the cell. Of course, the vibrations can also be introduced through the support 4. In this case, the member 1 assumes the function of the support.
The inherent stiffness of the metal bellows 3 is selected in such a way that the metal bellows 3 assumes the function of the spring between the vibrating part and the support 4, so that an isolator spring 2 can be omitted, thereby significantly simplifying the overall construction of the antiresonance force insolator.
The metal bellows 3 surrounds the primary fluid chamber in which there is arranged a secondary metal bellows 5 having a cross section which is smaller than that of the metal bellows 3. At the end face of the secondary bellows 5 located in the fluid chamber surrounded by the primary metal bellows, there acts a rod 6 which serves as a connecting element. The rod 6 is axially slidably guided in low friction bearings 8 which are arranged in a bushing 4a which projects upwardly from the support 4 in the interior of the secondary bellows 5. The interior of the secondary bellows 5 is connected to the atmosphere at its end face facing toward the support. Outside of the secondary bellows 5, an inertia mass 9 is suspended from the rod 6. A spring 7 acts on the end face of the inertia mass 9 which faces away from the secondary bellows 5, the spring 7 being supported on the support 4 which widens in a sleeve-like manner and presses the inertia mass 9 in the direction of the secondary bellows 5.
In the operation of the antiresonance force isolator, when the primary metal bellows 3--which assumes the function of the isolator spring and has a sufficient inherent stiffness--is compressed, its volume is reduced. Simultaneously, the secondary bellows 5 is compressed. As a result, the inertia mass 9, which is connected through the rod 6 to the upper end of the secondary bellows 5, moves downwardly. The closer the inertia mass 9 comes to the lower dead center of the periodic sequence of movements, the stronger the inertia mass 9 is decelerated, i.e. the larger becomes the downwardly directed inertia force acting on the mass. This inertia force causes a pressure reduction within the bellows system. This results in an upwardly directed force on the support 4. The dynamic portion of the force acting from the resiliently elastic metal bellows 3 on the support 4 is directed downwardly at this point in time. With a proper adjustment of the isolator for a certain excitation frequency, i.e. the antiresonance frequency, the sum of the dynamic forces acting on the support 4 equals zero, i.e. the support 4 remains at rest. The initial stress of the spring 7 is selected in such a way that the total volume of the bellows system is not increased during the phase of movements under consideration.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | A vibration isolator is formed with a spring mechanism and a fluid transmion mechanism interposed between a vibrating member and a support member. The fluid transmission mechanism includes a primary fluid chamber and a secondary fluid chamber, with the secondary fluid chamber being deformed to a greater extent than the primary fluid chamber as a result of vibrations. An inertia mass operatively associated with the secondary fluid chamber is displaced as a result of vibrations and is thereby accelerated with a resulting inertia force causing fluid pressure change in the fluid transmission mechanism which compensates as a dynamic force the dynamic portion of the spring force transmitted from the spring mechanism to the support member. | 5 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
The present application is a U.S. national stage entry under 35 U.S.C. §371 of Patent Cooperation Treaty Patent Application No. PCT/US2011/65020, filed Dec. 15, 2011, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
Disclosed are solubilized magnolol analogs.
BACKGROUND OF THE INVENTION
Magnolol analogs, such a propyl magnolol, isopropyl magnolol, butyl magnolol, and isobutyl magnolol, are known to have anti-bacterial activities and they are also shown to be capable of reducing the expression of pro-inflammatory mediators in oral tissues. The problem with using these magnolol analogs is their solubility in typical personal care, oral care, or home care compositions. Their use has been limited by their solubility. It would be desirable to solubilize these analogs to increase their use in personal, oral, or home care compositions. The problem is finding materials that can solubilize these analogs. Even in a given class of material, not all members of the class are effective at solubilizing these analogs.
BRIEF SUMMARY OF THE INVENTION
A composition comprising a solubilized magnolol analog comprising at least one magnolol analog chosen from propyl magnolol, isopropyl magnolol, butyl magnolol, and isobutyl magnolol, and PPG-1-PEG-9 lauryl glycol ether. Optionally, the composition can further include coceth-7 and PEG-40 hydrogenated castor oil.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Disclosed is a composition comprising a solubilized magnolol analog comprising at least one magnolol analog chosen from propyl magnolol, isopropyl magnolol, butyl magnolol, and isobutyl magnolol, and PPG-1-PEG-9 lauryl glycol ether.
Propyl magnolol is 5,5′-di-n-propylbiphenyl-2,2′-diol, butyl magnolol is 5,5′-di-n-butylbiphenyl-2,2′-diol, isopropyl magnolol is 5,5′-di-isopropylbiphenyl-2,2′-diol, and isobutyl magnolol is 5,5′-di-isobutylbiphenyl-2,2′-diol.
The PPG-1-PEG-9 lauryl glycol ether is capable of solubilizing up to 100 g per liter of neat propyl magnolol or isopropyl magnolol or up to 50 g per liter of butyl magnolol or isobutyl magnolol. In certain embodiments, the amount of PPG-1-PEG-9 lauryl glycol ether is at least 10 times the weight of the propyl magnolol or isopropyl magnolol in the composition. In certain embodiments, the amount of PPG-1-PEG-9 lauryl glycol ether is at least 20 times the weight of butyl or isobutyl magnolol in the composition.
PPG-1-PEG-9 lauryl glycol ether is available as Eumulgin™ L from Cognis Corporation.
The PPG-1-PEG-9 lauryl glycol ether can also be included in combination with coceth-7 and PEG-40 hydrogenated castor oil. This combination is available as Eumulgin™ HPS from Cognis Corporation. When this combination is used, the solubility stays the same except for butyl magnolol. This combination solubilizes up to 100 g per liter of butyl magnolol as compared to up to 50 g per liter for PPG-1-PEG-9 lauryl glycol ether alone. In certain embodiments, the amount of this combination is at least 10 times the weight of butyl magnolol.
It was surprising that these two materials were capable of solubilizing the analogs. Many other solubilizers, such as PEG-7 glyceryl cocoate, poloxamer 124, PPG-2 hydroxyethyl cocoamide, PPG-5 laureth-5 (Eumulgin™ ES), PEG-8/SMDI copolymer, isopropyl myristate, or C12-15 alkyl benzoate are not able to solubilize isobutyl magnolol.
The amount of magnolol analog in the composition can be any desired amount. In certain embodiments, the amount is 0.01 to 5% by weight of the composition. In other embodiments, the amount is at least 0.05, at least 0.1, at least 0.2, at least 0.3, at least 0.4, at least 0.5, or at least 1% by weight up to 5% by weight of the composition. In other embodiments, the amount is any of the foregoing minimum amounts up to 4, up to 3, up to 2, or up to 1% by weight of the composition. The weight of the PPG-1-PEG-9 lauryl glycol or the PPG-1-PEG-9 lauryl glycol ether, coceth-7 and PEG-40 hydrogenated castor oil combination is then the amount to solubilize the analog with the minimum amount of the PPG-1-PEG-9 lauryl glycol or the PPG-1-PEG-9 lauryl glycol ether, coceth-7 and PEG-40 hydrogenated castor oil combination being based on the maximum solubility of the analog in the PPG-1-PEG-9 lauryl glycol or the PPG-1-PEG-9 lauryl glycol ether, coceth-7 and PEG-40 hydrogenated castor oil combination. In certain embodiments, the amount of the magnolol analog is 0.1, 0.2, 0.3, 0.4, or 0.5% by weight.
These solubilized analogs are useful in personal care, oral care, and home care compositions. Examples of personal care compositions include, but are not limited to, body wash/shower gel, liquid hand cleanser, bar soap, shampoo, conditioner, antiperspirant/deodorants, and cosmetics. Examples of oral care compositions include, but are not limited to, dentifrices, toothpastes, tooth powders, prophylaxis pastes, mouth rinses, lozenges, gums, gels, paints, confectionaries, and denture cleaners. Examples of oral care compositions that can include solubilized magnolol analogs can be found in WO2011/106492. Examples of home care compositions include, but are not limited to, dish liquids, dish pastes, hard surface cleaners, fabric conditioners, and laundry detergents.
In certain embodiments, the magnolol analog can be present in a body wash/shower gel, liquid hand cleanser, or shampoo in which each of these compositions include a surfactant. The magnolol analog can also be included in a soap (fatty acid soap), which can be in the shape of a bar soap.
EXAMPLES
The following are non-limiting prophetic examples of compositions that can include solubilized magnolol analogs.
Liquid Cleanser (Body Wash or Liquid Hand Soap)
Ingredient Name
% Wt. Range
% Wt. Range
Propyl magnolol, isopropyl magnolol,
0.01-1
0
or butyl magnolol
Isobutyl magnolol
0
0.01-1%
PPG-1-PEG-9 lauryl glycol ether
At least 10
At least 20
times the
times the
weight of the
weight of the
magnolol
magnolol
analog
analog
Polyquaternium-7
0-0.25
0-0.25
SO 3 Na Pareth 145-2EO Sulfate
8-12
8-12
Cocamidopropyl Betaine
2.5-7
2.5-7
Decyl Glucoside
0-2
0-2
Demineralized Water and minors
Q.S.
Q.S.
Total Materials
100
100
Bar Soap
Ingredient Name
% Wt. Range
% Wt. Range
Propyl magnolol, isopropyl magnolol,
0.01-1
0
or butyl magnolol
Isobutyl magnolol
0
0.01-1%
PPG-1-PEG-9 lauryl glycol ether
At least 10
At least 20
times the
times the
weight of the
weight of the
magnolol
magnolol
analog
analog
Fatty acid soap
75-85
75-85
Demineralized Water and minors
Q.S.
Q.S.
Total Materials
100
100
Oral Care Composition
Ingredient
Weight %
Weight %
Purified water
Q.S.
Q.S.
Sorbitol
19.45
19.45
Glycerin
20
20
Sodium CMC-12 type USP
1.1
1.1
Iota carrageenan (LB 9505)
0.4
0.4
Sodium saccharin-USP
0.3
0.3
Sodium fluoride
0.24
0.24
Zeodent-115-dental type silica abrasive
8.5
8.5
Zeodent-165-synthetic amorphous PPT silica
3
3
Dental type silica sylodent XWA650
10
10
Titannium dioxide (TiO2)
0.5
0.5
Sodium lauryl sulphate powder-NF
1.5
1.5
Flavor
1
1
Propyl magnolol, isopropyl magnolol, or
0.01-1
0
butyl magnolol
Isobutyl magnolol
0
0.01-1%
PPG-1-PEG-9 lauryl glycol ether
At least 10
At least 20
times the
times the
weight of the
weight of the
magnolol
magnolol
analog
analog
Total
100
100
As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.
Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material. | A composition comprising a solubilized magnolol analog comprising at least one magnolol analog chosen from propyl magnolol, isopropyl magnolol, butyl magnolol, and isobutyl magnolol, and PPG-1-PEG-9 lauryl glycol ether. These solubilized analogs are useful in personal care, oral care, and home care compositions to provide anti-bacterial activity and reducing the expression of pro-inflammatory mediators. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bar-code printing device, and more particularly to a bar-code printing device with a function to omit a string of characters and symbols representing the contents of the bar-code when the set character size is found to be smaller than a prescribed value.
2. Description of Related Art
Bar-codes according to such specifications as JAN (Japan Article Number), EAN (European Article Number), and Code 39 have been popularly used as identifiers for distinguishing articles. Parcels and labels often carry such bar-codes printed thereon.
Normally, the bar-code has a string of characters and symbols representing the contents of the bar-code printed in juxtaposition on the lower end so that one can easily understand the contents of the bar-code. However, there is a technical requirement on the height of the bar-code, that is, the height of the bar of the bar-code is 6.35 mm (a quarter of an inch) or greater for ensuring stable read-out of the bar-code readers. When the height of the bar of the bar-code becomes far less than the recommended value of 6.35 mm, an unstable performance of the bar-code reader results.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a bar-code printing device with a function to enlarge the bar-code across the height for a smaller error rate in the bar-code reading operation.
The bar-code printing device according to the invention has an input means for inputting characters, data storage means for storing data on characters and bar-codes input from the input means, and print means including a print head consisting of a plurality of dot-like printing elements for printing characters and bar-codes on a print medium, and further comprises: size setting means for setting a common size for the characters and bar-codes so that printed images have an identical height; decision means for deciding whether or not the size set by said size setting means is greater than a prescribed value; pattern data combination means for combining dot pattern data of the size after receiving the data on characters and bar-codes from said size setting means; and pattern data re-combination means for combining the fixed height of the lowermost part of the bar-code into a string of characters and symbols representing the contents of the bar-code, when said decision means finds that the size set by said size setting means is greater than the prescribed value.
In the tape printing device, the data on the characters and bar-codes are stored in the data storage means, and the size setting means sets a common size for the characters, including alphabetic characters, numerics and symbols for example, so that they have an identical height. The pattern data combination means combines the dot pattern data for the characters in a size set by the size setting means. In the data combination process, if the decision means finds that the size set by the size setting means is greater than the prescribed value, the pattern data re-combination means replaces the lowermost part of the bar-code with an image for a string of characters corresponding to the contents of the bar-code. The bar-code printing device executes printing according to the re-combined image.
Otherwise, if the size is found to be smaller than the prescribed value, the bar-codes are printed across the entire height of the characters, reducing the error rate in read-out operation with a bar-code reader.
Accordingly, the bar-code printing device having size setting means, decision means, pattern data combination means and pattern data re-combination means prints bar-codes and juxtaposed strings of characters representing the contents of the bar-codes when the character size is greater than a determined criterion.
Further, if the character size is found to be smaller than a determined criterion, the bar-codes are printed across the height of the characters size, ensuring stable reading results by a bar-code reader.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a plan view of the tape printing device in accordance with the present invention.
FIG. 2 is a plan view schematically depicting the print mechanism.
FIG. 3 is a block diagram of a control system in the tape printing device.
FIG. 4 is a flowchart illustrating the tape print control routine.
FIG. 5 is a flowchart illustrating the bar-code data input process control routine.
FIG. 6 is a flowchart illustrating the print process control routine.
FIG. 7 is a flowchart illustrating the bar-code image combination process.
FIG. 8 is a chart describing the data structure on the text memory.
FIG. 9 is a chart describing the data structure on the bar-code buffer.
FIG. 10 is a drawing illustrating the data input console.
FIG. 11 is a drawing illustrating the data input console when a code corresponding to a data character is input.
FIG. 12 is a drawing illustrating printed characters and bar-codes in 44 points.
FIG. 13 is a drawing similar to FIG. 12, but where characters are printed in 19 points.
FIG. 14 is a drawing similar to FIG. 12, but where characters are printed in 13 points.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, a preferred embodiment of the present invention is described with reference to the appended figures.
The keyboard 3 has character keys for inputting alphabetic characters, numerals and symbols, a space key, a return key, cursor location keys for sending the cursor leftward or rightward, a text editing key for editing text, a bar-code key for inputting bar-code data, a format setting key for setting the format of the printed characters, a termination key for terminating input/edit operation, a cancel key for canceling various edit operations, a print execution key for initiating the print execution and a power key for controlling the power supply.
A brief description of the print mechanism PM is given with reference to FIG. 2. A tape cassette CS in the shape of a rectangular block is detachably installed to the print mechanism PM. The tape cassette CS houses a tape spool 6 to which a tape print medium 5 consisting of a transparent film of preferably 24 mm in width is wound, a ribbon supply spool 8 to which an ink ribbon 7 is wound, a supply spool 11 to which a double-sided adhesive tape 10 with a releasable sheet secured on the outer face of the tape roll is wound, and a contact roller 12 rotatably provided for contacting the tape print medium 5 with the double-sided adhesive tape 10.
A thermal head 13 is provided upright at a position where the tape print medium 5 and the ink ribbon 7 overlap. A platen roller 14 for urging the tape print medium 5 and the ink ribbon 7 against the thermal head 13 and a sending roller 15 are rotatably supported on a supporting member 16. The thermal head 13 preferably has 128 thermal elements along a perpendicular line.
In the above construction, the tape sending motor 24 (shown in FIG. 3) drives the contact roller 12 and the take up spool 9 in synchronism in a fixed direction, the electrically activated thermal elements print images by a plurality of dot columns, and the tape print medium 5 is sent in the direction A with the double-sided adhesive tape 10 secured on one side. A more detailed description of the printing mechanism PM is contained in Japanese Laid-Open Patent Publication No. 2-106555.
The control system of the tape printing device is shown in the block diagram in FIG. 3. The keyboard 3, a display controller (LCDC) 23 including a RAM for displaying patterns on a liquid crystal display (LCD) 22, a driving circuit 25 for driving the thermal head 13, a driving circuit 26 for driving a tape sending motor 24, and a driving circuit 21 for a warning buzzer 20 are connected to an input/output interface 27 in the controller C. The controller C consists of a CPU 29, the input/output interface 27, a CGROM 30, ROMs 31, 32 and a RAM 40.
The CGROM (pattern data memory) 30 stores dot pattern data corresponding to a plurality of character codes. The ROM (outline data memory) 31 stores data on contourings of characters (outline data) corresponding to character codes classified according to font styles (e.g. Gothic font, MINCHO-KANJI font).
The ROM 32 stores a display drive control program for controlling the display controller 23 based on the code data of the alphabetic characters, numerals, and symbols input from the keyboard 3, an image process control program for converting outline data corresponding to code data stored on the text memory 41 into dot pattern data to be spread on the print buffer 44, a print drive control program for driving the thermal head 13 and the tape sending motor 24 after sequentially reading out data stored on the print buffer 44 and a print drive control program for controlling the tape print control process which is unique to the present invention (described later), and the like. In the above construction, the tape print control process includes a bar-code data conversion subroutine for converting code data stored on the text memory 41 into bar-code data according to such standards as JAN (Japan Article Number), EAN (European Article number).
The text memory 41 allocated on the RAM 40 stores data characters corresponding to the text data, bar-code data, and the like input from the keyboard 3. A print format memory 42 stores format information such as character size SZ and font data. A bar-code buffer 43 stores character data which includes digits for printing the bar-code by a plurality of print lines. The print buffer 44 stores dot pattern data for characters decoded into image data and dot patterns for printing bar-codes. A print pointer (having a value PP) 45 holds an index address of the text memory 41 for reading out code data.
Now, the tape print control routine executed by the controller C of the tape printing device 1 is described with reference to the flowchart in FIG. 4. A symbol Si (i=10, 11, 12 . . .) corresponds to a single step in the flowchart.
Applying power to the tape printing device 1 invokes the control routine, pressing the text editing key starts a text data input process for transferring text data including characters, and pressing the bar-code key starts a bar-code data input process control to be described later (S10).
In the next step (S40), an operator can set various formats and fonts by operating the print format key or the font key.
In the above size setting process, operating the size key causes the tape printing device to display a size setting console, allowing the operator to set a character size with a cursor key. Pressing the termination key causes the print format memory 42 to store the size SZ for the selected characters at the termination.
After the above operation, pressing the print execution key starts a dot pattern combination process for spreading the dot pattern data for characters and bar-codes on the print buffer, followed by the print execution by the print mechanism PM (S50) to resume operation in S10.
The bar-code data input process control routine is described with reference to the flowchart in FIG. 5. In the description, a character string "Ag" is assumed to be stored on the text memory 41 at the initiation of the process as shown in FIG. 8.
The above Control routine activates a bar-code input mode and displays a bar-code input console (S15). A header code is stored on the bar-code buffer 43 (S16). if the tape printing device selects a bar-code standard `code 39`a start code "*" is added to the header code in S16. As shown in FIG. 10, if a start code for a left-pointed triangle MS is displayed at the top display area of the display 22, a header code and a start code "*" are stored at the start address of the bar-code buffer 43 as shown in FIG. 9 in the `code 39` mode. The symbol "K" in FIGS. 10 and 11 represents the cursor.
When a character key including a numeric key is pressed in the bar-code input mode (S17, S18:YES), the process advances to the input ready step (S19). If the number of numeric characters stored on the bar-code buffer 43 is less than a fixed number of digits and additional characters can be input (S19:YES) (e.g JAN bar-code standard), the character code is stored on the bar-code buffer 43 (S20), and characters corresponding to the character code appear on the display 22 (S21). The tape printing device then returns operation in S17. For example, the state of the display 22 appears as shown in FIG. 11 after numeric characters "12" are input in the `code 39` mode.
In the next step, when the termination key is pressed to end the character input (S17:Yes, S18:No, S22:Yes), the fixed digit step (S23) determines the number of numeric codes stored on the bar code buffer 43. If a fixed digit of numeric codes are stored on the bar-code buffer 43 (S23:Yes) , a bar-code termination code is added to the code data stored on the bar-code buffer 43, all the character strings on the bar-code buffer 43 are transferred to the text memory 41 (S25) and the bar-code buffer 43 is erased (S26), thus terminating the control process to resume the tape print control operation. If the bar-code standard `code 39` is selected in the above operation, a stop code "*" is added to the end of the code in S24. For example, as shown in FIG. 9, all the codes in the bar-code buffer including data characters for the bar-code in the `code 39` standard in FIG. 9 are added to the codes in the text memory 41.
If the cancel key is pressed (S17:Yes, S18, S22:No, S27:Yes), the bar-code buffer 43 is cleared (S26), the operation is terminated and the tape print control is resumed. If a character key is pressed when the fixed length of numeric characters are stored on the bar-code buffer 43 (S17, S18:Yes, S19:No) or the termination key is pressed while the bar-code buffer has not stored the fixed length of numeric characters on the bar-code buffer 43 (S23:No), the buzzer 20 beeps before a warning is issued (S29), and the operation in S17 is resumed.
Pressing a key other than a character key, a termination key or a cancel key (S17:Yes, S18, S22, S27:No) starts a process corresponding to the input key (S18) before the operation is resumed in S17.
A print process control routine is illustrated in the flowchart in FIG. 6. The routine is invoked by the print execution key.
In the initial step of the process, if any text data is found on the text memory 41 (S51:Yes), the print pointer PP loads a top address of the text memory (S52). If the code data addressed by the print pointer PP is found to be a character code (S53, S54:Yes), a magnification power is calculated from the preset character size. The magnification power is used in enlarging or condensing the outline characters to generate dot pattern images to be printed by the print mechanism PM (S56).
In the next step, the print pointer value PP is incremented by 1 (S57), and if any code data exists on the text memory 41 (S58:Yes), S53 and the following steps are repeated.
If the code data is found to be a header code (S53, S54:No, S59:Yes) , data characters on the next address through the end address are read (S60). The data characters are converted into a bar-code by the bar-code data conversion process control (S61), and the image combination process (shown in FIG. 7) converts the bar-code data to image data (S62).
In the image combination process, the net height of the bar BR is given by subtracting the height of juxtaposed alphabetic characters or numerals from the height of the bar-code BH, where BR gives the height of the bar-code to be scanned by bar-code readers. A bar BR having a net height greater than or equal to about 4.4 mm (31 dots) does not have significant influence on the performance of the bar-code readers. In other words, since the juxtaposed character string has a fixed height of about 2.4 mm (17 dots), a bar-code with the height BH of 19 points (about 6.7 mm) or more does not have a negative influence in the reading operation. Accordingly, in this image combination process, characters are imposed on the lowermost part of the bar-code as long as the value BH gives a corresponding character size SZ of 19 points or greater, where one point equals to 1/72 of and inch (25.4 mm/72) and the printing device has a dot density of 180 dpi (25.4 mm/180).
After the image combination process is initiated, dot pattern data with given character sizes is generated according to the size data SZ stored on the print format memory 42 and spread on the print buffer 44 (S70). Following the above process, if the size data value SZ is found to be 19 points or greater, that is, the height of the dot pattern BH is 6.7 mm (48 dots) or greater (S71:Yes), the lowermost part of the dot pattern data is deleted by a height of 17 dots. The image data of alphabetic characters, symbols or numerals (the so-called juxtaposed characters) are combined (S73) on the deleted area, terminating the process and starting the print process control in S63. In this condition, the net height of the bar BR is about 7.4 mm (31 dots).
In the above examination, if the size data SZ is found to be smaller than 19 points (S71:No), the image combination process is terminated and the print process control is invoked in S63 so that the BH has a sufficient value.
In the next step, the dot pattern data for the bar-code stored on the print buffer 44 is sent to the print mechanism PM for print execution (S63). The print pointer PP loads the address of the termination code (S64), and S57 and the following steps are executed.
In the print execution, if the code data is found to be neither a character code nor a header code, for example, a space code (S53, S54, S59:No), a command corresponding to the code data is issued to the print mechanism PM (S65), and S57 is executed.
After the print execution is completed for all the data stored in the text memory 41 (S58:No), the tape printing device resumes the tape print control operation shown in FIG. 4. If no text data is found on the text memory 41 at the initial stage of the print execution process (S51:No), the buzzer 20 beeps and the control returns to the tape print control shown in FIG. 4.
In the following step, as shown in FIG. 8, if the character size is set at 44 points for the characters and bar-codes stored on the text memory 41, the string "Ag" and bar-codes are printed on the tape medium 5 simultaneously. In this case, characters are juxtaposed under the bar-code because the height of the bar-code BH is 110 dots (about 15.5 mm). When the character size is set at 19 points, characters and bar-code are printed in 19 points as shown in FIG. 13 in accordance with the above description. The characters are juxtaposed under the bar-code because the height of the bar-code is 48 dots (about 6.7 mm). However, if the character size is found to be 13 points, the characters and bar-code are printed in 13 points without juxtaposed characters because the BH is 33 dots (about 4.6 mm in height).
As described thus far, if the character size SZ is found to be a fixed value or greater, for example 19 points, characters are printed under the bar-code with the net height of the bar-code BR kept greater than a criterion of 4.4 mm (31 dots) without a negative impact on the read-out results.
On the other hand, for example, if the character size SZ is smaller than 19 points, the bar-code is printed in dot pattern data generated in the character size SZ across the height of the characters, ensuring stable reading results by a bar-code reader.
Besides the above embodiment, the criterion for the character size SZ can be set at a size larger than 19 points or at 25 points for preserving the criteria of the bar height (about 6.35 mm) . The present invention has diverse applications in bar-code printing devices with a print mechanism for printing bar-codes, numeric characters and symbols in dot patterns. Other advantages and modifications will be apparent to those skilled in the art without departing from the scope of the invention as defined in the appended claims. | In a printing device for printing bar-codes, a string of characters and symbols representing the contents of the bar-codes are printed under the bar-codes by replacing the lower part of the dot pattern with the dot pattern for the string. The present invention is characterized in that the printing device has a decision means for deciding whether or not to print characters and for printing bar-codes with a sufficient height for reading operation by bar-code readers. The printing device automatically omits the string of characters when a character size set by an operator is not large enough to print a string and a bar-code in juxtaposition. | 6 |
FIELD OF THE INVENTION
[0001] The invention pertains to the field of providing hot liquid, particularly water for field application in the oil and gas industry. The apparatus comprises a means for effectively and inexpensively providing heated liquid on demand through a novel heating apparatus. Use of the apparatus provides significant quantity of heated water at a fraction of the heating costs currently contemplated for field use.
BACKGROUND OF THE INVENTION
[0002] The oil and gas industry began fracturing rock deposits, i.e., fracking, in approximately 1970. Since that time fracking has developed into the preferred method of gas exploration and recovery.
[0003] Liquid, typically heated water, is used in fracking operations. To accomplish fracking, heated liquid is applied or injected into formations. A constant and inexpensive supply of liquid is needed to maintain operations. Current and conventional technology employs a heater coil and boiler design, usually used to heat liquid and has been used in oil and gas field applications from 1950 to current. Again, the liquid most typically used is water.
[0004] There is a need for a means to provide significant amounts of heated liquid, typically water, in the oil and gas field. The conventional, current means of providing heated water are often expensive, unreliable, and require multiple apparatuses.
[0005] Thus, there is a long felt need for a system or method to effectively and inexpensively provided heated liquid, particularly water, for fracking operations in oil and gas fields.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an object of embodiments of the present invention to provide a means to provide an inexpensive and effective means to heat liquid, including water in remote gas and petroleum fields. The invention, which relates to a reservoir tube heater which flows liquid, typically water, through a series of reservoirs and liquid transfer tubes with a heat source, typically propane burners underneath. Liquid flows through the reservoir tube heater from the lower portion to the upper portion, contrary to current liquid heating systems currently used in the industry.
[0007] The present invention is concerned with a new and novel means to supply heated liquid for fracking and other oil and gas filed needs. To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, comprises a reservoir-tube heater apparatus comprising horizontally stacked rows of liquid transfer tubes separating a first column of horizontally layered reservoirs and an opposing second column of horizontally layered reservoirs, said horizontally stacked rows of liquid transfer tubes having a bottom row of liquid transfer tubes, a top row of liquid transfer tubes and multiple rows of liquid transfer tubes therebetween, said first column of reservoirs comprising first reservoir having an opening intake orifice and a row of multiple outlet orifices connected to the bottom row of liquid transfer tubes, a last reservoir having an exit outtake orifice and a row of inlet orifices connected to the top row of liquid transfer tubes, said bottom row of liquid transfer tubes and said top row of liquid transfer tubes connected to multiple reservoir pairs comprised of a bottom reservoir having liquid inlet orifices, a top reservoir having liquid outlet orifices and reservoir transfer tube between the top and bottom reservoirs.
[0008] Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
[0009] Benefits and advantages of the present invention include, but are not limited to, providing a system, which provides a means to effectively provide heated liquid at a fraction of the energy costs to the oil and gas industry. The invention is easy to use and can function in a variety of terrains without being cost prohibitive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
[0011] FIG. 1 illustrates a perspective front and side view of one embodiment of the present invention.
[0012] FIG. 2 illustrates a side view of one embodiment of the present invention and further demonstrates the flow of liquid through the invention.
[0013] FIG. 3 illustrates a front end cross-sectional view of one embodiment of the present invention.
[0014] FIG. 4 illustrates a close up front end cross-sectional view of one embodiment of the present invention, focusing in on the upper right section of FIG. 3 .
[0015] FIG. 5 illustrates a perspective front and side view of a first reservoir of one embodiment of the present invention.
[0016] FIG. 6 illustrates a perspective side view of a reservoir pair including a bottom reservoir and a top reservoir of one embodiment of the present invention.
[0017] FIG. 7 is another illustration of a perspective side view of a reservoir pair including a bottom reservoir and a top reservoir of one embodiment of.
[0018] FIG. 8 illustrates a perspective front and side view of a last reservoir of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Reference will now be made in detail to embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference characters refer to the same or similar elements in all figures. FIG. 1 depicts one embodiment of the present invention, the reservoir-tube heater 1 . This depiction shows a broad perspective side view of one embodiment of the instant invention. The sideways directional flow of liquid through the reservoir tube heater 1 as embodied in the instant invention is depicted with dashed arrows. A liquid inlet tube 2 is shown at the bottom and a liquid outlet tube 64 is shown at the top of the reservoir-tube heater 1 . Dashed arrows show the directional flow of liquid through the reservoir tube heater 1 as liquid flows into a horizontally stacked plurality of liquid transfer tubes 100 .
[0020] In one embodiment, the reservoir tube heater further comprises a trailer to which the reservoir tube heater is attached. This attachment, typically on the bed of a trailer, allows for transportation of the reservoir tube heater to remote locations. In another embodiment, the reservoir heater further comprising an outer covering to surround the reservoir heater and insulate the reservoir tube heater.
[0021] FIG. 1 depicts a first column of horizontally layered reservoirs 101 A and an opposing second column of horizontally layered reservoirs 101 B. The plurality of liquid transfer tubes provides a means for liquid to flow form reservoirs in the first column of horizontally layered reservoirs 101 A to the opposing second column of horizontally layered reservoir 101 B, and vice versa, i.e. liquid flowing from 101 B to 101 A. A pumping unit, which is typically a power train output motor, not pictured in this figure, forces liquid flow from the inlet tube into the first reservoir 4 from the liquid inlet tube 2 , multiple liquid transfer tubes 100 and horizontally layered reservoirs, and eventually out the liquid outlet tube 64 . Additionally, a liquid source, not depicted in FIG. 1 , provides liquid that flows into inlet tube 2 .
[0022] FIG. 2 , a side view of the present invention, depicts a more detailed view of the liquid flow route through the invention. From the liquid inlet tube 2 liquid into a first reservoir 4 via a liquid intake orifice 3 . Liquid then flows from the first reservoir 4 through a multiplicity of parallel liquid transfer tubes into a second reservoir 8 . In this side view diagram, only liquid transfer tubes 6 A is shown. It is understood that there are additional liquid tubes, 6 B, 6 C, 6 D, 6 E, 6 F, 6 G, 6 H, 61 providing a means for liquid to flow from first reservoir 4 to the second reservoir 8 . The second reservoir 8 is a bottom reservoir, having non-depicted water inlet orifices of a reservoir pair. The third reservoir 10 is a top reservoir, having non-depicted water outlet orifices. In this first reservoir pair, the second reservoir 8 and third reservoir 10 are connected via transfer tube 9 .
[0023] Second reservoir 8 eventually fills with liquid, originating from the first reservoir 4 via the liquid transfer tubes 6 A, 6 B, 6 C, 6 D, 6 E, 6 F, 6 G, 6 H, 6 I. Liquid flows up to third reservoir 10 via reservoir transfer tube 9 . From third reservoir 10 , liquid flows through multiplicity of parallel liquid transfer tubes into a fourth reservoir 14 . Liquid transfer tube 12 A is shown, although it is understood that there are additional liquid tubes 12 B, 12 C, 12 D, 12 E, 12 F, 12 G, and 12 H providing a means for liquid to flow from third reservoir 10 to fourth reservoir 14 , a bottom reservoir of a second reservoir pair with the fifth reservoir 16 being the top reservoir of the second reservoir pair.
[0024] Fourth reservoir 14 eventually fills with liquid and liquid flows up to a fifth reservoir 16 via reservoir transfer tube 15 . From fifth reservoir 16 , liquid flows through multiplicity of parallel liquid transfer tubes 18 A, 18 B, 18 C, 18 D, 18 E, 18 F, 18 G, 18 H and 18 I into a sixth reservoir 20 , although only liquid transfer tube 18 A is shown, providing a means for liquid to flow from fifth reservoir 16 to sixth reservoir 20 . Reservoir 20 and reservoir 22 are the bottom and top reservoirs, respectively, of the third reservoir pair.
[0025] Sixth reservoir 20 eventually fills with liquid and liquid flows up to a seventh reservoir 22 via reservoir transfer tube 21 . From seventh reservoir 22 , liquid flows through multiplicity of parallel liquid transfer tubes 24 A, 24 B, 24 C, 24 D, 24 E, 24 F, 24 G, and 24 H into an eighth reservoir 26 . Only liquid transfer tube 24 A is shown, although it is understood that there are additional liquid tubes providing a means for liquid to flow from seventh reservoir 22 to eighth reservoir 26 . Reservoir 26 and reservoir 28 are the bottom and top reservoirs, respectively, of the fourth reservoir pair.
[0026] Eighth reservoir 26 eventually fills with liquid and liquid flows up to a ninth reservoir 28 via reservoir transfer tube 27 . From ninth reservoir 28 , liquid flows through multiplicity of parallel liquid transfer tubes 30 A, 30 B, 30 C, 30 D, 30 E, 30 F, 30 G, 30 H and 30 I into a tenth reservoir 32 . Only liquid transfer tubes 30 A is shown, although it is understood that there are additional liquid tubes providing a means for liquid to flow from ninth reservoir 28 to the tenth reservoir 32 . Reservoir 32 and reservoir 34 are the bottom and top reservoirs, respectively, of the fifth reservoir pair.
[0027] Tenth reservoir 32 eventually fills with liquid and liquid flows up to an eleventh reservoir 34 via reservoir transfer tube 33 . From eleventh reservoir 34 , liquid flows through multiplicity of parallel liquid transfer tubes 36 A, 36 B, 36 C, 36 D, 36 E, 36 F, 36 G, and 30 H into a twelfth reservoir 38 . Again, in this diagram and at this angle, only liquid transfer tube 36 A is shown, although it is understood that there are additional liquid tubes providing a means for liquid to flow from eleventh reservoir 34 to twelfth reservoir 38 . Reservoir 38 and reservoir 40 are the bottom and top reservoirs, respectively, of the sixth reservoir pair.
[0028] Twelfth reservoir 38 eventually fills with liquid and liquid flows up to a thirteenth reservoir 40 via reservoir transfer tube 39 . From thirteenth reservoir 40 , liquid flows through multiplicity of parallel liquid transfer tubes 42 A, 42 B, 42 C, 42 D, 42 E, 42 F, 42 G, 42 H and 42 I into a fourteenth reservoir 44 . Only liquid transfer tube 42 A is shown, although it is understood that there are additional liquid tubes providing a means for liquid to flow from thirteenth reservoir 40 to the fourteenth reservoir 44 . Reservoir 44 and reservoir 46 are the bottom and top reservoirs, respectively, of the seventh reservoir pair.
[0029] Fourteenth reservoir 44 eventually fills with liquid and liquid flows up to a fifteenth reservoir 46 via reservoir transfer tube 45 . From fifteenth reservoir 46 , liquid flows through multiplicity of parallel liquid transfer tubes 48 A, 48 B, 48 C, 48 D, 48 E, 48 F, 48 G, and 48 H into a sixteenth reservoir 50 . Only liquid transfer tube 48 A is shown, although it is understood that there are additional liquid tubes providing a means for liquid to flow from fifteenth reservoir 46 to the sixteenth reservoir 50 . Reservoir 50 and reservoir 52 are the bottom and top reservoirs, respectively, of the eighth reservoir pair.
[0030] Sixteenth reservoir 50 eventually fills with liquid and liquid flows up to a seventeenth reservoir 52 via reservoir transfer tube 51 , not depicted in this diagram. From seventeenth reservoir 52 , liquid flows through multiplicity of parallel liquid transfer tubes 54 A, 54 B, 54 C, 54 D, 54 E, 54 F, 54 G, 54 H and 54 I into an eighteenth reservoir 56 . Only liquid transfer tube 54 A is shown, although it is understood that there are additional liquid tubes providing a means for liquid to flow from seventeenth reservoir 52 to the eighteenth reservoir 56 . Reservoir 56 and reservoir 58 are the bottom and top reservoirs, respectively, of the ninth reservoir pair. Eighteenth reservoir 56 eventually fills with liquid and liquid flows up to a nineteenth reservoir 58 via reservoir transfer tube 57 , not depicted in this diagram. From nineteenth reservoir 58 , liquid flows through multiplicity of parallel liquid transfer tubes 60 A, 60 B, 60 C, 60 D, 60 E, 60 F, 60 G, and 60 H into a twentieth reservoir 62 . Only liquid transfer tube 60 A is shown, although it is understood that there are additional liquid tubes providing a means for liquid to flow from nineteenth reservoir 58 to the twentieth reservoir 62 . Liquid eventually fills the last reservoir, the twentieth reservoir 62 , and flows out a liquid outlet tube 64 via a liquid exit outtake orifice 63 .
[0031] FIG. 2 depicts one embodiment of the present invention, wherein opening intake orifice 3 is disposed between the liquid inlet tube 2 and the first reservoir 4 via the opening intake orifice 3 . Further, FIG. 2 depicts the reservoir transfer tube 9 between second reservoir 8 and third reservoir 10 , the reservoir transfer tube 15 between the fourth reservoir 14 and fifth reservoir 16 , the reservoir transfer tube 21 between the sixth reservoir 20 and the seventh reservoir 22 , the reservoir transfer tube 27 between the eighth reservoir 26 and ninth reservoir 28 , the reservoir transfer tube 33 between the tenth reservoir 32 and the eleventh reservoir 34 , the reservoir transfer tube 39 between the twelfth reservoir 38 and the thirteenth reservoir 40 , the reservoir transfer tube 45 between the fourteenth reservoir 44 and the fifteenth reservoir 46 , the reservoir transfer tube between the sixteenth reservoir 50 and the seventeenth reservoir 52 , the reservoir transfer tube 57 between the eighteenth reservoir 56 and nineteenth reservoir 58 . FIG. 2 also depicts the exit outtake orifice 63 disposed between the liquid outlet tube 64 and the twentieth reservoir 62 and the twentieth reservoir 62 .
[0032] In FIG. 2 , 6 represents the plurality of liquid transfer tubes, 6 A, 6 B, 6 C, 6 D, 6 E, 6 F, 6 G, 6 H and 6 I. It is to be understood that the plurality of liquid transfer tubes not seen in this depiction of the instant invention. Similarly, 12 , 18 , 24 , 30 , 36 , 42 , 48 , 54 , and 60 represent similar pluralities of liquid transfer tubes. Similar to FIG. 1 , the dashed arrows represent the flow of liquid through the invention as outlined above.
[0033] FIG. 2 depicts thermocouple 65 attached to liquid inlet tube 2 and thermocouple 66 attached to liquid outlet tube 66 . The thermocouples allow the operator to measure the temperature between the inlet and outlet of the reservoir-tube heater. One way the operator can make adjustments to the temperature of the liquid would be by adjusting the rate of flow by adjusting the pto unit pumping the liquid through the reservoir-tube heater.
[0034] FIG. 3 shows a front cross-sectional view of one embodiment of the present invention. In this representation the liquid transfer tubes are shown in the reservoir tubes are omitted. Liquid transfer tubes 6 A, 6 B, 60 , 60 , six each, 6 F, 6 G, 6 H, and 6 I would flow from the first reservoir tube 4 , not depicted, into the second reservoir tube 8 , also not depicted. Liquid flowing through liquid transfer tubes 6 A through 6 I, 18 A through 18 I, 30 A through 30 I, 42 A through 42 I and 54 A through 54 I would flow parallel to each other and opposite to liquid flowing through liquid transfer tubes 12 A through 12 H, 24 A through 24 H, 36 A through 36 H, 48 A through 48 H and 60 A through 60 H.
[0035] FIG. 3 also depicts one embodiment of the instant invention wherein the liquid transfer tubes 6 A through 6 I are disposed offset from liquid transfer tubes 12 A through 12 H such that liquid transferred tube 12 they is immediately above the midpoint between liquid transfer tube 6 A and 6 B. As FIG. 3 shows, this pattern repeats itself. Thus, each row of liquid transfer tubes is offset by one half the distance between the liquid transfer tubes above and below and every other row of liquid transfer tubes aligns.
[0036] FIG. 3 also depicts a heat sources 300 A, 300 B, 300 C, 300 D, 300 E, 300 F, 300 G, 300 H, and 300 I underneath liquid transfer tubes 6 A through 6 I. In field use, these heat sources are typically propane burners that run the length of the liquid transfer tubes and provide 10,000,000+BTUs to heat the liquid transfer tubes of the reservoir-tube heater. Although not depicted in this diagram the reservoir tube heater in some embodiments is at least partially encased in a box and loaded onto a flatbed trailer. Accompanying the reservoir tube heater is a liquid propane tank to supply the energy to heat the liquid as it travels through the reservoir tube heater. Thus, via the input from the thermocouples 65 and 66 , the operator may also control the temperature of the liquid by adjusting the amount of propane sent to the propane burners from the attached propane tank.
[0037] FIG. 4 depicts the upper right liquid transfer tubes of FIG. 3 , namely liquid transfer tubes 54 A, 54 B, 60 A and 60 B. In one embodiment of the instant invention, 4 inches separates the center of every liquid transfer tube in a row. Thus, the distance from the center of liquid transfer tube 60 A and liquid transferred tube 60 B is 4 inches. Also, the distance between a line intersecting the center of every liquid transferred tube in one row, for example 60 A, 60 B, etc. and a line intersecting the center of every liquid transferred tube the next closest row of liquid transfer tubes, for example, 54 A, 54 B, etc. is 4 inches.
[0038] FIG. 5 depicts the liquid inlet tube 2 contacting the first reservoir 4 with liquid flowing through the opening intake orifice 3 . The first reservoir 4 comprises generally a rectangular cube having a first side 4 A, an opposing second side 4 B, a front side 4 C and an opposing back side 4 D, and a bottom portion 4 E and a top portion 4 F. Liquid flows out of the first reservoir 4 through the outlet orifices 5 A, 5 B, 5 C, 5 D, 5 E, 5 F, 5 G, 5 H, and 5 I, (not depicted) located on the second side 4 B of the first reservoir, into liquid transfer tubes 6 A, 6 B, 6 C, 6 D, 6 E, 6 F, 6 G, 6 H and 6 I, (not depicted) respectively, as the liquid flows to the second reservoir 8 .
[0039] FIG. 6 depicts first reservoir pair comprising the second reservoir 8 , the third reservoir 10 and the reservoir transfer tube 9 . Reservoir 8 comprises a generally rectangular cube having a first side 6 A, an opposing second side 6 B, a front side 6 C and an opposing back side 6 D, and a bottom portion 6 E and a top portion 6 F. Liquid flows into the second reservoir 6 through the inlet orifices 7 A, 7 B, 7 C, 7 D, 7 E, 7 F, 7 G, 7 H, and 7 I, located on the first side 6 A of the second reservoir 6 and from liquid transfer tubes 6 A, 6 B, 6 C, 6 D, 6 E, 6 F, 6 G, 6 H and 6 I, respectively (not depicted in FIG. 6 ). Once the second reservoir 8 is filled, liquid flows through the reservoir transfer tube 9 into the third reservoir 10 . The third reservoir 10 comprises a generally rectangular cube having a first side 10 A, an opposing second side 10 B, a front side 10 C and an opposing back side 10 D, and a bottom portion 10 E and a top portion 10 F. The reservoir transfer tube 9 is in contact with the top portion of the second reservoir, 6 F and the bottom portion of the third reservoir 10 E. As the third reservoir 10 begins to fill with liquid from the second reservoir 8 via the reservoir transfer tube 9 , the liquid flows out of liquid outlet orifices 11 A, 11 B, 11 C, 11 D, 11 E, 11 F, 11 G, and 11 H disposed on the first side 10 of reservoir 10 and into liquid transfer tubes 12 A, 12 B, 12 C, 12 D, 12 E, 12 F, 12 G, and 12 H (not depicted), respectively, as the liquid flows out of the third reservoir 10 to the fourth reservoir 14 .
[0040] The first reservoir pair comprising reservoir 8 and reservoir 10 shown in FIG. 6 is identical to the third reservoir pair, comprising reservoir 20 and reservoir 22 , the fifth reservoir pair, comprising reservoir 32 and reservoir 34 , the seventh reservoir pair, comprising reservoir 44 and reservoir 46 and the ninth reservoir pair, comprising reservoir 56 and 58 . FIG. 6 and FIG. 7 show an elongated reservoir transfer tube 9 and 15 . In these depictions, the reservoir transfer tubes have an exaggerated length. In practice, the length of the reservoir transfer tube would be shorter. The shorter length would be applicable for all reservoir transfer tubes in the reservoir tube heater.
[0041] FIG. 7 depicts the second reservoir pair comprising the fourth reservoir 14 , fifth reservoir 16 and reservoir transfer tube 15 . Reservoir 14 comprises a generally rectangular cube having a first side 14 A, an opposing second side 14 B, a front side 14 C and an opposing backside 14 D, and a bottom portion 14 E and a top portion 14 F. Liquid flows into the fourth reservoir 14 through the inlet orifices 13 A, 13 B, 13 C, 13 D, 13 E, 13 F, 13 G, and 13 H, located on the second side 14 B of the fourth reservoir 14 and from liquid transfer tubes 12 A, 12 B, 12 C, 12 D, 12 E, 12 F, 12 G, and 12 H (not depicted), respectively. Once the fourth reservoir tube 14 is filled, liquid flows through the reservoir transfer tube 15 into the fifth reservoir 16 . The fifth reservoir 16 comprises a generally rectangular cube having a first side 16 A, an opposing second side 16 B, a front side 16 C and an opposing backside 16 D, and a bottom portion 16 E and a top portion 16 F. The reservoir transfer tube 15 is in contact with the top portion 14 F of the second reservoir 14 and the bottom portion 16 E of the fifth reservoir 16 . As the fifth reservoir 16 begins to fill with liquid from the fourth reservoir 14 via the reservoir transfer tube 15 , the liquid flows out of liquid outlet orifices 17 A, 17 B, 17 C, 17 D, 17 E, 17 F, 17 G, 17 H and 17 I disposed on the second side 16 B of the fifth reservoir 16 and into liquid transfer tubes 18 A, 18 B, 18 C, 18 D, 18 E, 18 F, 18 G, 18 H, and 18 I respectively (not depicted in FIG. 7 ), as the liquid flows out of the fifth reservoir 16 to the sixth reservoir 20 . The liquid flow scheme for reservoir 14 and reservoir 16 shown in FIG. 6 is identical to the liquid flow scheme for reservoir 26 and reservoir 28 , reservoir 38 and reservoir 40 , and reservoir 50 and reservoir 52 .
[0042] The second reservoir pair comprising reservoir 14 and reservoir 16 shown in FIG. 7 is identical to the fourth reservoir pair, comprising reservoir 26 and reservoir 28 , the sixth reservoir pair, comprising reservoir 38 and reservoir 40 , and the eighth reservoir pair, comprising reservoir 50 and reservoir 52 .
[0043] FIG. 8 depicts the liquid outlet tube 64 contacting the last reservoir, twentieth reservoir 62 , and the exit outtake orifice 63 . The twentieth reservoir 62 comprises generally a rectangular cube having a first side 62 A, an opposing second side 62 B, a front side 62 C and an opposing back side 62 D, and a bottom portion 62 E and a top portion 62 F. Liquid flows into the twentieth reservoir 62 through the inlet orifices 61 A, 61 B, 61 C, 61 D, 61 E, 61 F, 61 G, and 61 H, located on the second side 62 B of the first reservoir 62 , from into liquid transfer tubes 60 A, 60 B, 60 C, 60 D, 60 E, 60 F, 60 G, 60 H and 60 I (not depicted), respectively.
[0044] The flow of the liquid from the bottom of the reservoir tube heater apparatus allows the initial liquid flowing into the apparatus to be heated most at first. As the liquid continues to flow up through the multiplicity of horizontally layered reservoirs and horizontally stacked rows of liquid transfer tubes, the liquid continues to be heated because the heat from the heat source rises. Thus, the design of the instant invention allows for energy conservation and optimization to effectively heat with much less energy than is currently used to heat water in fracking operations. As discussed throughout this application the work liquid is most often to include water, which is most often used in fracking applications.
[0045] It is believed that the apparatus of the present invention and many of its attendant advantages will be understood from the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction, and arrangement of the components without departing from the scope and spirit of the invention and without sacrificing its material advantages. The forms described are merely exemplary and explanatory embodiments thereof. It is the intention of the following claims to encompass and include such changes. | This invention pertains to an apparatus to efficiently provide a means to heat liquid in the oil and gas fields, specifically fracking operations. The apparatus described herein provides reservoir heaters connected via reservoir transfer tubes and a heat source, located at the bottom of the apparatus, which thoroughly heats liquid as the liquid travels from the bottom of the apparatus to the top of the apparatus. | 5 |
[0001] The present invention is a continuation of U.S. patent application Ser. No. 12/282,468, filed Sep. 10, 2008, which is a U.S. national stage application of PCT/US07/06253, filed Mar. 12, 2007, which is a non-provisional application of U.S. Provisional Patent Application 60/781,135, filed Mar. 10, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method and system for measuring and reporting time based parameters associated with heart activity. More particularly, the present invention relates to a cardiography system and method using automated recognition of hemodynamic parameters and waveform attributes for monitoring and recording signals derived from heart valve activity and guiding goal-directed therapy by correlating cardiovasculograms (CVG) with waveform and hemodynamic data stored in local memory.
[0004] 2. Discussion of the Related Art
[0005] Cardiac output and circulatory flow are a balance of the pumping ability of the heart. Congestive heart failure (CHF) is a condition in which the cardiac output is unable to meet the metabolic demands of the body. This condition can vary in severity from a simple elevation in cardiac filling pressures, known as compensated failure, to severe hypoxia and edema, known as decompensated failure.
[0006] CHF is thought to result from a failure in the contractile elements of the heart during the systolic phase of the cardiac cycle, which is known as systolic congestive heart failure. Systolic CHF is characterized clinically by an ejection fraction of less than 30%. Systolic CHF can be a result of a myriad of possible pathologies affecting the contractile ability of the heart muscle including myocardial infarction, cardiomyopathies, and metabolic disorders. Management of this disorder has evolved over recent years and is highly dependent upon the severity of the condition. Most treatment regimens involve attempting to increase systolic contractility or focusing on hemodynamic manipulations that allow the heart to take a passive role in circulatory control.
[0007] More recently it has been recognized that limitations in cardiac filling and venous return during diastole can also result in an abnormal circulatory flow, which is known as diastolic congestive heart failure. Diastolic CHF is defined as the condition in which there is evidence of the clinical signs of CHF in the presence of normal systolic functioning. This condition occurs in as many as 30% of patients presenting with heart failure. Some of this dysfunction may be due to a stiff myocardium limiting the passive phase of diastolic filling. However, the majority of dysfunction is caused by lengthening of isovolumic myocardial relaxation or isovolumic relaxation times (IVRT). Myocardial relaxation is an energy-dependent, active process that is mainly unconstrained by preload and afterload considerations. Ventricular hypertrophy is often the end result of long-standing hypertension and is commonly responsible for delays in IVRT due to abnormalities in calcium kinetics. Researchers have shown that an IVRT greater than 0.125 sec is indicative of diastolic dysfunction. Patients presenting with CHF due to diastolic dysfunction may not respond to traditional therapies. These traditional therapies can even be detrimental to patients presenting with CHF due to diastolic dysfunction. Patients with evidence of acute decompensation secondary to a diastolic mechanism may have worsening of symptoms, hypotensive response, and reduced cardiac output with the typical off-loading treatments of diuretics or preload reducing medication. As a result, it is important to identify accurately which type of CHF a patient is presenting, in order to identify appropriate goal directed therapies.
[0008] The analysis of waveforms obtained from physiologic monitoring is a common practice in medicine. Clinicians have used waveform patterns obtained from electrocardiography, capnography, cardiotocography, and spirometry to assist in the diagnostic assessment of patient pathology. The unassisted, human interpretation of CVG pattern recognition and differentiation of these waveforms is a clinical art form that requires experience and skilled expertise. However, automated computerized interpretations of waveforms based upon specific segmental waveform criteria have been widely used in medicine to assist clinicians in the diagnostic process. In the field of electrocardiography, the interpretative waveform criteria have been developed based upon evidence from clinical correlations and standardized for specific diagnoses. Proprietary computerized algorithms use these criteria for their electrocardiographic interpretation.
[0009] Clinical evidence supports the use of waveform analysis and diagnostic interpretation in the field of impedance cardiography (ICG). ICG is a technique used to provide non-invasive monitoring and analysis of a patient's cardiac performance. ICG systems measure and report several time-based parameters related to cardiac performance, including the pre-ejection period (PEP) and the left ventricular ejection time (LVET). ICG systems produce ICG signals from monitoring movement and volume of blood as a result of the heart contracting. Exemplary ICG systems are shown and described in Ackmann et al., U.S. Pat. No. 5,178,154; and Reining, U.S. Pat. No. 5,505,209 both incorporated by reference herein in their entireties. The '154 and '209 patents disclose the use of electrode bands placed on a patient with high frequency, low magnitude electrical current applied to the electrode bands. Voltage changes across the bands are read, filtered and converted into thoracic impedance. The ICG system displays the thoracic impedance signal versus time to create a visual display of the ICG signal. The '154 patent further discloses that ICG systems can receive conventional electrocardiograph signals, signals from blood pressure monitors, signals from piezoelectric microphones attached to the chest of the patient and the like. These signals, in addition to thoracic impedance, can be stored and averaged via a memory storage device connected to the ICG system.
[0010] A CVG is a waveform produced by the processing of impedance cardiography (ICG) signals and which may also be supported by processing other signal inputs such as electrocardiography (ECG) signals, phonocardiography (PCG) signals and other hemodynamic signals. The CVG waveform in combination with the accompanying electrocardiograph, describe the electromechanical events of the cardiac cycle. The CVG is a signature waveform and can be interpreted by physicians in much the same way as electrocardiograms are interpreted. Despite improvements in ICG systems and/or signal processing, there have been no advances in the methodology of automated waveform analysis for ICG systems. Specifically, there exists a need for using CVG waveforms in an automated system to differentiate decompensated heart failure from other common clinical conditions and to further distinguish between diastolic and systolic forms of heart failure.
[0011] Phonocardiography (PCG) is a non-invasive technique used by healthcare professionals to monitor cardiac performance. PCG systems generate PCG signals by monitoring the opening and closing of valves within a patient's heart. PCG systems use a microphone that records sounds of heart valve activity, similar to electronic stethoscopes known in the art, in order to provide indications of aortic heart valve opening (shown as S 1 on FIG. 1 ) and aortic heart valve closure (shown as S 2 on FIG. 1 ).
[0012] Another non-invasive system used to monitor heart activity is an electrocardiogram (ECG) system. ECG signals are electrical signals that are generated from the depolarization and repolarization of myocardial cells in a patient's heart. ECG systems are known to include a first external electrode attached to a patient's skin, a second external electrode attached to a patient's skin and optionally a third external electrode attached to a patient's skin. An amplifier is used to monitor electrical heart activity signals at the first and second electrodes and generate an ECG signal based on the difference between these activity signals. The optional third electrode can be used to reduce or offset noise in the ECG signal.
[0013] Still another non-invasive system used by healthcare professionals to monitor cardiac performance is a blood pressure system. A patient's blood pressure is monitored according to known techniques and converted into a blood pressure signal. The blood pressure signal is then displayed on a blood pressure waveform. Blood pressure waveforms, similar to PCG waveforms, can be used by healthcare professionals to identify heart valve closure because the dicrotic notch in blood pressure waveforms reflects closure of the aortic heart valve. Other exemplary systems using signals that have pulsatile characteristics resulting from the contraction of the heart are shown and described in Kimball et al., U.S. Pat. No. 6,763,256, herein incorporated by reference in its entirety.
[0014] The PEP is defined as the period of isovolumic ventricular contraction when the patient's heart is pumping against the closed aortic valve. In ICG systems, the PEP is measured starting with the initiation of the QRS complex (the “Q” point on FIG. 1 ) of the ECG signal and ending with the start of the mechanical systole as marked by the initial deflection of the systolic waveform (the “B” point on FIG. 1 ) of the ICG signal coincident with the opening of the aortic valve or the onset of left ventricular ejection into the aorta. The LVET begins at the end of the PEP and ends at the closure of the aortic valve (the “X” Point on FIG. 1 ) when ejections ends.
[0015] It is important that ICG systems provide accurate results for the PEP and the LVET because healthcare professionals utilize the results of these parameters when making decisions about patient diagnosis and care. Additionally, accurate determination of the PEP and the LVET time intervals is also required for accurate and reliable determination of subsequent and dependent parameters. For example, results from determination of the PEP and the LVET are used to calculate the systolic time ratio (STR), where STR=PEP/LVET. While many ICG systems use proprietary equations for determination of stroke volume (SV), it is commonly known that SV equations frequently incorporate LVET as an input parameter. Accordingly, accurate determination of time intervals between the PEP and the LVET is also necessary for accurate determination of SV, and subsequently for cardiac output (CO) based on SV and heart rate (HR), where CO=SV*HR.
[0016] Many CVG waveforms, particularly for healthy individuals, provide sufficient detail so that ICG systems can identify the location of the aortic valve opening and closing, or the LVET, with a high degree of confidence. For example, in the CVG waveform depicted in FIG. 1 , opening, B point, of the aortic valve and closing, X point, of the aortic valve are easily identifiable. When comparing the CVG waveform with the phonocardiograph (PCG) waveform (both shown in FIG. 1 ), marking of the B point in the CVG waveform is confirmed by the time-associated presence of the S 1 component in the PCG waveform. Similarly, marking of the X point in the CVG waveform is confirmed by the time associated presence of the S 2 component in the PCG waveform.
[0017] A number of parameters, including but not limited to cardiac output, thoracic fluid content, Heather Index, and the like, have been derived from impedance signals to assist in the diagnosis of decompensated heart failure. Traditionally, however, ICG systems only analyze attributes of the impedance signal when determining the location of heart valve activity. Some ICG systems may record and display PCG signals, blood pressure signals, and/or other signals having pulsatile characteristics resulting from contraction of the heart, but these ICG systems do not integrate these signals into the automatic location of heart valve activity. ICG systems alone often lack sufficient information to accurately and reliably determine the PEP and the LVET because of confounding information related to opening and closing of the patient's aortic valve. For example, in the CVG waveform depicted in FIG. 2 , closure, X point, of the aortic valve could be any of several depressions following the peak blood flow, C. The known algorithm selected the deepest depression in the CVG waveform because the aortic valve closure is often thought to produce the strongest negative signal. However, when the CVG waveform depicted in FIG. 2 is compared with the PCG waveform depicted in FIG. 2 , the aortic valve closure, X point, should have been one of the later depressions in the CVG waveform in order to correlate with the time associated presence of the S 2 component in the PCG waveform. Accordingly, there is a need for an impedance cardiography method and system for automated correlation of impedance signals from ICG systems with other signals derived from heart valve activity in order to provide more accurate identification of heart valve activity.
[0018] Many of the specific segmental criteria used in this comprehensive pattern recognition are based upon well-established characterizations of changes in systolic and diastolic function as determined from elements of the impedance cardiogram.
[0019] It is known that experienced healthcare professionals can recognize, or diagnose, certain disease states by analyzing hemodynamic parameters in combination with visual displays of ICG signals provided by some ICG systems. Experienced healthcare professionals can easily recognize the systolic and diastolic segments of these visual displays in addition to other attributes such as amplitude, shape, tone, slope and timing, in combination with hemodynamic parameters. Analysis of these attributes allows experienced healthcare professionals to ascertain an underlying disease state. However, variations in ICG signal attributes makes non-automated diagnosis difficult.
[0020] It is also known that some ICG systems provide minimal waveform information. When using these types of systems, healthcare professionals must rely largely on numeric parameters to make a diagnosis because these systems do not provide other information. With ICG systems that do not display waveforms, even experienced healthcare professionals may be unable to make a diagnosis. Based on the foregoing, there exists a need for an automated cardiography method and system for measuring cardiovasculograms that provides suggested underlying conditions based on correlating the recognized waveform attributes and hemodynamic parameters with waveform attributes and hemodynamic parameters associated with particular underlying conditions.
SUMMARY OF THE INVENTION
[0021] The present invention provides a cardiography method and system for measuring cardiovasculograms including signals derived from heart valve activity that are time coordinated with ICG signals, such that the signals derived from heart valve activity are used as confirmation that the cardiography system is accurately positioning heart valve activity. The present invention also provides improved accuracy in reported values such as PEP, LVET, STR, SV and CO. The present invention also provides improved accuracy of graphic presentation of heart activity when the graphic presentation includes identifying heart valve activity. The present invention categorizes and saves waveform attributes and hemodynamic parameters correlated with various patient disease states such that measured waveform attributes and hemodynamic parameters can be matched with the categorized and saved data in order to provide automated diagnoses. The present invention provides physicians with assistance in achieving goal directed therapy.
[0022] The present invention includes a cardiography system for automated recognition of hemodynamic parameters and waveform attributes including one or more sensors for providing one or more waveform signals and a hemodynamic parameter input; a knowledge base for providing data corresponding to various disease states; a processing device connected to the sensor(s) and the knowledge base, where the processing device receives the waveform signal(s) and the hemodynamic parameter input, identifies waveform attributes on the waveform signal, measures the waveform attributes, measures the hemodynamic parameter input, cross-references the waveform attributes and the hemodynamic parameter input with the knowledge base, and outputs a suggested likelihood of a particular disease state based on the cross-referencing. The system in accordance with the present invention optionally includes a display device for displaying the output. The knowledge base of the present invention can also include goal-directed therapies associated with particular disease states for providing suggested goal-directed therapies based on the cross-referencing of the waveform attributes and the hemodynamic parameters with the knowledge base.
[0023] The present invention also includes a method for automated recognition of hemodynamic parameters and waveform attributes to assess disease states including the steps of providing one or more sensor for generating one or more waveform signal and a hemodynamic parameter input; providing a knowledge base having data corresponding to various disease states; providing a processing device in communication with the sensor(s) and the knowledge base, where the processing device is used for receiving the waveform signal(s) and the hemodynamic parameter input, identifying waveform attributes on the waveform signal, measuring the waveform attributes, measuring the hemodynamic parameter input, accessing the knowledge base, cross-referencing the waveform attributes with data in the knowledge base, cross-referencing the hemodynamic parameter input with data in the knowledge base, and outputting a suggested likelihood of a particular disease state based on the cross-referencing step. The method in accordance with the present invention optionally includes a display device for displaying the output. The knowledge base of the present invention can also include goal-directed therapies associated with particular disease states for providing suggested goal-directed therapies based on the cross-referencing of the waveform attributes and the hemodynamic parameters with the knowledge base.
[0024] The invention will be further described with reference to the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 represents CVG and PCG waveforms of a healthy patient;
[0026] FIG. 2 represents CVG and PCG waveforms of an unhealthy patient;
[0027] FIG. 3 is a schematic diagram of the system of the present invention illustrating the principal components thereof;
[0028] FIG. 4 represents common ECG and ICG signals;
[0029] FIG. 5 represents a correlation between an O/C ratio, which is derived from an impedance cardiogram, and invasively measured pulmonary capillary wedge pressure (PCWP);
[0030] FIG. 6 represents a correlation between the change in baseline thoracic impedance Z 0 and the change in the central venous pressure;
[0031] FIG. 7 represents a correlation between degree of severity of left ventricular hypertrophy (LVH) and isovolumic relaxation time (IVRT);
[0032] FIG. 8 is a flowchart illustrating one method for using cardiovasculogram (CVG) criteria for the diagnosis of heart failure;
[0033] FIG. 9 is a block diagram of the exemplary components of an electronic processing device used in accordance with the system of the present invention;
[0034] FIG. 10 represents an CVG waveform of a patient with systolic heart failure;
[0035] FIG. 11 represents an CVG waveform of a patient with diastolic heart failure;
[0036] FIG. 12 is a flowchart illustrating one method of correlating measured cardiovasculograms with known cardiovasculograms in accordance with the present invention;
[0037] FIG. 13 represents the CVG waveform shown in FIG. 10 with additional information from an experienced healthcare professional; and
[0038] FIG. 14 represents the CVG waveform shown in FIG. 11 with additional information from an experienced healthcare professional.
DETAILED DESCRIPTION
[0039] Referring to FIGS. 1 and 2 , there is shown a CVG waveform 12 and a PCG waveform 14 in accordance with the system and method of the present invention. Both figures depict heart valve activity in CVG waveform 12 . The PEP is determined by identifying the time period between the starting point of the QRS complex based on an ECG signal, labeled as the Q point, and the starting point of the mechanical systole as marked by the initial deflection of the systolic waveform based on the ECG signal coincident with the opening of the aortic valve or the onset of left ventricular ejection into the aorta, labeled as the B point. The LVET is determined by identifying the time period between the end of the PEP and the closure of the aortic valve when ejection ends, labeled as the X point. Both figures also depict heart valve activity in PCG waveform 14 , where known devices and methods are used to monitor and record sounds associated with the aortic valve opening, labeled as S 1 , and closing, labeled as S 2 . While FIGS. 1 and 2 depict PCG waveforms, those skilled in the art can appreciate that waveforms generated from any signals derived from heart valve activity can be depicted in relation to CVG waveforms.
[0040] Referring to FIG. 3 , one embodiment of the system in accordance with the present invention includes a display device 16 used to display cardiovasculograms and a processing device 18 . Processing device is used to receive inputs from a sensor 20 hooked to a patient, generate cardiovasculograms and communicate with display device 16 . Those skilled in the art can appreciate that display device 16 may include any type of device for presenting visual information such as, for example, a computer monitor or flat-screen display. Display device 16 may be equipped with user input devices, such as buttons for silencing audible alarms, erasing visual alarms or a combination thereof.
[0041] In one embodiment, sensor 20 includes electrodes for measuring ICG signals, PCG signals and ECG signals, microphones for measuring and recording heart sounds, blood pressure monitors, signals representing central venous pressure, finger plethysmographs and the like. While FIG. 3 depicts one sensor 20 , in another embodiment more than one sensor 20 is used. Here, a first sensor is used to convert physiological data from a patient being monitored to a waveform having particular waveform attributes representing the physiological data. The first sensor can be an ICG system, an ECG system, a PCG system, or a combination thereof. An output generated from the first sensor can be a physical output, including but not limited to graphical display, printout, and the like. The output from the first sensor can alternately or simultaneously be an electrical output signal configured to be received by processing device 18 . A second sensor is used to measure other hemodynamic parameters from the patient being monitored and convert them into a second output. These hemodynamic parameters include, but are not limited to thoracic fluid content (TFC), heart rate (HR), pre-ejection period (PEP), left ventricular ejection time (LVET), isovolumic relaxation time (IVRT), stroke volume (SV), cardiac output (CO), blood pressure, Heather Index (HI), and systemic vascular resistance (SVR). The second output generated from the second sensor can be a physical output, including but not limited to graphical display, printout, and the like. The second output from the second sensor can alternately or simultaneously be an electrical output signal configured to be received by processing device 18 . Those skilled in the art can appreciate that the number and use of the sensors can vary. Those skilled in the art can appreciate that the system in accordance with the present invention may include stationary systems used in intensive care units or emergency rooms in hospitals, or may comprise portable units for use by emergency medical technicians in ambulances, at the scene of accidents, and when responding to other emergency situations.
[0042] Processing device 18 includes cardiovasculogram criteria for the diagnosis of heart failure based upon changes noted in the normal contours and dimensions of the typical cardiovasculogram waveform. While clinicians often use a subjective pattern recognition methodology for determination of aberrancy, the present invention includes objective criteria that can be utilized for a more exacting analysis. These objective criteria are useful in the development of a computerized algorithmic analysis of cardiovasculogram waveforms. Those skilled in the art can appreciate that the system may contain criteria for diagnoses of other disease states.
[0043] Referring now to FIG. 4 , there are shown waveform attributes, including baseline thoracic impedance (Z 0 ), atrial wave (A), aortic valve opening (B), maximum aortic flow (C) (also represented as dZ/dt max ), aortic valve closing (X); pulmonic valve closing (Y), mitral valve opening (O); pre-ejection period (PEP); ventricular ejection time (VET), isovolumic relaxation time (IVRT), and ventricular filling time (FT). These waveform attributes can be used to build the cardiovasculogram criterion for diagnosing heart failure based upon changes noted in the normal contours and dimensions of typical cardiovasculogram waveforms.
[0044] Still referring to FIG. 4 , the C-wave is the major upward deflection in impedance seen during systolic phase of the cardiac cycle that peaks at the point of dZ/dt max . It is seen as the first deflection from baseline thoracic impedance (Z 0 ) after the A-wave, beginning with the B point and ending with the X point. During systole, the form of the C-wave is based on the force of ventricular contraction and the resultant aortic pulse pressure wave generated when blood is transferred out of the ventricle and into the aorta. The dZ/dt max point of the C-wave is correlated with the peak aortic blood flow. Systolic function is generally defined by the shape, depth, and duration of the C-wave. Normal amplitudes for the C-wave will vary depending on the system used but may range from 1.05 to 2.70.
[0045] The O-wave is defined by the diastolic portion of the cardiac cycle and peaks at the point of mitral valve opening, shown as the 0 point on FIG. 4 . The filling of the vena cava and pulmonary vein during the early phase of diastole results in the up-slope of the impedance signal. The ventricular filling phase begins when the tricuspid and mitral valves open. During the terminal portion of the O-wave, there is an increase in the impedance signal and a return to baseline thoracic impedance (Z 0 ) at the end of diastole as the venous system empties into the heart. Accordingly, this waveform reflects the events of diastole, including cardiac filling and venous return.
[0046] LVET begins at the end of the PEP when the aortic valve opens. The LVET ends at the closure of the aortic valve when ejection ends as determined by the dZ/dt waveform. A typical normal value for LVET is about 295±26 msec.
[0047] IVRT is a measure of diastolic function and active ventricular relaxation. IVRT is represented as the X to O period, which begins with the aortic valve closure and ends at the point of the maximum second deflection. A typical normal value for IVRT is less than 125 msec.
[0048] Referring now to FIG. 5 , there is shown one embodiment for specific criteria used to interpret a heart failure waveform based on the foregoing attributes in accordance with the present invention. In one embodiment, specific criteria for determination of the proportional changes in the C-wave and O-wave in a patient with decompensated heart failure are based upon the correlation of the O/C ratio and the pulmonary capillary wedge pressure (PCWP). A typical normal range of the O/C ratio, i.e. 0.43±0.09, was correlated with a PCWP of about 10 to 12 mmHg, which is within typical normal PCWP range. Increases in the O/C ratio greater than 0.6±0.12 indicate pathologic congestion. This level of O/C ratio correlates with a PCWP of about 20 to 25 mmHg, which is considered the break point for the onset of pulmonary edema formation. Therefore, an O/C ratio of about greater than 0.6 can be used to indicate cardiopulmonary congestion as seen in acute decompensated heart failure.
[0049] Referring now to FIG. 6 there is shown another embodiment for specific criteria used to interpret a heart failure waveform in accordance with the present invention. Systolic heart failure is typically due to failure of in contraction strength of the myocardium during systole. Systolic contractile force can be viewed from a basic physical perspective, such as force=mass×acceleration, where systolic contractile force is defined as the amount of blood ejected, mass, times the velocity at which it is ejected, acceleration. In a normal CVG waveform, cardiac systole manifests as a sharp peaking C-wave (as shown in FIG. 4 ). The upslope of the C-wave and the length of the base of the LVET wave are both independently correlated with a general myocardial contractile state. A CVG waveform pattern with a broad blunted C-wave is characteristic of general heart failure in a patient and can be used to help differentiate that condition. The typically normal values for the C-wave and LVET as previously discussed herein are used in the determination of aberrancy. A decompensated systolic heart failure condition is expected to physiologically lead to congestion within the venous side of the circulatory system.
[0050] This congestion can be correlated with increasing thoracic fluid content and increasing baseline thoracic impedance (Z 0 ) in the CVG waveform as depicted in FIG. 6 . Large O-waves with elevated peaks are common in CVG waveforms depicting decompensated heart failure.
[0051] Referring now to FIG. 7 , there is depicted another embodiment for specific criteria used to interpret a heart failure waveform in accordance with the present invention. A correlation between left ventricular hypertrophy measured in mV and active ventricular relaxation time measured in seconds can be used when assessing diastolic heart failure. Diastolic heart failure is caused by a limitation in ventricular compliance and relaxation, resulting in a limitation in cardiac filling during diastole. The diastolic IVRT can be measured from the O-wave of the CVG. Prolongation in the IVRT is indicated by a general pattern of a widening of the base of the O-wave, which suggests a diagnosis of diastolic heart failure. As shown in FIG. 7 , IVRT by CVG waveform analysis can be correlated with the degree of left ventricular hypertrophy, a major determinant of diastolic dysfunction. When there is concurrent venous congestion due to the delay in cardiac filling during diastole combined with the occurrence of decompensation, the O-wave pattern may also have an elevated peak. This combination of factors provides a general CVG waveform pattern characterized by an overall substantial and prolonged O-wave with a large area under the curve. This type of O-wave may be indicative of decompensated diastolic heart failure. Normal values for the O-wave and IVRT, as previously discussed, can be used for determination of aberrancy.
[0052] As illustrated in the flowchart depicted in FIG. 8 , one method for using CVG criterion for the diagnosis of heart failure in accordance with the present invention includes: inputting an ICG signal 30 ; inputting an ECG signal 32 ; compiling an R-wave triggered ensemble average based on ECG and ICG signals 33 ; producing a CVG waveform; identifying the C, or systolic, wave 34 ; identifying the O, or diastolic, wave 35 ; measuring C-wave attributes 36 ; measuring other supporting parameters 37 ; measuring O-wave attributes 38 ; inputting knowledge base for heart failure classification 39 ; cross-referencing C-wave and O-wave attributes and other supporting parameters with knowledge base 40 ; suggesting the likelihood of systolic heart failure 42 ; and suggesting the likelihood of diastolic heart failure 44 . Those skilled in the art can appreciate that cross-referencing of the measured attributes with the knowledge base can be accomplished by Bayesian probability statistics, fuzzy logic, or other advanced mathematical techniques. While FIG. 8 shows the use of an R-wave triggered ensemble average, those skilled in the art can appreciate that other waveform averaging techniques, non-averaged waveforms and/or various compilations of waveforms and/or multi-beat sequences of waveforms can be used in accordance with the present invention. The term knowledge base as used herein is defined as a database, a computer program, any type of data readable by an electronic medium, any data (whether or not alpha-numeric) that can be indexed and stored in an electronic medium, data stored in hard copy that can be accessed by or entered into the system of the present invention by users, and the like.
[0053] In the flowchart depicted in FIG. 8 , the C-wave attributes and O-wave attributes that could be measured in steps 36 and 38 include, but are not limited to, amplitude, duration, upward slope, downward slope, shape, depth, area, tone and presence of additional peaks. Other supporting parameters that could be measured in step 37 include, but are not limited to, thoracic fluid content (TFC), heart rate (HR), pre-ejection period (PEP), left ventricular ejection time (LVET), systolic time ratio, isovolumic relaxation time (IVRT), stroke volume (SV), stroke volume index, cardiac output (CO), cardiac index, blood pressure, Heather Index (HI), rate pressure product, ejection fraction, end diastolic volume, pulmonary artery occlusion pressure, central venous pressure and systemic vascular resistance (SVR). FIG. 8 depicts the use of PCG signals and other supporting parameters to confirm heart valve activity in the CVG waveform for illustrative purposes only. Those skilled in the art can appreciate that PCG signals and/or other supporting parameters could be used alone or in combination to confirm heart valve activity in CVG waveforms.
[0054] In step 40 , waveform attributes and other supporting parameters are cross-referenced against a knowledge base containing known attributes of heart failure classifications. Cross-reference logic for identifying likelihood of systolic heart failure and diastolic heart failure, including assessing C-wave parameters, O-wave parameters, and supporting parameters, is included in processing device 18 . In one embodiment, the logic could also be used to assess cross-factors. One exemplary cross-factor is the ratio of the O-wave height to C-wave height. Those skilled in the art can appreciate that cross-referencing of the measured attributes with the knowledge base can be accomplished by Bayesian probability statistics, fuzzy logic, or other advanced mathematical techniques.
[0055] In one embodiment, the suggestion of the likelihood of systolic heart failure in step 42 or diastolic heart failure in step 44 could be presented with confidence information in a numeric, graphical, bar presentation, or other format. In another embodiment, the suggestion of the likelihood of systolic heart failure in step 42 or diastolic heart failure in step 44 could be associated with the likelihood or coincidence of waveform attributes being associated with a standardized heart failure classification system such as the New York Heart Association (NYHA) classification system.
[0056] Referring now to FIG. 9 , processing device 18 illustrates typical components of a processing device. Processing device 18 includes a local memory 46 , a secondary storage device 54 , a processor 56 , a user interface device 60 and an output device 58 . Local memory 46 may include random access memory (RAM) or similar types of memory, and it may store one or more applications 48 , including system software 50 , and a web server 52 , for execution by processor 56 . Local memory 46 is generally located in individual pieces of equipment used to monitor cardiac performance of patients. Secondary storage device 54 may include a hard disk drive, floppy disk drive, CD-ROM drive, or other types of non-volatile data storage. The local cache that includes a patient's CVG data may be stored on secondary storage device 54 . Processor 56 may execute system software 50 and other applications 48 stored in local memory 46 or secondary storage 54 . Processor 56 may execute system software 50 in order to provide the functions described in this specification including, but not limited to, measuring, reporting, displaying and comparing cardiovasculograms. User interface device 60 may include any device for entering information into processing device 18 , such as a keyboard, mouse, cursor-control device, touch-screen, infrared, microphone, digital camera, video recorder, or any other instrument or device necessary to measure, report, display and compare cardiovasculograms. Output device 58 may include any type of device for presenting a hard copy of information, such as a printer, and other types of output devices including speakers or any device for providing information in audio form.
[0057] Web server 52 is used to provide access to patient data stored in memory 46 and on secondary storage devices 54 and display the data. Web server 52 allows users secure remote access to the system through which they can monitor the status of a patient's CVG data and access patient data. Web server 52 can allow access to a user running a web browser. Any web browser, co-browser, or other application capable of retrieving content from a network and displaying pages or screens may be used.
[0058] Examples of processing devices 18 for interacting within the impedance cardiography system include embedded microprocessors, digital signal processors, personal computers, laptop computers, notebook computers, palm top computers, network computers, Internet appliances, or any processor-controlled device capable of storing data, system software 50 and any other type of application 48 stored in local memory 46 or accessible via secondary storage device 54 .
[0059] Local memory 46 can further include an application for using the knowledge base for heart failure classification in step 39 of FIG. 8 . This application is used to provide automated recognition of hemodynamic parameters and waveform attributes. One method includes saving waveforms and hemodynamic parameters in local memory 46 to be used in the aforementioned methods as depicted in FIGS. 5-7 and as templates for future comparison and identification of associated disease states. For example, a patient having CVG waveform 62 as depicted in FIG. 6 was diagnosed by an experienced healthcare professional as having systolic heart failure. A patient having CVG waveform 64 as depicted in FIG. 11 was diagnosed by an experienced healthcare professional as having diastolic heart failure. These waveforms 62 and 64 are stored as waveform and hemodynamic data in local memory 46 . The method illustrated in FIG. 12 can incorporate the stored waveforms and hemodynamic data depicted in FIGS. 10 and 11 and includes: measuring CVG waveform and hemodynamic parameters of a new patient 66 ; providing access to a knowledge base of waveform attributes and hemodynamic parameter data stored in local memory 68 ; automatically correlating the new patient CVG waveform attributes and hemodynamic parameters to at least one record stored in local memory 70 ; and guiding a goal directed therapy for a possible disease based on this correlation 72 .
[0060] While FIG. 8 depicts the application for using the knowledge base for heart failure classification included in processing device 18 , those skilled in the art can appreciate that processing device 18 and knowledge base can be two or more separate systems that communicate with one another via known communication techniques, including but not limited to modem connections, wireless connections, optical connections and the like.
[0061] In another embodiment, certain waveform attributes may be learned from waveforms associated with disease states, where combinations of these attributes are used to form a template for that disease state. In yet another embodiment, analysis and diagnoses for various disease states as determined by experienced healthcare professionals can be correlated with saved waveforms attributes and hemodynamic parameters. For example, as shown in FIG. 13 , an experienced healthcare professional can input specific information 74 about waveform 62 (also shown without information in FIG. 10 ) correlated with systolic heart failure. In addition, as shown in FIG. 14 , an experienced healthcare professional can input specific information 76 about waveform 64 (also shown without information in FIG. 11 ) correlated with diastolic heart failure. These waveforms and hemodynamic data along with additional information can be stored in local memory 46 . When a new waveform is generated, it can be compared to the information stored in local memory 46 and healthcare professionals can utilize all of the information, as well as the waveforms and hemodynamic data, to diagnose a possible disease. In this manner, less experienced healthcare professionals get the benefit of experienced healthcare professionals in recognizing and diagnosing a possible disease based on waveform attributes, hemodynamic parameters and/or other information. In addition, recognition and diagnosis of a possible disease can occur quicker based on past diagnoses. The method can optionally further provide healthcare professionals with assistance in achieving a goal directed therapy.
[0062] While the waveforms depicted in FIGS. 10 , 11 , 13 and 14 are CVG waveforms, those skilled in the art can recognize that this method may be used on any type of waveform. Those skilled in the art can also recognize that this method may be used with CVGs that correlate ICG signals with any signals derived from heart valve activity, hemodynamic events and any other combination thereof.
[0063] While the invention has been described with reference to the specific embodiments thereof, those skilled in the art will be able to make various modifications to the described embodiments of the invention without departing from the true spirit and scope of the invention. The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that these and other variations are possible within the spirit and scope of the invention as defined in the following claims and their equivalents. | A cardiography system and method using automated recognition of hemodynamic parameters and waveform attributes is provided. The cardiography system and method includes at least one sensor, a knowledge base and a processing device. The at least one sensor provides a waveform signal and a hemodynamic parameter input. The knowledge base includes data corresponding to various disease states. The processing device receives the waveform signal and hemodynamic parameter input from the sensor, identifies waveform attributes on the waveform signal, measures the waveform attributes, accesses the knowledge base, cross-references the waveform attributes and the hemodynamic parameters with data in the knowledge base, and outputs a suggested likelihood of a particular disease state. The knowledge base optionally includes goal-directed therapies associated with particular disease states for providing suggested goal-directed therapies based on the cross-referencing of the waveform attributes and the hemodynamic parameters with the knowledge base. | 0 |
[0001] This invention relates to a flat, distortion-free, zero-shrink, low-temperature co-fired ceramic (LTCC) bodies, composites, modules or packages from precursor green (unfired) laminates of three or more different dielectric tape chemistries that are configured in an uniquely or pseudo-symmetrical arrangement in the z-axis of the laminate.
BACKGROUND OF THE INVENTION
[0002] An interconnect circuit board or package is the physical realization of electronic circuits or subsystems from a number of extremely small circuit elements electrically and mechanically interconnected. It is frequently desirable to combine these diverse type electronic components in an arrangement so that they can be physically isolated and mounted adjacent to one another in a single compact package and electrically connected to each other and/or to common connections extending from the package.
[0003] Complex electronic circuits generally require that the circuit be constructed of several levels of conductors separated by corresponding insulating dielectric tape layers. The conductor layers are interconnected through the dielectric layers that separate them by electrically conductive pathways, called via fills.
[0004] In all subsequent discussion it is understood that the use of the term tape layer or dielectric layer implies the presence of metallizations both surface conductor and interconnecting via fills which are cofired with the ceramic tape. In a like manner the term laminate or composite implies a collection of metallized tape layers that have been pressed together to form a single entity.
[0005] The use of a ceramic-based green tape to make low temperature co-fired ceramic (LTCC) multilayer circuits was disclosed in U.S. Pat. No. 4,654,095 to Steinberg. The co-fired, free sintering process offered many advantages over previous technologies. However, when larger circuits were needed, the variation of firing shrinkage along the planar or x,y direction proved too broad to meet the needs. Given the reduced sizes of the current generation of surface mount components, the shrinkage tolerance (reproducibility of x,y shrinkage) has proved too great to permit the useful manufacture of LTCC laminates much larger than 6″ by 6″. This upper limit continues to be challenged today by the need for greater circuit density as each generation of new circuits and packages evolves. In turn this translates into ever-smaller component sizes and thereby into smaller geometry's including narrower conductor lines and spaces and smaller vias on finer pitches in the tape. All of this requires a much lower shrinkage tolerance than could be provided practically by the free sintering of LTCC laminates.
[0006] A method for reducing X-Y shrinkage during firing of green ceramic bodies in which a release layer, which becomes porous during firing, is placed upon the ceramic body and the assemblage is fired while maintaining pressure on the assemblage normal to the body surface was disclosed in U.S. Pat. No. 5,085,720 to Mikeska. This method used to make LTCC multilayer circuits provided a significant advantage over Steinberg, as a reduction X-Y shrinkage was obtained through the pressure assisted method.
[0007] An improved co-fired LTCC process was developed and is disclosed in U.S. Pat. No. 5,254,191 to Mikeska. This process, referred to as PLAS, an acronym for pressure-less assisted sintering, placed a ceramic-based release tape layer on the two major external surfaces of a green LTCC laminate. The release tape controls shrinkage during the firing process. Since it allows the fired dimension of circuit features to be more predictable the process represents a great improvement in the fired shrinkage tolerance.
[0008] A slight modification of the art proposed by Mikeska is presented in U.S. Pat. No. 6,139,666 by Fasano et al. where the edges of a multilayer ceramic are chamfered with a specific angle to correct edge distortion, due to imperfect shrinkage control exerted by externally applied release tape during firing.
[0009] Shepherd proposed another process for control of registration in an LTCC structure in U.S. Pat. No. 6,205,032. The process fires a core portion of a LTCC circuit incurring normal shrinkage and shrinkage variation of an unconstrained circuit. Subsequent layers are made to match the features of the pre-fired core, which then is used to constrain the sintering of the green layers laminated to the rigid pre-fired core. The planar shrinkage is controlled to the extent of 0.8-1.2% but is never reduced to zero. For this reason, the technique is limited to a few layers, before registration becomes unacceptable.
[0010] During the release tape-based constrained sintering process, the release tape acts to pin and restrain any possible shrinkage in x- and y-directions. The release tape itself does not sinter to any appreciable degree and is removed prior to any subsequent circuit manufacturing operation. Removal is achieved by one of a number of suitable procedures such as brushing, sand blasting or bead blasting. The use of the sacrificial constraining tape or release tape means that the user must purchase a tape material that does not reside in the final product. Furthermore, the top and bottom conductors cannot be co-processed with the laminate. These necessary steps may only be carried as part of a post-fired strategy after firing and removal of the release tape.
[0011] In a more recent invention, U.S. patent application 60/385,697 the teachings of constrained sintering are extended to include the use of a non-fugitive, non-removable, non-sacrificial or non-release, internal self-constraining tape. The fired laminate comprises layers of a primary dielectric tape which define the bulk properties of the final ceramic body and one or more layers of a secondary or self-constraining tape. The purpose of the latter is to constrain the sintering of the primary tape so that the net shrinkage in the x, y direction is zero. This process is referred to as a self-constraining pressure-less assisted sintering process and the acronym SCPLAS is applied. The self-constraining tape is placed in strategic locations within the structure and remains part of the structure after co-firing is completed. There is no restriction on the placement of the self-constraining tape other than that z-axis symmetry is preserved.
[0012] FIG. 1 , which contains some generic dielectric tape arrangements, is used to illustrate the definition of z-axis symmetry as noted in U.S. Patent Application 60/385,697. In this embodiment, only one type of self-constraining (SC) tape ( 101 ) is used with a primary tape ( 100 ). The criterion is that the distribution of the two tape materials ( 100 , 101 ) is balanced in terms of thickness and position around the centerline ( 103 ) of the structure. The consequence of not preserving z-axis symmetry is a severely bowed or cambered circuit.
[0013] This invention described in U.S. patent application 60/385,697 represents an alternative to release tape-based constrained sintering. However, it is not obvious as to how one can apply this to the practical manufacture of ceramic structures with asymmetric arrangements of metallized tape layers comprising two different dielectric chemistries.
[0014] The introduction of dielectric layers with a higher dielectric constant (k) than the bulk dielectric material can produce localized enhanced capacitor capability when suitably terminated with a conductor material. This is commonly referred to as a buried passive structure and is a robust and cost-effective alternative to the use of standard, externally applied, surface mount components such as multilayer capacitors (MLC). In U.S. Pat. No. 5,144,526 awarded to Vu and Shih, LTCC structures are described whereby high dielectric constant materials are interleaved with layers of low dielectric constant material in a symmetrical arrangement.
[0015] In practical terms the need for symmetry limits the freedom of a designer to layout a circuit in its most optimal form. This, in turn, has some unfavorable consequences relative to the performance, the form factor and the overall cost of the circuit. An ability to obviate this problem represents a significant competitive advantage to the continued growth of ceramic circuit packages. The only solution currently available, namely, to balance the asymmetrical and functional part of the structure with dummy, non functioning compensating layers (see FIG. 2 ) does not alleviate all of the disadvantages described above.
[0016] FIG. 3 shows some examples of some simple asymmetric arrangements. Actual designs would be more complex. Nonetheless, regardless of the complexity factor, the most intractable problem associated with such arrangements is that the structure will bow or camber to an unacceptable degree after co-firing. Moreover it will be cambered to a degree that will render it unusable for subsequent processing such as assembly by pick and place of passive and active surface components. The conventional definition of unacceptable camber or bowing is greater than an 0.003 inch deflection of the center point of a substrate per one inch of substrate diagonal length, e.g. a total of 0.025 inches for a 6″×6″ co-fired substrate. Different operations have different requirements but the above definition meets the majority of applications. The extent of this disadvantage increases with substrate size. It can pass almost unnoticed for substrates less than 2″×2″ but becomes very marked as the standard substrate dimension is increased to 6″×6″.
[0017] The above problem is caused by differences in the physical and chemical properties of the two dielectric materials in contact with each other and exists with all known combinations of dielectric chemistries. It will occur regardless of the absence or presence of metallic conductors in the structure. It thus represents a significant limitation to the ongoing development of the technology as a whole.
[0018] In a more recent application, U.S. patent application Ser. No. 10/430,081, the teachings of constrained sintering is extended to the production of large area camber-free, co-fired LTCC structures that are derived from asymmetric arrangements of low dielectric constant primary tape and high k dielectric constant self-constraining tape materials, each of a different chemistry. It combines the use of both of internal, permanent, self-constraining tape and external, removable release constraining tape.
[0019] As already discussed the asymmetric structures as illustrated in FIG. 3 cannot be co-fired flat by conventional processing techniques. They will tend to bow or camber in a concave manner i.e. the two edges of the laminate will be significantly higher than the center-point in the direction perpendicular to the plane of maximum asymmetry.
[0020] In an embodiment of U.S. patent application Ser. No. 10/430,081, as shown in FIG. 4 , an internal constraining layer ( 101 ) is formulated to provide a self-constraining function and an embedded capacitor function within a LTCC assembly. The properties of the processed internal constraining layer provide a rigid physical form restraining x and y shrinkage of primary tapes ( 100 ) and impart functional properties to the final LTCC assembly. The internal constraining tape precedes the sintering of the primary tape layers. To prevent bowing and permanent structural distortion after co-firing because of the difference in dielectric chemistries without the need to symmetrically balance it with dummy or compensating layers, a layer of removable, non permanent release layer ( 201 ) is applied to the outside surface directly opposite the source of greatest asymmetry. This enables extremely asymmetric structures to be fired flat. After firing, the release layer is removed using conventional brushing or sand blasting methods.
[0021] However, the necessary inclusion of a release layer ( 201 ) and its removal after firing still adds cost in material, equipment, and process. Meanwhile, the bottom conductor in contact with the release layer cannot be co-processed with the laminate. This necessary step may only be carried as part of a post-fired strategy after firing and removal of the release tape.
[0022] The current invention represents an innovative approach and innovative novel compositions and examples to produce a structure exhibiting an interactive suppression of x,y shrinkage without the use of a sacrificial dielectric release tape at one side of the laminate as specified in U.S. patent application Ser. No. 10/430,081.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIGS. 1 a - 1 b are an illustration of generic dielectric tape arrangements used to illustrate the definition of z-axis symmetry, these are related to U.S. patent application 60/385,697.
[0024] FIGS. 2 a - 2 c are an illustration of the addition of prior art non-functional material necessary to render the LTCC structure symmetrical and co-fireable without any bowing or cambering. The equal sign means that the function of the severely cambered assemblage 2 A can only be provided by a camber-free assemblage after adding 2 C to the 2 B laminate before firing.
[0025] FIGS. 3 a - 3 d are an illustration of prior art asymmetrical structures where tapes of two different chemistries are present and all will display severe camber after co-firing.
[0026] FIGS. 4 a - 4 b are an illustration of asymmetrical structures of the previous invention, U.S. patent application Ser. No. 10/430,081.
[0027] FIGS. 5 a - 5 d are an illustration of pseudo-symmetrically configured mixed k dielectric layers within a third and primary low k, low temperature cofired ceramic matrix of the current invention. Tapes 501 and 502 represent internal constraining tapes of the same or different k value whereas tape 100 represents the primary tape component and 103 is the centerline of the structure.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The current invention further extends the concept of making asymmetrical configured LTCC dielectric multilayer circuits to include at least two internal constraining tapes having the same or different k values, without the use of sacrificial release tape at one side of the multilayer laminate. In order to preserve the balance in sintering stress to produce a flat or camber-free substrate, it is necessary that (1) each internal constraining tape ( 501 or 502 ) can independently provide a zero-shrink SCPLAS system with the primary tape ( 100 ), and (2) The internal constraining tapes are arranged to preserve structural symmetry regarding the class of internal constraining tapes as an entity with respect to primary tape. Since the internal constraining tapes are generally of different composition and dielectric constant (k), the term of “pseudo-symmetry” is created. The above pseudo-symmetrical arrangement treats all of the self-constraining tapes as a class with respect to the primary tape, and the name “pseudo” reflects the differences among the self-constraining tapes involved.
[0029] While the structure of the LTCC multilayer circuit of the present invention may be asymmetrical around the centerline, there is still a requirement that the internal constraining tapes be arranged to preserve structural symmetry regarding the class of internal constraining tapes as an entity with respect to the primary tape. This means that when viewing the structure as two pieces, a top and bottom around the centerline, the level of shrinkage associated with each piece independently should be the same (or about the same) to ensure a uniform shrinkage with regard to the structure as a whole. Of course, the preferred level of shrinkage for the structure as a whole is zero-shrinkage, although any uniform level may be achieved for the structure as a whole, as long as each independent piece about the centerline may achieve the same shrinkage level independently.
[0030] There are several possible embodiments of the present invention subject to the above requirements for preservation of the balance in sintering stress as noted above. These embodiments include: (1) all internal constraining tapes and the primary tape have the same dielectric constant (k); (2) at least one internal constraining tape has the same dielectric constant (k) as the primary tape; and (3) at least one internal constraining tape is a low k tape and at least one internal constraining tape is a high k tape. This invention also applies to a primary tape of either low k or high k characteristic. In the case with a low k primary tape, the internal constraining tapes may have the same or higher k. In the case of a high k primary tape, the internal constraining tapes may have the same or lower k.
[0031] The differences in the dielectric tape chemistry result from differences in the types and compositions of the glass(es) and/or the filler(s) used to formulate the tapes and reflect in their corresponding dielectric constant (k) at any given frequency. For the purpose of clarification of this invention, a standard k is between 7 and 9. The typical primary tape is generally at a k value between 7 and 9, although this k value is not a necessary requirement of the primary tape. For purposes of this invention, a tape with a k value at or lower than 8 is considered a low k tape, whereas a tape with a k value greater than 8 is considered a high k tape. It is therefore apparent that the high k values can be multiples of tens, hundreds, or thousands as far as this invention is concerned. Furthermore, tapes having k values within 0-15% of one another are considered to have the same k.
[0032] In the case when one of the internal constraining tapes has the same k as the primary tape, a compositionally and electrically asymmetrical configuration is attained. It is noted that, due to the structural symmetry between internal constraining tapes and primary tape, the multilayer circuit can be fired flat and provide zero-shrink without the use of a sacrificial release tape as described in the prior art noted above.
[0033] FIGS. 5 a - 5 d illustrate various multilayer arrangements of internal constraining tapes and primary tape according to this invention. It is noted that the present invention can be applied but not limited to these examples. internal constraining tapes 501 and 502 form the central core in 5 a . internal constraining tape 501 or 502 serves as the constraining layer in the upper or lower portion of structure in 5 b . Either internal constraining tape 501 or 502 by itself can form the core as in 5 c , which is the simplest configuration of this invention and represents a typical SCPLAS concept previously filed for patent. FIG. 5 d illustrates an expanded version of 5 b to include flexibility in tape thickness and layer count variation.
[0000] Internal Self-Constraining Tape(s)
[0034] The internal constraining tape ( 501 , 502 ) as utilized in the present invention contains glasses that flow, densify, and become rigid at temperatures significantly below 850° C., which is a standard process temperature. Because the constraining tape becomes part of the final LTCC body it significantly increases the performance requirements for the constraining tape material. The electrical properties (e.g., dielectric constant k) of the constraining tape may also be adjusted with a choice of materials that make up the tape. This makes possible the use of more than one chemical type of primary tape to locally control the dielectric and other electrical properties of a portion of a LTCC circuit.
[0000] Primary Tape
[0035] The primary tape ( 100 ) is generally the majority tape in a LTCC assembly and the resultant fired assembly derives its mechanical and electrical characteristics from it. In most situations the constraining tape has a minority presence in the structure. It can be used effectively to locally modify aspects of the dielectric and other electrical performance of the assembly, but its biggest influence is to control the physical structure by constraining its x,y shrinkage substantially to zero.
[0000] LTCC Structure
[0036] During the heating of the assembly of the present invention, the glass in the constraining tapes (low or high k, respectively for 501 or 502 ) attains its transition temperature (the temperature at which the glass initiates sintering, followed by flow and densification) earlier than the glass of the primary tape (low k) and it flows sufficiently to coat the surface particles of the adjacent layers of the primary tape. Since the crystallization temperature of the constraining tape glass is both close to and above its transition temperature, crystallization occurs very soon thereafter. This has the result of stiffening the glass and significantly raising its composite viscosity or elevating its re-melting temperature beyond the peak firing temperature of 825 to 875° C. of the first co-firing and/or subsequent post-firing process.
[0037] The constraining influence of the primary tape ensures that x,y shrinkage in the constraining tape is very small, if not zero. Subsequent increases in temperature cause the constraining tape to sinter fully and its glass to complete its crystallization. Since a suitable glass will, typically, develop in excess of 50 volume % crystalline phases, the constraining tape body becomes rigid when dominated by the volumetric accumulation of crystalline content of filler and in site formation of crystal from the glass. Then, when the transition temperature of the primary tape glass is achieved and flow occurs, it is kept physically in place by its previous interaction with the constraining tapes. Thus, the already-sintered constraining tape layers become the constraining force and the primary tape is constrained while sintering to shrink only in the z-direction. Once the assembly is fully sintered and has cooled down, the assembly will be seen to possess the same dimensions in the x,y direction as the original “green” or unfired assembly. The layers of the now chemically-reacted inorganic components of the two or more individual tapes used in the assembly are interleaved in various configurations. The only still observable boundaries being those where tapes of different chemistries were placed adjacent to each other and where the various inner circuit features reside. The above discussion is applicable to configurations presented in FIGS. 5 b and 5 d.
[0038] In the special case of 5 a , the two different internal constraining tapes, 501 and 502 , are in direct contact. This type of structure requires sufficient interfacial bonding between the internal constraining tapes without significant inter-diffusion of glass from either or both tapes during the firing process. As in all of the cases, the primary tape ( 100 ) serves as the constraining force for both internal constraining tapes ( 501 , 502 ) in the lower temperature range; and the sintered and crystalline, rigid internal constraining layers serve as the constraining force for the primary tape in the higher temperature range.
[0039] Such an innovation offers the advantages of facilitating cofireable top and bottom conductors, relieves the practical restrictions that externally-constrained sintered structures experience as the layer count is increased and the constraining influence of the external release tape is felt less and less. Furthermore, there is no need to remove the sacrificial constraining tape by mechanical and/or chemical means. This represents a saving of material and equipment expenditure and labor, and also possible environmental contamination. In addition, the use of the constraining tape allows the formation of exactly dimensioned, non-shrink cavities in a tape structure. Both blind and through cavities can be produced by this constrained sintering technique.
[0040] In order to meet the performance requirements of LTCC circuit manufacturers, additional material performance factors must be considered beyond the simple process of constraining the x,y shrinkage in the green tape assembly when thermally processed. The coefficient of thermal expansion of the constraining tapes and the primary tape must be sufficiently close in magnitude to provide for the production of 6″×6″ or larger ceramic boards consisting of many layers of laminated green tape materials. Inattention to this could result in stress induced cracking in the fired ceramic LTCC body during the temperature descending portion of the furnace firing or thereafter.
[0041] Another design factor is created because the constraining tapes must be thermally processed to a rigid body prior to the primary tape to provide proper system x,y constraint. This means that the glass-filler material in the constraining tapes should be designed to attain a lower composite viscosity to the primary tape, but at approximately 50-150° C. lower in temperature and preferably in the range of 80-150° C. It should be noted that the above assessment was based on a belt furnace firing profile at an ascending rate of 6-8° C. per minute between 450° C. and −850° C. Such a profile is commonly used to achieve high throughput in mass production of LTCC circuit substrates. However, a smaller temperature difference (e.g. <50° C.) can also be effective if the firing profile in a multiple zone belt or box furnace provides a plateau to facilitate the full densification, and/or crystallization, and revivification of the constraining tapes. It should also provide sufficient compatibility between constraining and primary tapes during the densification to maintain the strength and bonding at the respective tape interfaces. This compatibility can be influenced by tape formulation, physical characteristics of the constituents and changes in thermal processing conditions. The electrical properties of the constraining tape materials must also meet performance requirements for high frequency circuit applications.
[0000] Components of Internal Constraining and Primary Tapes
[0042] Internal constraining and primary tape components and formulations are discussed below. The internal constraining tapes (501, 502) are further characterized as composed of a filler ceramic material such as Al 2 O 3 , TiO 2 , ZrO 2 , ZrSiO 4 , BaTiO 3 , etc., with a crystallizable or filler reactable glass composition so that its flow, densification and rigidification during firing proceed the remaining layers of primary tape. Although a constraining or primary tape normally may consist of a glass and filler, it may be designed by skilled artisans to utilize more than one glass or more than one filler. The physical act of restricting the x,y shrinkage of the constraining tapes by the primary tape during thermal processing is quite similar to the externally applied release layers of a conventional primary tape assembly. It is to be noted, however, that although the terms of “primary tape” and “constraining tape” are used in this invention, the “primary tape” constrains the “constraining tape” during its lower temperature sintering/crystallization process; whereas the already sintered “constraining tape” constrains the “primary tape” during its higher temperature firing. The requirements for suitable materials to serve as a non-sacrificed constraining tape are however different. The material requirements are considered below.
[0043] Specific examples of glasses that may be used in the primary or constraining tape are listed in Tables 1 and 1a. Preferred glass compositions found in the high k constraining tape comprise the following oxide constituents in the compositional range of: B 2 O 3 6-13, BaO 20-22, Li 2 O 0.5-1.5, P 2 O 5 3.5-4.5, TiO 2 25-33, Cs 2 O 1-6.5, Nd 2 O 3 29-32 in weight %. The more preferred composition of glass being: B 2 O 3 11.84, BaO 21.12, Li 2 O 1.31, P 2 O 5 4.14, TiO 2 25.44, Cs 2 O 6.16, Nd 2 O 3 29.99 in weight % shown in Table 1a as composition #3. An example of additional primary tape is shown in #2 Table 1a. Preferred glasses for use in the primary tape comprise the following oxide constituents in the compositional range of: SiO 2 52-55, Al 2 O 3 12.5-14.5, B 2 O 3 8-9, CaO 16-18, MgO 0.5-5, Na 2 O 1.7-2.5, Li 2 O 0.2-0.3, SrO 04, K 2 O 1-2 in weight %. The more preferred composition of glass being: SiO 2 54.50, Al 2 O 3 12.72, B 2 O 3 8.32, CaO 16.63, MgO 0.98 Na 2 O 2.20, Li 2 O 0.24, SrO 2.94, K 2 O 1.47 in weight %. Composition #1 Table 1a is repeated here for a formulation example and is the same as listed previously in Table 1 #15.
[0044] Example glasses for use in the low k constraining tapes comprise the following oxide constituents in the compositional range of: Glasses #4-#7 Table 1 are examples of glasses that have a suitably low dielectric constant while serving suitably as a constraining glass in an LTCC tape structure. Composition #4 Table 1a contains Cs 2 O and ZrO 2 whereas #5-#7 contain K 2 O without ZrO 2 . This illustrates the ability to functionally replace the function of Cs 2 O by K 2 O. Since ZrO 2 is known to raise glass viscosity, a smaller content of K 2 O is sufficient when ZrO 2 is not present. The dielectric constant of the tapes composed of these glasses and 33.9 volume % alumina filler having a D50 PSD of 2.5 micron is about 8. Preferred glasses for use as a low k constraining tape comprise the following oxide constituents in the compositional range of SiO 2 7-9, ZrO 2 0-3, B 2 O 3 11-14, BaO 7-23, MgO 3-9, La 2 O 3 14-28, Li 2 O 0.5-2, P 2 O 5 2-6, K 2 O 0.5-3, Cs 2 O 0-7, Nd 2 O 3 28-34 in weight %. The more preferred composition of glass being: SiO 2 8.22, B 2 O 3 12.93, BaO 11.99, MgO 8.14, La 2 O 3 16.98, Li 2 O 1.46, P 2 O 5 5.55, K 2 O 1.84, Nd 2 O 3 32.89 in weight %.
[0045] In order to match the dielectric constant (k) in one of the constraining tape to that of the primary tape, the design of glass varies significantly from that in the high k constraining tape. It is well known that the choice of inorganic filler(s) in the constraining tape compositions also affect their resultant k; hence the tape compositions represent an overall property balance in order to provide zero-shrink, material compatibility, and desirable electrical performance such as k and loss tangent for high frequency applications. Several suitable fillers that maybe used to adjust lower the composite dielectric constant of a suitable LTCC tape composition include cordierite, forsterite, steatite, amorphous silica, aluminum phosphate (AlPO4), (CGW) Vycor glass or other crystalline or amorphous lower k ceramic materials.
[0046] In the primary or constraining tape the D 50 (median particle size) of frit is preferably in the range of, but not limited to, 0.1 to 5.0 microns and more preferably 0.3 to 3.0 microns. As the constraining tapes must undergo simultaneous densification and crystallization, their averaged glass particle size and particle size distribution are most critical for the attainment of desirable microstructure within the temperature range above the organic burnout (pyrolysis) and the softening point of the glass in the primary tape,
[0047] The glasses described herein are produced by conventional glass making techniques. The glasses were prepared in 500-1000 gram quantities. Typically, the ingredients are weighed then mixed in the desired proportions and heated in a bottom-loading furnace to form a melt in platinum alloy crucibles. As well known in the art, heating is conducted to a peak temperature (1450-1600° C.) and for a time such that the melt becomes entirely liquid and homogeneous. The glass melts were then quenched by counter rotating stainless steel roller to form a 10-20 mil thick platelet of glass. The resulting glass platelet was then milled to form a powder with its 50% volume distribution set between 1-5 microns. The glass powders were then formulated with filler and organic medium to cast tapes as detailed in the Examples section. The glass compositions shown in Table 1 represent a broad variety of glass chemistry (high amounts of glass former to low amounts of glass former). The glass former oxides are typically small size ions with high chemical coordination numbers such as SiO 2 , B 2 O 3 , and P 2 O 5 . The remaining oxides represented in the table are considered glass modifiers and intermediates.
[0048] Ceramic filler such as Al 2 O 3 , ZrO 2 , TiO 2 , ZrSiO 4 , BaTiO 3 or mixtures thereof may be added to the castable composition used to form the tapes in an amount of 0-50 wt. % based on solids. Depending on the type of filler, different crystalline phases are expected to form after firing. The filler can control dielectric constant and loss over the frequency range. For example, the addition of BaTiO 3 can increase the dielectric constant significantly.
[0049] Al 2 O 3 is the preferred ceramic filler since it reacts with the glass to form an Al-containing crystalline phase. Al 2 O 3 is very effective in providing high mechanical strength and inertness against detrimental chemical reactions. Another function of the ceramic filler is rheological control of the entire system during firing. The ceramic particles limit flow of the glass by acting as a physical barrier. They also inhibit sintering of the glass and thus facilitate better burnout of the organics. Other fillers, α-quartz, CaZrO 3 , mullite, cordierite, forsterite, zircon, zirconia, BaTiO 3 , CaTiO 3 , MgTiO 3 , SiO 2 , amorphous silica or mixtures thereof may be used to modify tape performance and characteristics. It is preferred that the filler has at least a bimodal particle size distribution with D50 of the larger size filler in the range of 1.5 and 3 microns and the D50 of the smaller size filler in the range of 0.3 and 0.8 microns.
[0050] In the formulation of constraining and primary tape compositions, the amount of glass relative to the amount of ceramic material is important. A filler range of 20-40% by weight is considered desirable in that the sufficient densification is achieved. If the filler concentration exceeds 50% by wt., the fired structure is not sufficiently densified and is too porous. Within the desirable glass/filler ratio, it will be apparent that, during firing, the liquid glass phase will become saturated with filler material.
[0051] For the purpose of obtaining higher densification of the composition upon firing, it is important that the inorganic solids have small particle sizes. In particular, substantially all of the particles should not exceed 15 μm and preferably not exceed 10 μm. Subject to these maximum size limitations, it is preferred that at least 50% of the particles, both glass and ceramic filler, be greater than 1 μm and less than 6 μm.
[0052] The organic medium in which the glass and ceramic inorganic solids are dispersed is comprised of a polymeric binder which is dissolved in a volatile organic solvent and, optionally, other dissolved materials such as plasticizers, release agents, dispersing agents, stripping agents, antifoaming agents, stabilizing agents and wetting agents.
[0053] To obtain better binding efficiency, it is preferred to use at least 5% wt. polymer binder for 90% wt. solids, which includes glass and ceramic filler, based on total composition. However, it is more preferred to use no more than 30% wt. polymer binder and other low volatility modifiers such as plasticizer and a minimum of 70% inorganic solids. Within these limits, it is desirable to use the least possible amount of polymer binder and other low volatility organic modifiers, in order to reduce the amount of organics which must be removed by pyrolysis, and to obtain better particle packing which facilitates full densification upon firing.
[0054] In the past, various polymeric materials have been employed as the binder for green tapes, e.g., poly(vinyl butyral), poly(vinyl acetate), poly(vinyl alcohol), cellulosic polymers such as methyl cellulose, ethyl cellulose, hydroxyethyl cellulose, methylhydroxyethyl cellulose, atactic polypropylene, polyethylene, silicon polymers such as poly(methyl siloxane), poly(methylphenyl siloxane), polystyrene, butadiene/styrene copolymer, polystyrene, poly(vinyl pyrollidone), polyamides, high molecular weight polyethers, copolymers of ethylene oxide and propylene oxide, polyacrylamides, and various acrylic polymers such as sodium polyacrylate, poly(lower alkyl acrylates), poly(lower alkyl methacrylates) and various copolymers and multipolymers of lower alkyl acrylates and methacrylates. Copolymers of ethyl methacrylate and methyl acrylate and terpolymers of ethyl acrylate, methyl methacrylate and methacrylic acid have been previously used as binders for slip casting materials.
[0055] U.S. Pat. No. 4,536,535 to Usala, issued Aug. 20, 1985, has disclosed an organic binder which is a mixture of compatible multipolymers of 0-100% wt. C 1-8 alkyl methacrylate, 100-0% wt. C 1-8 alkyl acrylate and 0-5% wt. ethylenically unsaturated carboxylic acid of amine. Because the above polymers can be used in minimum quantity with a maximum quantity of dielectric solids, they are preferably selected to produce the dielectric compositions of this invention. For this reason, the disclosure of the above-referred Usala application is incorporated by reference herein.
[0056] Frequently, the polymeric binder will also contain a small amount, relative to the binder polymer, of a plasticizer that serves to lower the glass transition temperature (Tg) of the binder polymer. The choice of plasticizers, of course, is determined primarily by the polymer that needs to be modified. Among the plasticizers which have been used in various binder systems are diethyl phthalate, dibutyl phthalate, dioctyl phthalate, butyl benzyl phthalate, alkyl phosphates, polyalkylene glycols, glycerol, poly(ethylene oxides), hydroxyethylated alkyl phenol, dialkyldithiophosphonate and poly(isobutylene). Of these, butyl benzyl phthalate is most frequently used in acrylic polymer systems because it can be used effectively in relatively small concentrations.
[0057] The solvent component of the casting solution is chosen so as to obtain complete dissolution of the polymer and sufficiently high volatility to enable the solvent to be evaporated from the dispersion by the application of relatively low levels of heat at atmospheric pressure. In addition, the solvent must boil well below the boiling point or the decomposition temperature of any other additives contained in the organic medium. Thus, solvents having atmospheric boiling points below 150° C. are used most frequently. Such solvents include acetone, xylene, methanol, ethanol, isopropanol, methyl ethyl ketone, ethyl acetate, 1,1,1-trichloroethane, tetrachloroethylene, amyl acetate, 2,2,4-triethyl pentanediol-1,3-monoisobutyrate, toluene, methylene chloride and fluorocarbons. Individual solvents mentioned above may not completely dissolve the binder polymers. Yet, when blended with other solvent(s), they function satisfactorily. This is well within the skill of those in the art. A particularly preferred solvent is ethyl acetate since it avoids the use of environmentally hazardous chlorocarbons.
[0058] In addition to the solvent and polymer, a plasticizer is used to prevent tape cracking and provide wider latitude of as-coated tape handling ability such as blanking, printing, and lamination. A preferred plasticizer is BENZOFLEX® 400 manufactured by Rohm and Haas Co., which is a polypropylene glycol dibenzoate.
Application
[0059] A green tape for use as a constraining tape or a primary tape is formed by casting a thin layer of a slurry dispersion of the glass, ceramic filler, polymeric binder and solvent(s) as described above onto a flexible substrate, heating the cast layer to remove the volatile solvent. It is preferred that the primary tape not exceed 20 mils in thickness and preferably 1 to 10 mils. It is preferred that the constraining tapes be 1 to 10 mils and preferably 1 to 3 mils in thickness. The tape is then blanked into sheets or collected in a roll form. The green tape is typically used as a dielectric or insulating material for multilayer electronic circuits. A sheet of green tape is blanked with registration holes in each corner to a size somewhat larger than the actual dimensions of the circuit. To connect various layers of the multilayer circuit, via holes are formed in the green tape. This is typically done by mechanical punching. However, a sharply focused laser can be used to volatilize and form via holes in the green tape. Typical via hole sizes range from 0.004″ to 0.25″. The interconnections between layers are formed by filling them via holes with a thick film conductive ink. This ink is usually applied by standard screen printing techniques. Each layer of circuitry is completed by screen printing conductor tracks. Also, resistor inks or high dielectric constant inks can be printed on selected layer(s) to form resistive or capacitive circuit elements. Furthermore, specially formulated high dielectric constant green tapes similar to those used in the multilayer capacitor industry can be incorporated as part of the multilayer circuitry.
[0060] After each layer of the circuit is completed, the individual layers are collated and laminated. A confined uniaxial or isostatic pressing die is used to insure precise alignment between layers. The laminates are trimmed with a hot stage cutter. Firing is carried out in a standard thick film conveyor belt furnace or in a box furnace with a programmed heating cycle. This method will, also, allow top and/or bottom conductors to be co-fired as part of the constrained sintered structure without the need for using a conventional release tape as the top and bottom layer, and the removal, and cleaning of the release tape after firing.
[0061] As used herein, the term “firing” means heating the assemblage in an oxidizing atmosphere such as air to a temperature, and for a time sufficient to volatilize (burn-out) all of the organic material in the layers of the assemblage to sinter any glass, metal or dielectric material in the layers and thus densify the entire laminate.
[0062] It will be recognized by those skilled in the art that in each of the laminating steps the layers must be accurate in registration so that the vias are properly connected to the appropriate conductive path of the adjacent functional layer.
[0063] The term “functional layer” refers to the printed green tape, which has conductive, resistive or capacitive functionality. Thus, as indicated above, a typical green tape layer may have printed thereon one or more resistor circuits and/or capacitors as well as conductive circuits.
[0064] According to the defined configuration of the various laminates (see FIGS. 1 to 5 ), green tape sheets of various thickness were blanked with corner registration holes into sheets with x- and y-dimensions ranging from 3″×3″ to 8″×8″. These were then punched to form via holes and then metallized with suitable surface and via fill conductors using standard processing techniques well known to those skilled in the art.
[0065] The parts were then fired by heating in an oxidizing atmosphere such as air to a temperature, and for a time sufficient to volatilize (burn-out) all of the organic material in the layers of the assemblage to sinter any glass, metal or dielectric material in the layers. In this way the entire laminate was densified.
[0066] The parts were then evaluated for any shrinkage and substrate camber.
TABLE 1 ID SiO 2 Al 2 O 3 ZrO 2 B 2 O 3 CaO BaO MgO La 2 O 3 Na 2 O Li 2 O SrO P 2 O 5 TiO 2 K 2 O Cs 2 O Nd 2 O 3 1 53.50 13.00 8.50 17.00 1.00 2.25 0.25 3.00 1.50 2 54.50 12.72 8.32 16.63 0.98 2.20 0.24 2.94 1.47 3 11.84 21.12 1.31 4.14 25.44 6.16 29.99 4 8.77 2.45 11.81 7.32 3.06 27.63 1.02 4.01 5.40 28.53 5 7.63 12.63 22.26 5.36 15.76 1.26 2.58 1.99 30.52 6 8.24 13.19 12.02 8.16 17.02 1.46 5.10 1.85 32.96 7 8.22 12.93 11.99 8.14 16.98 1.46 5.55 1.84 32.89
EXAMPLES
[0067] Tape compositions used in the examples were prepared by ball milling the fine inorganic powders and binders in a volatile solvent or solvent blend. To optimize the lamination, the ability to pattern circuits, the tape burnout properties and the fired microstructure development, the following volume % formulation of slip was found to provide advantages. The formulation of typical slip compositions is also shown in weight percentage, as a practical reference. The inorganic phase is assumed to have a specific density of 4.5 g/cc for glass and 4.0 g/cc for alumina and the organic vehicle is assumed to have a specific density of 1.1 g/cc. The weight % composition changes accordingly when using glass and oxides other than alumina as the specific density maybe different than those assumed in this example.
Volume % Weight % Inorganic phase 42% typical range 74% typical range 37-47% practical 70-78% practical Organic phase 58% typical 26% typical 63-53% practical 30-22% practical
[0068] Since the tape is usually coated from slip, the composition for the slip must include sufficient solvent to lower the viscosity to less than 10,000 centipoise; typical viscosity ranges are 1,000 to 4,000 centipoise. An example of a slip composition is provided in Table 2. Depending on the chosen slip viscosity, higher viscosity slip prolongs the dispersion stability for a longer period of time (normally several weeks). A stable dispersion of tape constituents is usually preserved in the as-coated tape.
TABLE 2 Slip Composition Typical Practical Component Range Weight % Range Acrylate and methacrylate polymers 4-6 4-6 Phthalate type plasticizers 1-2 1-2 Ethyl acetate/methyl ethyl ketone mixed 19.7 18-22 solvent Glass powder 50.7 47-54 Alumina powder 23.2 20-27 Inorganic pigment 0.6 0-1
[0069] The glasses for the Examples found herein were all melted in Pt/Rh crucibles at 1450-1600° C. for about 1 hour in an electrically heated furnace. Glasses were quenched by metal roller as a preliminary step and then subjected to particle size reduction by milling. The powders prepared for these tests were adjusted to a 1-5 micron mean size by milling prior to formulation as a slip. Since additional milling is utilized in the fabrication of slip, the final mean size is normally in the range of 1-3 microns.
Example 1
[0070] Primary Tape Composition #1 (Glass #1, Table 1a) (4.5 mils Tape Thickness)
Glass: Filler: Al 2 O 3 (D50 = 2.8 micron) Glass content 66.1 vol % B 2 O 3 8.50 wt. % Filler content 33.9 vol % SiO 2 53.50 Li 2 O 0.25 wt. % Al 2 O 3 13.00 SrO 3.00 CaO 17.00 K 2 O 1.50 MgO 1.00 Na 2 O 2.25 Glass Density 2.53 g/cc Alumina Density 4.02 g/cc
[0071] Constraining Tape Composition #1 (Glass #3, Table 1a) (4.0 or 2.0 mils Tape Thickness)
Glass: Filler: Al 2 O 3 (D50 = 2.8 micron) Filler content 33.9 vol % B 2 O 3 11.84 wt. % BaO 21.12 Li 2 O 1.31 P 2 O 5 4.14 TiO 2 25.44 Cs 2 O 6.16 Nd 2 O 3 29.99 Glass Density 4.45 g/cc Alumina Density 4.02 g/cc
[0072] Constraining Tape Composition #2 (Glass #4, Table 1a) (4.0 or 2.0 mils Tape Thickness)
Glass: Filler: Al 2 O 3 (D50 = 2.8 micron) Filler content 33.9 vol % SiO 2 8.77 wt. % Cs 2 O 5.40 ZrO 2 2.45 Nd 2 O 3 28.53 B 2 O 3 11.81 BaO 7.32 MgO 3.06 La 2 O 3 27.63 Li 2 O 1.95 P 2 O 5 4.34 Glass Density 4.65 g/cc Alumina Density 4.02 g/cc
[0073] Comparing the dielectric constant (k) of the above tape, the Constraining #1 (about 16) is greater than that of the Primary #1 (about 8) which is similar to Constraining #2. The solids formulation of the primary and constraining tapes are shown as filler and glass content above. Three tape structures were made using these materials in construction as follows:
Test #1 Prim#1/Constraining#1/Prim#1/Constraining#2/Prim#1 Layer count ratio = 3/1/6/1/3 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 7.8 Test #2 Prim#1/Constraining#1/Prim#1/Constraining#2/Prim#1 Layer count ratio = 2/1/4/1/2 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 5.5 Test #3 Prim#1/Constraining#1/Prim#1/Constraining#2/Prim#1 Layer count ratio = 3/1/4/1/3 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 6.6 Test #4 Prim#1/Constraining#1/Prim#1/Constraining#2/Prim#1 Layer count ratio = 2/1/3/1/2 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 4.9
[0074] All samples were flat following belt furnace firing at 850° C., and they showed the following % x,y-shrinkage: Test #1 0.35%, Test #2 0.20%, Test #3 0.23% and Test #4 0.07%.
[0075] The onset of tape sintering between the respective primary and constraining tape in the above configurations is separated by about 75-85° C. The constraining tape developed rigid property near 700° C. and the primary tape at this temperature is just beginning to sinter.
[0076] The influence of the total/constraining tape thickness is seen to relate in general to the x,y-shrinkage values, and the smaller the ratio, the smaller the x,y-shrinkage. Furthermore, the above laminate configuration exhibits a pseudo-symmetry if treating Primary #1 as one type and both Constraining #1 and #2 as the other type. However, if adopting a dielectric constant classification, the Constraining #1, a high k (=16) tape is located at layer 4 of a 14 layer laminate for Test #1; layer 3 of a 10 layer laminate for Test #2, layer 4 of a 12 layer laminate for Test #3, and layer 3 of a 9 layer laminate for Test #4. Therefore, the above EXAMPLE 1 illustrates asymmetrical arrangement of electrical property and hence flexibility for circuit designs.
Example 2
[0077] A Primary #2 Tape (4.5 mils thick) is paired with two different constraining tape compositions (Constraining #1 and Constraining #2) having identical total/constraining tape thickness ratio as those shown in the EXAMPLE 1.
[0078] Primary Tape Composition #2 (Glass #2, Table 1a) (4.5 mils Tape Thickness)
Glass: Filler: Al 2 O 3 (D50 = 2.8 micron) Filler content 33.9 vol % SiO 2 54.50 wt % Na 2 O 2.20 Al 2 O 3 12.72 Li 2 O 0.24 B 2 O 3 8.32 SrO 2.94 CaO 16.63 K 2 O 1.47 MgO 0.98 Glass Density 2.55 g/cc Alumina Density 4.02 g/cc
[0079]
Test #5
Prim#2/Constraining#1/Prim#2/Constraining#2/Prim#2
Layer count ratio = 3/1/6/1/3
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 7.8
Test #6
Prim#2/Constraining#1/Prim#2/Constraining#2/Prim#2
Layer count ratio = 2/1/4/1/2
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 5.5
Test #7
Prim#2/Constraining#1/Prim#2/Constraining#2/Prim#2
Layer count ratio = 3/1/4/1/3
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 6.6
Test #8
Prim#2/Constraining#1/Prim#2/Constraining#2/Prim#2
Layer count ratio = 2/1/3/1/2
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 4.9
Test #9
Prim#2/Constraining#1/Prim#2/Constraining#2/Prim#2
Layer count ratio = 2/2/3/2/2
constraining thickness 2.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 4.9
[0080] All samples were flat following belt furnace firing at 850° C. and they showed the following % x,y-shrinkage: Test #5 0.18%, Test #6 0.12%, Test #7 0.15%, Test #8 0.06%, and Test #9 0.07%.
[0081] As one can see in the group Tests #5 to #8 (as compared to the group Tests #1 to #4), the role of the primary tape influences the degree of x,y-shrinkage control and the primary tape #2 is more effective to drive the x,y-shrinkage to zero. Furthermore, the configuration of Test #9 is similar to that of Test #8 except that both the Constraining tape constituents for Test #9 are consisted of two layers of tape at half of the thickness as those for Test #8. This adds another dimension of flexibility for circuit designs should more or less circuit layers are suitable to achieve desirable functional performances.
Example 3
[0082] This example uses the Constraining Tape #1 and 3 with the Primary Tape #2. Regarding the dielectric constant k values, the Constraining tape #1 is higher (k=16) than that of Primary tape #2 (k=8) which is similar to that of the Constraining tape #3.
[0083] Constraining Tape #3 (Glass #5, Table 1a) (4.0 or 2.0 mils Tape Thickness)
Glass: Filler: Al 2 O 3 (D50 = 2.8 micron) Filler content 33.9 vol % SiO 2 7.63 wt. % Nd 2 O 3 30.52 wt. % B 2 O 3 12.63 BaO 22.26 MgO 5.35 La 2 O 3 15.76 Li 2 O 1.26 P 2 O 5 2.58 K 2 O 1.99 Glass Density 4.50 g/cc Alumina Density 4.02 g/cc
[0084]
Test #10
Prim#2/Constraining#1/Prim#2/Constraining#3/Prim#2
Layer count ratio = 3/1/6/1/3
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 7.8
Test #11
Prim#2/Constraining#1/Prim#2/Constraining#3/Prim#2
Layer count ratio = 2/1/4/1/2
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 5.5
Test #12
Prim#2/Constraining#1/Prim#2/Constraining#3/Prim#2
Layer count ratio = 3/1/4/1/3
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 6.6
Test #13
Prim#2/Constraining#1/Prim#2/Constraining#3/Prim#2
Layer count ratio = 2/1/3/1/2
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 4.9
[0085] All samples were flat following belt furnace firing at 850° C. and they showed the following % x,y-shrinkage: Test #10 0.39%, Test #11 0.25%, Test #120.19% and Test #130.11%. Comparing the shrinkage values of the above 13 tests, it appears that the combination of the Primary tape #2 with the Constraining tape #1 and #2 provides the most effective x,y shrinkage control.
Example 4
[0086] This example uses the Constraining Tape #1 and 4 with the Primary Tape #2. Regarding the dielectric constant k values, the Constraining tape #1 is higher (k=16) than that of Primary tape #2 (k=8) which is similar to that of the Constraining tape #4.
[0087] Constraining Tape #4 (Glass #7, Table 1a) (4.0 or 2.0 mils Tape Thickness)
Glass: Filler: Al 2 O 3 (D50 = 2.8 micron) Filler content 33.9 vol % SiO 2 8.22 wt. % Nd 2 O 3 32.88 wt. % B 2 O 3 12.93 BaO 11.99 MgO 8.14 La 2 O 3 16.98 Li 2 O 1.46 P 2 O 5 5.55 K 2 O 1.89 Glass Density 4.27 g/cc Alumina Density 4.02 g/cc
[0088]
Test #14
Prim#2/Constraining#1/Prim#2/Constraining#4/Prim#2
Layer count ratio = 3/1/6/1/3
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 7.8
Test #15
Prim#2/Constraining#1/Prim#2/Constraining#4/Prim#2
Layer count ratio = 2/1/4/1/2
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 5.5
Test #16
Prim#2/Constraining#1/Prim#2/Constraining#4/Prim#2
Layer count ratio = 3/1/4/1/3
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 6.6
Test #17
Prim#2/Constraining#1/Prim#2/Constraining#4/Prim#2
Layer count ratio = 2/1/3/1/2
constraining thickness 4.0 mils,
primary thickness 4.5 mils
total/constraining thickness ratio = 4.9
[0089] All samples were flat following belt furnace firing at 850° C. and they showed the following % x,y-shrinkage: Test #14 0.19%, Test #15 0.15%, Test #16 0.17% and Test #17 0.06%. Comparing the shrinkage values of the EXAMPLE 4 with those in the EXAMPLE 2, it appears that the combination of the Primary tape #2 with both of the Constraining tape #1 and #2 provides as effective x,y shrinkage control as a combination of the Primary tape #1 and #4.
Example 5
[0090] In another experiment, Primary Tape #2 and Constraining Tape #1 and #4 were used. The differences between Test #16 of EXAMPLE 4 and Tests #18-#20 of EXAMPLE 5 are in the configuration of the multilayer laminates.
Test #18 Prim#2/Constraining#1/Prim#2/Constraining#4/Prim#2 Layer count ratio = 1/1/8/1/1 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 6.6 Test #19 Prim#2/Constraining#1/Prim#2/Constraining#4/Prim#2 Layer count ratio = 4/1/2/1/4 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 6.6 Test #20 Prim#2/Constraining#1/Constraining#4/Prim#2 Layer count ratio = 5/1/1/5 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 6.6 Test #21 Prim#2/Constraining#1/Constraining#4/Prim#2 Layer count ratio = 5/1/2/5 constraining thickness 4.0 mils, primary thickness 4.5 mils total/constraining thickness ratio = 4.8
[0091] Despite the layer order arrangement among the Primary tape and two Constraining tapes, the above Tests #18-#20 have identical total tape thickness/constraining tape thickness ratio of 6.6. This is one of the critical factors controlling the x,y fired shrinkage. The x,y-shrinkage values for test 18, 19, or 20 of, respectively, 0.19%, 0.15%, or 0.15% are close to one another mainly due to the same tape thickness ratio of 6.6. Test #20 is a special case where the two Constraining tapes were in direct contact. Since both of them formed rigid microstructure due to crystallization of the glass/filler in the tape, they served as the core to constrain the Primary tape at its peak firing temperature of 850° C. Test #21 resulted in a smaller x,y-shrinkage of 0.03%, which was contributed by a thicker core, consisted of one layer of Constraining tape #1 and two layers of Constraining tape #4. As disclosed in this invention, the first of the two Constraining tape #4 layers was located at the geometrical center of the laminate configuration and a pseudo-symmetry was attained.
[0092] Furthermore, the above laminate configuration exhibits a pseudo-symmetry if treating Primary #2 as one type and both Constraining #1 and #4 as the other type. However, if adopting a dielectric constant classification, the Constraining #1, a high k (=16) tape is located at layer 2 of a 12 layer laminate for Test #18; layer 3 of a 12 layer laminate for Test #19, layer 6 of a 12 layer laminate for Test #20, and layer 6 of a 13 layer laminate for Test #21. Therefore, the above EXAMPLE 5 illustrates asymmetrical arrangement of electrical property and hence flexibility for circuit designs.
[0093] The primary/constraining tape laminates disclosed in this invention can be fired in a typical LTCC belt furnace profile to achieve full densification and zero or nearly zero x,y-shrinkage. A typical LTCC belt furnace profile for 951 GREEN TAPE™ (a commercial product from E. I. DuPont) is a three and a half-hour burnout and sintering profile which includes: (1) 25° C. to 60° C. at 2.5° C./min, (2) 60° C. to 400° C. at 19.2° C./min, (3) 400° C. to 435° C. at 1.4° C./min, (4) 435° C. to 850° C. at 7.0° C./min, (5) dwell at 850° C. for 17 min, (6) 850° C. to 40° C. at 17.3° C./min, and (7) 40° C. to room temperature at 0.5° C./min. For anyone skilled in the art, the above profile can be modified according to one's belt furnace specifications so long as adequate organic burnout, ramp rate to peak temperature, peak temperature duration, and descending rate can be optimized to produce the desirable results.
[0094] The primary/constraining tape laminates disclosed in this invention can be fired in a typical LTCC belt furnace profile to achieve full densification and zero or nearly zero x,y-shrinkage. A typical LTCC belt furnace profile for 951 GREEN TAPE™ (a commercial product from E. I. DuPont) is a three and a half-hour burnout and sintering profile which includes: (1) 25° C. to 60° C. at 2.5° C./min, (2) 60° C. to 400° C. at 19.2° C./min, (3) 400° C. to 435° C. at 1.4° C./min, (4) 435° C. to 850° C. at 7.0° C./min, (5) dwell at 850° C. for 17 min, (6) 850° C. to 40° C. at 17.3° C./min, and (7) 40° C. to room temperature at 0.5° C./min. For anyone skilled in the art, the above profile can be modified according to one's belt furnace specifications so long as adequate organic burnout, ramp rate to peak temperature, peak temperature duration, and descending rate can be optimized to produce the desirable results. | This invention relates to a process which produces flat, distortion-free, zero-shrink, low-temperature co-fired ceramic (LTCC) bodies, composites, modules or packages from precursor green (unfired) laminates of three or more different dielectric tape chemistries that are configured in an uniquely or pseudo-symmetrical arrangement in the z-axis of the laminate. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates generally to farm implements and, more particularly, to a central fill system having a stowable ladder for a stack-fold planter.
Increasingly, farm implements have been designed to have frames that can be folded between field-working and transport positions. One such type of farm implement is a stack-fold planter, such as the 1230 Stackerbar planter from Case New Holland, LLC. Stack-fold planters generally consist of a center frame section and a pair of wing frame sections. In the field-working position, the wing frame sections are evenly aligned with the center frame section. In the transport position, however, the wing sections are lifted to a position directly above the center frame section, i.e., to a “stacked” position. In the stacked position, the width of the implement is generally that of the center frame section, thus making the implement better suited for transport along roads and between crops.
Openers are mounted to the frame sections at equal intervals, with each of the wing sections typically carrying one-half the number of openers mounted to the center frame section. The openers are designed to a cut a furrow into a planting surface, deposit seed and/or fertilizer into the furrow, and then pack the furrow. In this regard, each opener will have a seed box that is manually loaded with seed and/or fertilizer. Since the size of the seed box determines how much particulate matter the box can retain, there is generally a desire to have larger seed boxes for each of the openers. Since the larger seed boxes can hold more material, fewer refilling stops are needed when planting a field.
Larger seed boxes, however, have drawbacks. The additional material that can be carried by larger seed boxes adds to the overall weight of the openers, including those mounted to the wing sections. This additional weight can stress the lifting/lowering system that stacks the wing sections, or require a more robust system, which can add to the overall size, mass, complexity, and cost of the implement. Additionally, larger seed boxes can affect the spacing between adjacent openers, and thus the spacing between seed trenches that are formed by the openers. Larger spacing between seed trenches lower per acre crop yields. Further, it can be problematic and time consuming to individually fill each of the seed boxes, whether using bags or a conveyor system.
Many central fill systems for such stack-fold planters have a rearward platform accessible by a ladder that is fixed to a rearward edge of the platform. The platform provides a work space for an operator when refilling the central hoppers or visually inspecting the fill level in the hoppers. The ladder provides a means to access the platform. One known central fill system for a stack-fold planter includes means for raising the hoppers when the planter is in transport. It is believed that raising the hoppers provides better weight distribution and therefore allows for faster travel speeds when the planter is in transport. The transport position is commonly used as the position for the planter when being stored and serviced, particularly, the central fill system, such as the air blower and its related components, hoses, and the like. For systems having a fixed ladder mounted to the platform, the ladder constrains the workspace around the central fill system and creates a structure of which a service technician must be cognizant to avoid unnecessary contact. Alternately, the technician may find avoiding the fixed ladder cumbersome and therefore elect to remove the ladder.
SUMMARY OF THE INVENTION
The present invention is directed to a central fill system having a stowable ladder for use with a stack-fold implement. The bulk fill hopper assembly is mounted to the center frame section of the stack-fold implement and does not affect the narrowness of the stack-fold implement when in a stacked, transport position. The hopper assembly preferably includes a pair of bulk fill hoppers or tanks supported by cradle that is in turn supported by a pair of wheels. The cradle is removably coupled to the center frame section by a pair of rigid frame members. Parallel linkages interconnected the cradle and the wheels, and allow the wheels to, in effect, float to accommodate changes in terrain as the implement is being towed in either the working or transport positions. The rigid frame members preferably hold the position of the cradle constant but the position of the wheels change in response to changes in terrain. A ladder is provided that may be stowed adjacent the cradle when not being used, but may be slid rearward and lowered when its use is desired. A platform rearward of hoppers includes catches that engage the forward end of the ladder as the ladder is being withdrawn from its stowed position. The catches prevent the unintentional removal of the ladder from the central fill system.
According to one aspect of the invention, an agricultural implement is provided, and includes a tool bar adapted to be coupled to a prime mover, with the tool bar having an inner section and at least one outer section, and a plurality of row units coupled to the inner and outer sections of the tool bar. The implement further includes means for raising the outer section to a stacked position generally above the inner section, and a frame member coupled to and extending rearward from the inner section of the tool bar. A bulk fill hopper assembly is supported by the frame member and operative to deliver particulate material to the plurality of row units. The bulk fill hopper assembly includes a stowable ladder that when in use enables access to hopper(s) that store particulate matter that is ultimately delivered to the row units.
In accordance with another aspect of the invention, a central fill system for a stack-fold planter is provided. The central fill system includes a frame that supports one or more bulk fill hoppers or tanks, and is adapted to be coupled to a tool bar of the stack-fold planter. The frame further supports a platform rearward of the hoppers that provides a work space for adding product to the fill hoppers or visually inspecting the hoppers. A ladder is provided that is removably engaged with the platform such that when the platform is in a use-position, the ladder may be used to gain access to the platform. When not in use, the ladder may be stowed on the frame beneath the hoppers.
According to one object of the invention, a more efficient, greater material capacity stack-fold planter is provided.
It is another object of the invention to provide a stack-fold implement having a central bulk fill system.
It is a further object of the invention to provide a central bulk fill system for a stack-fold implement, such as a stack-fold planter.
It is yet another object of the invention to provide a central bulk fill system having a stowable ladder for use with a stack-fold planter.
Other objects, features, aspects, and advantages of the invention will become apparent to those skilled in the art from the following detailed description and accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout.
In the drawings:
FIG. 1 is a pictorial view of an agricultural planting system comprised of a stack-fold planter coupled to a tractor;
FIG. 2 is an isometric view of the stack-fold planter of FIG. 1 in a field-working position;
FIG. 3 is a rear elevation view of the stack-fold planter of FIG. 1 in a stacked, transport position;
FIG. 4 is an isometric view of the central bulk fill system of FIG. 1 in a lowered, field working position;
FIG. 5 is a side elevation view of the central bulk fill system of FIG. 4 ;
FIG. 6 is a side elevation view of the central bulk fill system in a raised, transport position;
FIG. 7 is a rear isometric view of the central bulk fill system with a stowable ladder in a withdrawn ready-for-use position; and
FIG. 8 is a detailed view of the stowable ladder and platform arrangement.
DETAILED DESCRIPTION
Referring now to FIG. 1 , a planting system 10 according to one embodiment of the invention includes a stack-fold implement 12 , shown in a field working position, coupled to a prime mover 14 , e.g., tractor, in a known manner. For purposes of illustration, the stack-fold implement 12 is a row crop planter, which as shown in FIG. 2 , includes a frame 16 generally comprised of a center section 18 and wing sections 20 , 22 on opposite lateral sides of the center section. The center section 18 includes a tongue (not shown) that extends forwardly of the center section 18 for hitching the implement 12 to the prime mover 14 . Gauge wheels 24 on the frame sections 18 , 20 , and 22 set the seeding or cutting depth for the implement.
In the illustrated embodiment, sixteen openers 26 are mounted to the frame 16 at equally spaced intervals, but it is understood that more than or fewer than sixteen openers could be mounted to the frame 16 . As known in the art, the wing sections 20 , 22 may be raised to a transport position, as shown in FIG. 3 , in which the openers carried by the wing sections 20 , 22 are stacked over the center section 18 . As also known in the art, the openers 26 are designed to cut a furrow into the soil, deposit seed and/or fertilizer into the furrow, and then pack the furrow. Seed boxes or “mini-hoppers” 28 are optionally mounted to each of the openers 26 . The mini-hoppers 28 are preferably smaller than conventional mini-hoppers used with stack-fold crop row planters and thus hold less material than conventional seed boxes.
The present invention allows for smaller mini-hoppers as the invention provides for a central bulk fill assembly 30 that delivers material, such as seed and/or fertilizer, to the openers 26 and/or the mini-hoppers 28 . The central bulk fill assembly 30 preferably includes a pair of bulk fill hoppers 32 and 34 supported adjacently to one another on a cradle 36 . The cradle 36 is supported by a frame 38 that is mounted to the center section 18 by a set of rearwardly extending frame members 40 , 42 , and 44 . In a preferred embodiment, the frame members 40 , 42 , and 44 are removably coupled to center frame section 18 which allows the bulk fill assembly 30 to be removed from the implement 12 or added as an after-market add-on to an existing stack-fold implement.
The platform 38 is supported above the work surface (or transport surface) by a pair of wheels 46 , 48 that are each connected to the platform 40 by respective parallel linkages 50 , 52 . Each linkage includes an upper link 54 , 56 and a lower link 58 , 60 , respectively. In addition to the links 54 - 60 , a pair of lift arms 62 , 64 are provided. Lift arm 62 is coupled to frame member 44 at a knuckle 62 to which parallel linkage 50 is also connected. In a similar manner, lift arm 64 is coupled to frame member 40 at a knuckle 64 to which parallel linkage 52 is also connected. As shown particularly in FIG. 4 , the cradle 36 further includes a Y-beam 66 that is pivotally coupled to the center frame member 42 . As is customary for most central bulk fill assemblies, an air blower 68 is mounted beneath cradle 36 is operable transfer particulate matter from the hoppers 32 , 34 to the individual mini-hoppers 28 or directly to the openers 26 in a forced air stream.
As known in the art, central bulk fill hoppers, such as those described above, provide the convenience of a central fill location rather than having to fill the individual seed boxes. Also, the central fill hoppers have greater capacity than the seed boxes, which reduces the number of fill iterations that must be taken when planting. Simply mounting a central bulk fill assembly to a stack-fold planter, such as planter 12 , can create stability issues, especially when the stack-fold planter is in the transport position. In this regard, the present invention provides a mechanism for raising the bulk fill assembly 30 when the stack-fold planter 10 is in the folded, transport position. Raising the bulk assembly 30 provides greater stability during transport as well provides increased clearance between the bulk fill assembly 30 and the roadway.
Accordingly, the present invention provides a pair of hydraulic lift cylinders 70 and 72 for lifting the cradle 36 , and thus the bulk fill assembly 30 . Cylinder 70 is interconnected between forward knuckle 62 and a rearward knuckle 74 . As shown in FIG. 5 , the rearward knuckle 74 includes, or is coupled to, a mounting arm 76 that is coupled to axle 78 about which wheel 46 rotates. Cylinder 70 includes a ram 80 that is coupled to the rearward knuckle 74 whereas cylinder 70 is coupled to the forward knuckle 62 . In a similar fashion, cylinder 72 includes a ram (not shown) connected to a rearward knuckle 82 whereas the cylinder 72 is connected to the forward knuckle 64 . It will be appreciated that a mounting arm 84 is connected to, or formed with, the rearward knuckle 82 , and the mounting arm 84 is connected to an axle (not shown) about which wheel 48 rotates.
FIG. 6 shows the central bulk fill assembly 30 in the raised-for-transport position. The bulk fill assembly 30 is raised from the lower, field or working position by the actuation of cylinders 70 and 72 . In a preferred embodiment, the cylinders 70 , 72 are linked to the hydraulic system that raises and lowers the stack-fold planter 12 . Thus, the central bulk fill assembly 30 is automatically raised and lowered as the planter 12 is raised and lowered. It is contemplated however that the bulk fill assembly 30 could be raised and lowered independent of the stack-fold planter. Additionally, it is contemplated that a separate hydraulic system could be used to raise and lower the central bulk fill assembly 30 .
The following description details how the central bulk fill assembly 30 is raised and lowered. While reference will be made to cylinder 70 and its ram 80 , it should be noted that the other cylinder 72 and its ram operate similarly and in-tandem with cylinder 70 and ram 80 . In operation, the ram 80 is extended or retracted based on the pressure in cylinder 70 . When the ram 80 is extended, the force applied against the rearward knuckle 74 causes the forward knuckle 62 to elevate. Conversely, when the ram is retracted, the forward knuckle 74 is drawn downward resulting in lowering of the central bulk fill assembly 30 . It will be appreciated that the parallel linkages 50 , 52 maintain the lift arms at a consistent orientation throughout the range of motion provided by extension and retraction of the rams. In this regard, a substantially level central fill bulk assembly 30 is maintained during raising and lowering. Further, as shown by comparing the views of FIGS. 5 and 6 , the lift arms 62 , 64 remain above the parallel linkages throughout the range of vertical motion of the bulk fill assembly 30 .
Referring now to FIGS. 4 and 5 , a platform 86 is mounted to the Y-beam 66 and extends rearward therefrom beneath the bulk fill hoppers 32 , 34 . The platform 86 provides a standing area for a user to access the respective top hatches 88 , 90 for the hoppers 32 , 34 for inspecting the fill level of the hoppers 32 , 34 or add additional material to the hoppers 32 , 34 . Extending uprightly generally from a back edge of the platform 86 is a barrier 92 designed to prevent a user from falling off the back edge of the platform 86 .
As shown in FIG. 5 , even when the bulk fill assembly 30 is in the lowered, field position, the platform is substantially elevated above the field surface. Thus, to provide access to the platform, the present invention provides a stowable ladder 94 that when stowed is retained in a slot 95 formed between the bottom surface of platform 86 and a floor 97 that is mounted below the platform 86 . The ladder 94 may be slid rearwardly from the slot 95 and then lowered to a use position, as illustrated in FIG. 7 . It will be appreciated that the rearward end of the slot 95 includes catches 96 that retain the forward (top) end of the ladder 94 so that the ladder 94 is not completely removed from the slot 95 when the ladder 94 is moved to the use position. The catches 96 are shaped such that the ladder 94 , when it reaches it fully extended position, it may be pivoted or rotated downward so that the trailing (bottom) end engages the ground.
FIG. 8 is a detailed view of the stowable ladder and platform arrangement generally described above. When the ladder 94 is in the working, extended position ( FIG. 7 ), the ladder 94 may be stowed by lifting up at (or near) the ground engaging end of the ladder along pivot line 98 extending through catches 96 and then sliding the ladder toward the front of the central bulk fill assembly 30 as indicated by arrow 100 until the ladder 94 is fully seated in position in slot 97 beneath the platform 92 . It will therefore be appreciated that when the ladder 94 is in the stowed position, the ladder 94 does not interfere with access to the lower components of the central bulk fill assembly 30 , such as the air blower 68 for example.
It will be appreciated that the present invention provides a stack-fold implement having a central bulk system and thus the advantages typically associated with bulk fill systems, such as reducing filling intervals, longer seeding times, and greater efficiency. Additionally, the centralized hoppers provide the convenience of a central fill location that is generally clear of the openers whether the implement 12 is in a working position or a stacked, transport position. The placement of the bulk fill system rearward of the center section 18 also provides additional stability to the implement 12 when the implement is in the stacked position.
Many changes and modifications could be made to the invention without departing from the spirit thereof. The scope of these changes will become apparent from the appended claims. | A stack-fold implement having a central bulk fill hopper assembly is provided. The bulk fill hopper assembly is mounted to the center frame section of the stack-fold implement and does not affect the narrowness of the stack-fold implement when it's in a stacked, transport position. The hopper assembly includes a pair of bulk fill hoppers or tanks supported by cradle that is in turn supported by a pair of wheels. The cradle is removably coupled to the center frame section by a plurality of rigid frame members. A retractable ladder may be stowed beneath the hopper assembly. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/771,386, filed Feb. 8, 2006, hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to spray quench systems used in heat treatment processes of metal products.
BACKGROUND OF THE INVENTION
Quench, or quench and temper, metallurgical processes are widely used to harden, or harden and temper, a manufactured metal product such as steel pipe, to achieve desired metallurgical properties different from those for the starting material used to produce the metal product. Quenching is done after heating of the product, for example, by electric induction heating. Open spray quenching systems are one type of quench systems that can be used to accomplish the hardening and tempering of the metal product. When in-line quenching long, round products, such as pipes, bars or tubing, at production line speed, an important parameter that determines the material properties achieved by these processes is the metal cooling rate, which must generally be as fast as is possible to obtain the desired results. The cooling rate, in turn, is determined by the volume of quenchant used during the rapid cooling of a heated metal part. The traditional apparatus used to provide a high volume flow of water to the surface of a heated part is sometimes known as a quench barrel. The typical quench barrel is a large diameter, monolithic cylinder equipped with a multitude of holes through which quench media flows under medium pressure. Upon contact with the heated metal part, the quenchant provides the rapid cooling necessary to obtain a desired hardness. Also well known is the fixed position quench ring or slot quench. This apparatus is a hollow ring through which the part to be quenched passes. The apparatus contains a multitude of equally spaced holes or slots that act as nozzles for the quenching fluid. The slot quench is typically used in single part, small volume applications, such as induction hardening scanners.
Quenching systems must be capable of treating a range of product diameters. However, existing quench barrels and quench rings have a fixed inside diameter. When products having different diameters pass through these fixed diameter devices, the shape of the spray impinging on the product, the spray flow rate, and spray pressure change due to the difference in gap between the spray nozzles and the product. For existing quench systems when the spray is reflected from the product for a given nozzle, the reflected spray can interfere with the spray pattern of adjacent nozzles, and diminish or even destroy their effectiveness. The above limitations of existing quench systems can also cause expanding steam to form at the surface of the product to be quenched. This creates a thermal steam barrier that greatly reduces the rate of cooling of the product.
Further the small “pin hole” quench nozzles used to create the water jets in existing barrel quench systems limit the effective spray volumes and pressures that can be achieved.
Additionally since the product typically must move through the quench device both linearly and while rotating, the supporting conveyor rolls are skewed relative to the axis of travel of the product. This causes different diameter product to run on different centerlines through the conventional fixed geometry quench systems.
It is an object of the present invention to overcome the above limitations of existing spray quench systems.
BRIEF SUMMARY OF THE INVENTION
In one aspect the present invention is an apparatus for and method of spray quenching a metal product. At least one quench ring comprises a quenchant plenum and outlet for ejecting quenchant onto the metal product. The quench ring may be formed from two interconnecting ring elements. The interconnected ring elements form the quenchant plenum and outlet for ejecting quenchant onto the metal product. Adjusting the relative positions of the two interconnecting ring elements changes the shape and volume of the outlet to change the pressure, flow rate and/or pattern of the spray from the outlet.
In other aspects the present invention comprises an apparatus for and method of spray quenching a metal product with a plurality of quench rings, wherein each of the quench rings comprises a quenchant plenum and outlet for ejecting quenchant onto the metal product. Each quench ring may be formed from two interconnecting ring elements. The interconnected ring elements form the quenchant plenum and outlet for ejecting quenchant onto the metal product. Adjusting the relative positions of the two interconnecting ring elements changes the shape and volume of the outlet to change the pressure, flow rate and/or pattern of the spray from the outlet. A spray guard may be associated with one or more of the quench rings to prevent interference of the quenchant spray from a quench ring by the reflected spray from an adjacent quench ring.
The above and other aspects of the invention are further set forth in this specification and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing brief summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings exemplary forms of the invention that are presently preferred; however, the invention is not limited to the specific arrangements and instrumentalities disclosed in the following appended drawings:
FIG. 1 is a perspective view of one example of a quench ring used in the spray quench system of the present invention.
FIG. 2 is a perspective view of one example of a plurality of quench rings used in the spray quench system of the present invention.
FIG. 3 is a sectional view of one example of two quench rings of the spray quench system of the present invention.
FIG. 4 is a sectional view of one example of three quench rings of the spray quench system of the present invention.
FIG. 5 is a sectional view of one example of two quench rings of the spray quench system of the present invention with one quench ring having an extended spray guard.
FIG. 6 is a perspective view of one example of a plurality of quench rings in the spray quench system of the present invention wherein the plurality of quench rings are attached to a support structure.
DETAILED DESCRIPTION OF THE INVENTION
In all examples of the invention, workpiece 90 (metal product) being heat-treated moves linearly through one or more quench rings along the Z-axis and in the direction of the arrow shown in the figures. In some examples of the invention, the workpiece may also rotate about the Z-axis as it moves through the one or more quench rings. Suitable mechanical means, not shown in the figures, such as support rollers are used to advance the workpiece through the quench rings. Although workpiece 90 is illustrated as a cylindrical pipe or conduit, the invention may be used with workpieces of different shapes such as, but not limited to, a rectangular tube. Also the workpiece may comprise a series of discrete workpieces, such as gears, suitably mounted on a conveyance means for moving the discrete workpieces through the one or more quench rings. Heating apparatus for heating the workpiece prior to quenching is not shown in the figures, but may be, by way of example and not limitation, one or more solenoidal electric induction coils surrounding the workpiece for inductively heating the workpiece when an ac current flows through the one or more coils. Also in some configurations, heating apparatus may be interspaced between two or more of the quench rings.
Referring to FIG. 1 , there is shown one example of a quench ring 12 used in the spray quench system of the present invention. In this example the quench ring comprises interconnecting first ring element 14 and second ring element 16 . In this non-limiting example, second ring element 16 is adjustably inserted into first ring element 14 as best seen in FIG. 3 , FIG. 4 or FIG. 5 , to form quench ring plenum 18 and outlet passage 20 . Moving the first and/or second ring elements along the defined central axis, Z r ( FIG. 1 ), increases or decreases the size of outlet passage 20 of the quench ring to change the pressure, flow rate and/or pattern of the spray from the outlet passage. In this non-limiting example of the invention, one or more fasteners 28 are used to control the spacing between the first and second ring elements so that the shape and volume of the outlet opening will correspondingly change as the spacing is changed. Quenchant is supplied to the quench ring plenum by one or more inlet passages 22 from a suitable source. In this non-limiting example of the invention, outlet passage 20 is an annular opening, generally conical in shape, and ejects quenchant 360 degrees around workpiece 90 in a generally conical volume as illustrated by typical flow volume 92 (partially shown as a shaded section) in FIG. 3 , FIG. 4 or FIG. 5 . While the present example uses a 360 conical flow pattern, other examples of the invention may use different flow patterns as determined by the particular configurations of first and second ring elements. For example one alternative may be annularly segmented conical flow sections around the workpiece where segmented sections are separated by a barrier to produce quenchant flow in selected one or more regions around the workpiece. For example rather than 360 degrees quenchant flow as described above, quenchant flow may be restricted to angular regions defined as 0 to 90 degrees and 180 to 270 degrees around the workpiece by the separation barriers. In some examples of the invention the shape and volume of the outlet of the quench ring may be fixed.
FIG. 2 illustrates another example of the spray quench system of the present invention. In this example, a plurality of quench rings 12 a , 12 b , 12 c and 12 d , surround workpiece 90 as it moves through the quench rings. Each quench ring is similar in construction to the quench ring shown in FIG. 1 . The distance, d s , between adjacent quench rings can be independently adjusted by suitable mounting structure to satisfy the quench conditions of a particular application. Further the location of the central axis, Z r , of each quench ring may be independently adjusted by suitable mounting structure to satisfy the quench conditions of a particular application. As noted above, in some applications the workpiece rotates about the Z-axis while moving through the one or more quench rings. In this arrangement torque forces may cause the position of the central axis of the workpiece to deviate as it passes through the quench rings. Moving a quench ring so that its central axis tracks this deviation of the position of a workpiece moving through it may be beneficial. FIG. 6 diagrammatically illustrates one non-limiting example of a suitable mounting support structure 30 . Support structure 30 comprises support arms 32 a - 32 d and quench ring position control element 34 . Support arms 32 a - 32 d connect quench rings 12 a - 12 d , respectively, to quench ring position control element 34 . The position of each support arm can be adjusted along the Z-axis by control element 34 to change the distance between two or more adjacent quench rings. In some examples of the invention the location of the central axis of one or more of the quench rings can be changed in the X-Y plane by moving the support arm associated with the one or more quench rings in the X-Y plan by control element 34 . Control element 34 and the support arms can be driven by suitable actuators that are responsive to the output of a computer process controller to rapidly perform the desired changes in positions of the one or more quench rings.
FIG. 3 illustrates another example of the spray quench system of the present invention. Quench rings 12 e and 12 f are similar in construction to the quench ring shown in FIG. 1 , and also include spray guard 24 , which is attached to the upstream side of the quench rings to deflect and dissipate reflected spray volume 94 (partially shown as a shaded segment in the figures). One non-limiting example of a spray guard is in the shape of an annular disk. Spray volume 94 represents a typical envelope for spray reflected off of the workpiece from incident spray in volume 92 . Deflecting and dissipating the reflected spray volume before quenchant release from an upstream quench ring prevents interference of the reflected spray with the released quenchant from the upstream quench ring. For example in FIG. 4 reflected quenchant released from quench ring 12 e is deflected by spray guard 24 associated with upstream quench ring 12 f , and reflected quenchant from quench ring 12 f is deflected by spray guard 24 associated with upstream quench ring 12 g . Spray guard 24 may be permanently affixed to a side of its associated quench ring, or adjustably attached to its associated quench ring as shown in FIG. 5 , wherein one or more offset fasteners 26 are used to offset spray guard 24 from associated quench ring 12 j . This arrangement is of advantage in applications where the downstream quench ring is located further downstream than suitable for mounting a spray guard directly on the side of the quench ring. The shape and positioning of each spray guard can change depending upon a particular arrangement of quench rings and the workpiece being heat-treated.
In another example of the invention, in combination with one or more of the above examples of the invention, individual quench ring flows can be adjusted to optimize the distribution of the cooling flows from each quench ring to match the quench rate to the mass cooling requirement of the workpiece. For example a computer processor with suitable input and output devices may be used to accomplish one or more of the following quench system adjustments: (1) change of distance between two or more quench rings; (2) change of centerline position of one or more quench rings; (3) change in position of one or more spray guards and (4) change in outlet shape and volume of one or more quench rings, including complete closure of the outlet for one or more quench rings. These quench system adjustments may be dynamically accomplished by a computer program executed by the processor based upon the mass cooling requirements of the workpiece passing through the quench rings. In some examples of the invention heat imaging of the workpiece, for example infrared imaging, may be used to provide feedback data to the control system to indicate real time cooling results.
In another example of the invention, one or more quench rings of a particular inside diameter can be assembled in a module. The module can incorporate the support structure describe above. Different modules having quench rings of different inside diameters, and/or other different quench system features, may be interchanged on a heat treatment line to accommodate workpieces of different dimensions and/or workpieces having different mass cooling requirements. Quick connections for quenchant and any electrical and/or mechanical interfaces may be provided with each module.
The particular shape of the first and second quench ring elements shown in the examples of the invention may be changed without deviating from the scope of the invention as long as the elements form a quenchant plenum chamber and adjustable outlet opening or openings. Further more than two ring elements (first and second quench ring elements) may perform the same functions of the described invention without deviating from the scope of the invention. In some examples of the invention the one or more quench rings may be formed as a split ring assembly, with optional hinge elements, so that the one or more quench rings may be interchanged around a workpiece.
While a certain number of quench rings are shown in the various examples of the invention, the number of quench rings may be changed without deviating from the scope of the invention. Further one or more quench rings may be interspaced with other components in a particular application, such as mechanical supports or transport components for the workpiece, and heating components, such as induction heating devices. In arrangements with two or more quench rings, the outlet volume of each quench ring may be independently adjusted to form a unique spray volume as required for a particular application.
The above examples of the invention have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the invention has been described with reference to various embodiments, the words used herein are words of description and illustration, rather than words of limitations. Although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein; rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification and the appended claims, may effect numerous modifications thereto, and changes may be made without departing from the scope of the invention in its aspects. | A spray quench system is provided with one or more spray quench rings that eject a controlled volume of spray onto a workpiece passing through the quench rings. The quench rings can be adjusted in position independently of each other relative to the workpiece being sprayed. Reflected spray guards may be provided to prevent spray interference between adjacent quench rings. The outlets of the quench rings may be adjustable in volume. A controller can be provided to optimize the distribution of quench cooling flows from the quench rings. Sets of quench rings with different diameters in each set may be provided in modular form. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon, and claims the filing date of, prior U.S. Provisional application, Ser. No. 61/130,935, entitled “Automated Garment Storage Retrieval and Drop-Off System”, filed Jun. 4, 2008.
BACKGROUND OF THE INVENTION
I. Field of the Invention
Our invention relates generally to automatic self service dry cleaning delivery systems. More particularly, the present invention relates to a software controlled, computerized dry cleaning drop-off and retrieval system that intelligently recognizes and processes inventory, and which provides a wide range of corrective measures that are user selectable to maintain accuracy and customer satisfaction.
II. Description of the Prior Art
While numerous partially automated dry cleaning systems exist, we are aware of no fully operational, self service dry cleaning drop-off and retrieval stations.
U.S. Pat. No. 5,581,064 issued Dec. 3, 1996 discloses a system for reading popular retail discount coupons. Identifying information can be derived with a bar code reader, an OCR scanner, a combination bar code reader/OCR scanner, or manual entry. The manufacturer's discount coupon has an alphanumeric identification of a particular item, a description and an amount by which to decrease the retail price of the item, an expiration date, and a U.P.C. (Universal Product Code), or other code, that identifies it. The system correlates the first identifying code with one or more second identifying codes, and chooses a particular one of the second identifying codes in uniquely identifying the coupon.
U.S. Pat. No. 6,832,726 issued Dec. 21, 2004 provides barcode optical character recognition software configured to create a printer format based on scanned labels. After an existing label is scanned, the software converts the scan into a label format through optical character recognition (OCR). The software recognizes and distinguishes text, graphics, and barcodes.
U.S. Pat. No. 5,880,451 issued Mar. 9, 1999 discloses an OCR processing system that reads human readable characters corresponding to an unsuccessfully decoded word in a bar code symbol. An imaging system captures an image of the label including its bar code symbol and corresponding human readable characters. If a bar code character is not successfully decoded, the system locates the associated human readable text and segments the text into individual character images. The unsuccessfully decoded bar code character is mapped to one or more of the alphanumeric character images, which are converted into text characters. The resulting ASCII data is used to create a substitute bar code character in the bar code symbology.
U.S. Pat. No. 6,744,938 issued Jun. 1, 2004 discloses a retail terminal with an imaging scanner that scans and reads labels to derive identifying product attributes. An attribute recognition program such as an optical character recognition (OCR) program is used on the scanned product label that generates text strings from alphanumeric label information and graphics images from graphics and logos. Text strings and/or graphics data are then compared to various text strings and graphics data in a database or look-up table to return information relative to the scan. Data, stored either locally or at a remote site accessible via a network or the like, is correlated to a plurality of text strings/graphics that correspond to alphanumeric text/graphics on a plurality of product labels.
U.S. Pat. No. 5,770,841 issued Jun. 23, 1998 discloses a scanner including an imaging system and a label decoding system. The imaging system captures an image of a package surface that includes a machine readable code such as a bar code and an alphanumeric destination address. The label decoding system locates and decodes the machine readable code and uses OCR techniques to read the destination address. The destination address is validated by comparing the decoded address to a database of valid addresses. If the decoded address is invalid, an image of the destination address is displayed on a workstation and an operator enters the correct address. The system forms a unified package record by combining the decoded bar code data and the correct destination address data. The unified package record is used for subsequently sorting and tracking the package and is stored in a database and applied to a label that is affixed to the package.
U.S. Pat. No. 4,550,246 issued Oct. 29, 1985 discloses an inventory control and reporting system for dry cleaning establishments. A data input keyboard provides information for analyzing processing costs of laundry articles, a data processor adapted to calculate pricing information and to generate reports based upon such data. Sequential bar code records and tags for attachment to the laundry articles are generated in sequential transactions. The bar code tags are attached to articles of clothing and are used with scanning apparatus to facilitate generation of reports according to various management needs.
U.S. Pat. No. 5,962,834 issued Oct. 5, 1999 discloses a tracking and management system designed especially for dry cleaning inventory control using RF encoding device and optical encoding. The optical pattern includes a barcode for automatic or semiautomatic data capture as well as human readable characters that are cross referenced to the RF identifying code and to inventory control records in a database. An identification packet is attached to each garment for tracking.
U.S. Pat. No. 4,803,348 issued to Lohrey, et al. on Feb. 7, 1989 involves an automated customer interface for services relating to drop-off and pickup at laundry and dry cleaning establishments. A customer's processed order is retrieved via a customer interface through a door which opens to enable the customer to pick up his order. Included in the customer interface panel are a card reader for reading the customer's credit card, a display for presenting information and instructions to the customer, a menu of services for selection by the customer and a keyboard or other input device to select desired services. A printer is included for printing a receipt and/or a transaction record.
SUMMARY OF THE INVENTION
This invention provides a self service dry cleaning drop-off and retrieval method and apparatus that responds with user-friendly computer prompts to maximize customer satisfaction. The apparatus recognizes and associates orders with particular customers, and subsequently delivers dry cleaned products in batches accessible at the kiosk.
Our automated, self-service dry cleaning delivery system described herein accepts orders of garments or items to be cleaned, and delivers them back to customers at a convenient kiosk. An upright kiosk has an access door for customers to drop off items for cleaning, or to pick up and retrieve items that have already been cleaned. A touch-screen monitor interface provides numerous customer options, and allows for user-friendly customer inputs. Payment transactions are facilitated with a card reader and a printer for customer receipts. Disposable bags are available from a convenient dispenser.
Clothing to be cleaned is bagged and put into a kiosk compartment by the customer at time of drop-off. A conveyor system with material handling apparatus stores and delivers cleaned garment orders to the kiosk at time of customer pick-up. Barcode scans, or alternatively RFID or OCR scans or manual entry, provide inventory control. A customer user interface program runs on a computer with a touch screen monitor mounted on the kiosk.
Thus a basic object is to provide a fully automated, computerized self service dry cleaning delivery system.
A related object is to provide a user-friendly, computerized self service dry cleaning delivery system of the character described that maximizes customer convenience and satisfaction.
Another object of the invention is to provide a self service dry cleaning delivery system of the character described with an inventory tracking system to maximize product delivery efficiency.
Another object of the invention is to provide a self service dry cleaning delivery system of the character described with security features that assure no customer gains access to any items other than their own.
Another object of the invention is to provide a self service dry cleaning delivery system of the character described that allows customers to return cleaned items through the kiosk to be re-hung on a storage conveyor or rack so as not to require re-cleaning.
These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
FIG. 1 is a front plan view of the preferred customer kiosk;
FIG. 2 is a diagrammatic block diagram of the preferred customers interfacing and computer portions of our invention;
FIG. 3 is a block diagram of the machine control and hardware of the present invention;
FIG. 4 is a schematic view of the preferred load station where an operator loads cleaned customer orders onto the system;
FIG. 5 is a fragmentary pictorial view of the dry cleaning delivery system;
FIG. 6 is a fragmentary diagrammatic overhead view of the dry cleaning delivery system;
FIGS. 7-18 are flow charts of the preferred computer software executed by the invention;
FIG. 19 is a pictorial view of the garment transfer unit that transfers cleaned customer orders from the storage conveyor to the kiosk delivery hook as well as from the kiosk delivery hook back to the storage conveyor; and,
FIGS. 20-21 are flow charts of the steps used by the garment transfer unit when transferring garments.
DETAILED DESCRIPTION
According to the invention, an automated self-service dry cleaning delivery system seen generally in FIGS. 1-6 and 19 provides customers with fully automatic, unattended dry cleaning drop-off and retrieval services. When installed within a staffed dry cleaning store, the system will deliver cleaned customer orders to the kiosk 10 when requested by a customer using the kiosk, and it will also deliver cleaned customer orders to a position on the conveyor accessible by a customer service representative (CSR) when requested by the CSR through a point-of-sale (POS) terminal located behind a customer service counter. The system design allows clothes items to be dropped-off and picked-up through the same kiosk door and compartment. This results in a space savings versus systems using one point for customer pick-up and another area for customer drop-off.
The system operates independently of an outside Point of Sale (POS) system, other than obtaining data records used to identify customers and their orders. Data is dumped from a POS into the database, then the system accesses only it's own database during operation. This allows the system to operate without the need for any continuous communication with another system.
This invention incorporates certain technology presented in a co-pending Utility Patent Application, entitled Automated Dry Cleaning Assembly Conveyor System, Ser. No. 11/801,728, filed May 10, 2007, which is hereby incorporated by reference.
With initial reference directed now to FIG. 1 of the appended drawings, the upright, kiosk 10 generally in the form of a parallelepiped is disposed within an area or facility providing high visibility and easy ingress and egress to consumers, i.e., actual or potential dry cleaning customers. Front door 11 allows the customer to drop off items for cleaning, or to pick up and retrieve items that have already been cleaned. Operations are self service, and customer preferences are inputted via a touch-screen monitor interface generally designated by the reference numeral 12 . For payment transactions and customer identification there is a magnetic card reader 13 adjacent a thermal printer 14 that outputs customer receipts. For customer convenience, disposable bags are available from dispenser 15 . The system incorporates the built-in garment bag dispenser in order to provide a bag to any customer who drops off clothes and does not already have a bag. The bag dispenser apparatus 15 is located inside of the kiosk so that bags can only be accessed upon being dispensed after customer has been identified and has requested a bag. Audio feedback is provided to assist customers through speaker 16 . All instructions are provided to customers both visually through text on the kiosk monitor and audibly through voice prompts via the kiosk speaker.
The system is modular so that the kiosk cabinet may be located at most any point along the storage conveyor (along one side or at the nose end). This allows for almost unlimited configuration options so the system may be installed in a large variety of spaces. The kiosk cabinet is designed so that it can be installed through a wall either on the exterior of a building, or into a lobby or vestibule area inside a building. All components on the front of the kiosk cabinet are sealed and weather resistant.
The system is represented diagrammatically in FIG. 2 . Touch screen monitor 20 and the barcode canner 21 allow operator inputs to the processing unit 28 during the order loading process. Identification card reader electronics 13 , a thermal receipt printer circuit 14 , and the touch screen monitor interface 12 likewise communicate with the processing unit 28 . A diagnostic monitor 25 , a mouse 26 , and a keyboard 27 aid operator information input and diagnostics, and these units also interface with processing unit 28 . A PLC machine control unit 31 and an optional external “point of sale” (i.e., “POS”) system 30 communicate with the processing unit 28 via communication interface 29 , which ideally communicates locally through Ethernet communications, and which may communicate externally of the system through the Internet. An advantage of our system is that the processing unit 28 is provided by an inexpensive personal computer that runs the software to be hereinafter described.
In FIG. 3 , the machine control unit 31 processes inputs and outputs from the communication interface 29 , the bag dispenser 15 , front door lock 34 that locks front door 11 ( FIG. 1 ), and rotary door lock 37 that locks an internal rotary door 35 ( FIG. 6 ). Steps are included to insure that no customer has access to any clothing/order other than their own: Any time front door is unlocked, the rotary door is locked. Further, the rotary door 35 will not rotate when front door is open or unlocked.
Manual conveyor controls including an emergency stop function are designated generally by the reference numeral 36 . Item handling apparatus includes the garment transfer unit 38 , the conveyor motor control 39 , and the clothes drop RAM 40 . A front door sensor 32 detects whether the front door 11 ( FIG. 1 ) is open or closed, and a rejected clothes sensor 33 detects presence of clothing on rotary door hook 52 ( FIG. 5 ). Conventional power supply 41 supplies power.
The relatively large kiosk compartment used for both drop-off and pick-up allows for large and/or bulky items to be facilitated. Smooth surfaces and gaps between the rotary door 35 and surrounding kiosk surfaces allow for long dresses and other large items to be handled without the risk of snags or catching.
Turning to FIG. 4 , cleaned customer orders are loaded onto the conveyor by an operator at loading shroud 42 , and materials are moved by electric garment storage conveyor 48 . This is monitored by the touch screen monitor 20 , that also displays the barcode scans from scanner 21 . Manual control of the conveyor is provided by manual control switch 46 , that is located next to an emergency “STOP” button 45 . A typical garment hanging bracket is designated by the reference numeral 47 . Conveyor 48 controls a plurality of such spaced apart brackets 47 .
In FIG. 5 , the kiosk structure is designated by the reference numeral 54 . Dirty clothes or other items to be cleaned are placed into the kiosk in a bag by a customer. For fast drop-off only, customers are given an “express drop-off” button on the touch screen monitor after swiping a card and entering their phone number for identification. This allows repeat customers to skip all screens related to order pick-up and item detail for drop-off for time savings.
Items dropped off are moved out of the kiosk by rotary door 35 , then pushed clear of the rotary door by bag drop ram 40 . Processed items (i.e., cleaned garments) 51 to be returned to the customer are temporarily suspended upon a delivery hook 52 attached to the rotary door 35 .
Customers may return items with which they are not completely satisfied. The system asks customers at pick-up to examine their order and answer “yes” or “no” as to their satisfaction with the order. If they select “no”, they are given the option to return any unsatisfactory items by hanging them back inside the kiosk. The items are then removed by the garment transfer unit and placed onto the conveyor. The rejected clothes sensor 33 (i.e., FIG. 3 ) detects if clothes are present on the delivery hook 52 . In the event a customer forgets clothes they are picking up, and leaves them on the delivery hook (inside the kiosk) after the customer's transaction is completed, the garment transfer unit is activated to remove any such items from the delivery hook and place them back onto the conveyor prior to allowing the next customer access to the kiosk. Assignment and recording of the conveyor slot on which the items are hung allows the system to return the items when that customer returns to retrieve them again.
A mechanical garment transfer unit 38 is computer controlled for transferring items to and from the electric garment storage conveyor 48 and the delivery hook 52 . Customer orders 57 disposed upon conventional clothes hangers are held by conveyor hanging brackets displaced by the storage conveyor 48 . A customer order aligned to be picked up from the conveyor by the garment transfer unit is designated by the reference numeral 58 . A computer and other controls are located within the machine controls cabinet 63 portion of the kiosk structure 54 .
Each conveyor hanger bracket 47 is designed with an internal slots with a ‘V’ configuration. Each such “dip” in each hanger slot causes garment hangers to all gravitate toward the middle of the bracket slot (i.e., the bottom of the “V”) assuring that the gripper fingers on the garment transfer unit can easily grip all hangers. This bracket design along with the garment transfer unit design prevent items from falling off the conveyor or being dropped during transfer from the conveyor to the kiosk.
Customers who have an order ready for pick-up, are given the option of either picking it up now or leaving it for pick-up later. This is useful for a customer who uses the system to drop off dirty clothes on their way to catch a train for a commute to work for example, but doesn't want to pick up cleaned orders until they return on their way home from work.
Each order has a unique identification number. This number is normally assigned and printed (usually in the form of a bar code) onto a paper invoice by the Point of Sale system. This invoice is then attached to each order and the bar code is then scanned by scanner 21 ( FIG. 4 ) by moving the invoice in front of the scanner 21 at the load station. (Alternatively, an RFID chip and reader may be used, or alpha/numeric characters may be printed and read with an OCR reader for this step.) At this time the order information from the POS system has been received, and the system then references the order number in the database to find the customer information so that the order can be properly loaded onto the conveyor.
FIG. 6 schematically shows an overhead view of the floor plan for the equipment. The machine controls cabinet 63 is located near rotary door 35 that supports delivery hook 52 . Dirty clothes are dropped by customers into cavity 83 which is spaced apart from kiosk usage or customer area 84 on the interior side of building wall 85 . The garment transfer unit 38 is located between the electric garment storage conveyor 48 and the kiosk cabinet 10 ( FIG. 1 ). The conveyor load area is generally designated by the reference numeral 90 .
Customer User Interface:
The customer user interface program of FIG. 7 runs on the primary computer whose display 12 ( FIG. 1 ) is mounted proximate the front face of the kiosk 10 ( FIG. 1 ). This display is touch screen enabled. Audio is provided through speaker system 16 ( FIG. 1 ) also mounted on the front face of kiosk 10 ( FIG. 1 ). All of the verbal instructions are dynamically generated using computer speech synthesis.
After the “start” function, the Display Welcome Screen step 100 executes, prompting the customer to press the start button on the computer touch screen or to swipe a magnetic card in the card reader 13 ( FIG. 1 ).
The “Wait for card swipe” step 200 ( FIG. 7 ), follows. At this time the computer monitors the magnetic card reader 13 waiting for a customer input. A Card Swipe is processed in step 300 wherein magnetic data is parsed and swipe is validated. This routine will return to the main program either a loyalty card number or the first and last name of the card holder, in the event the swiped card was a credit card.
Referring to FIG. 8 , the “Process Card Swipe” step 300 of FIG. 7 is detailed. Step 305 tests for a Valid Swipe, wherein magnetic track data is parsed from the reader to check for validity of the input. Invalid Swipe step 310 determines if magnetic card data was corrupt or in a format that was not compatible. An error condition is set and control is passed back to the customer user interface at 300 . If the “valid swipe” step 305 ( FIG. 8 ) is “yes”, the Parse Magnetic Data step 315 executes. Track data is parsed for information including card number, expiration date and the card holder name.
Step 320 ( FIG. 8 ) determines if a “loyalty card” is in use. The loyalty card is a custom branded card supplied by the assignee of this case, i.e., HMC Solutions LLC. The loyalty card contains a loyalty number that uniquely identifies a particular customer. A “yes” results in step 325 , wherein the loyalty card number is stored, and control is passed back to the customer user interface at 300 . If step 320 produces a negative, the “Return Customer Name” step 330 stores customer name data from the magnetic stripe and passes it back to the customer user interface at 300 .
Returning again FIG. 7 , the “Valid Data” step 400 follows the steps of FIG. 8 , and the output of Process Card Swipe step 300 is checked for validity. If validity is negative, the process returns to the “Display Welcome Screen” step 100 . If validity is yes, the “Prompt Customer For Phone” step 500 follows. In step 500 the screen on the kiosk displays a phone number entry screen and instructions for the customer to enter their phone number. In addition to the display, the instructions are read aloud through computer synthesized speech and broadcast on speaker 16 ( FIG. 1 ). The customer enters their phone number and presses the continue button on the touch screen.
In the “Look Up Customer” step 600 the customer is looked up by matching the name field in the event of a credit card, or the loyalty number in the event of a loyalty card, obtained from step 300 with the phone number the customer entered in step 500 . Referencing FIG. 9 , step 600 is followed by the “Locate customer ID” step 605 wherein a customer table is queried with the phone number entered and customer name or loyalty number. The “Customer Locate” step 610 determines if a match was located in step 605 . Step 615 , the “no customer match” step, follows, returning to customer user interface step 600 ( FIG. 7 ) if no customer ID is located. If a customer ID is found, “Customer found” step 620 uses a unique customer ID field to identify the correct customer to the system application, as well as third party software pertinent to the system and control is passed back to the customer interface step 600 ( FIG. 7 ).
The “New Customer” step 700 ( FIG. 7 ) proceeds if step 600 returns no customer ID. At this point the customer is presented with an option to set up a new account or enter a new phone number. The “Get New Customer Information” step 800 ( FIG. 10 ) gathers information and creates a new customer record. The “Display screen for daytime contact number” step 805 ( FIG. 10 ) causes the front kiosk screen to display instructions for the customer to enter a daytime phone number using the touch screen interface 12 ( FIG. 1 ). The instructions are also read to the customer via synthesized computer voice over speaker 16 . In the following “User Inputs Phone Number ” step 810 ( FIG. 10 ) the customer enters a daytime contact number for an employee to contact them and set up their profile, via the touch screen interface 12 . When the phone number is entered the customer selects “continue” on the touch screen 12 , and the “New Customer Record Created” step 815 creates a record in the new customer table based on information from the customers magnetic card data gathered in step 300 ( FIG. 7 ) and phone number entered in step 810 . Then the “New customer file created for third party software” step 820 creates a file and passes it to a third party software point of sale system, in a format that has been pre-agreed upon.
The “Check For Ready Items” step 900 in FIG. 7 occurs when a return customer is involved (i.e., the customer is found not to be new in preceding step 700 et. al.). Step 900 queries the conveyor and order tables in the database to determine if the customer identified in step 600 has items that are able to be delivered through the kiosk. The “Check conveyor table in database for ready orders” step 905 ( FIG. 11 ) checks the conveyor table looking for orders that are ready for the identified customer. If no order is found in step 910 , the routine returns to step 900 . If an order is detected in the “Orders Found” step 910 , i.e., if orders were located in the conveyor table for the identified customer, the “Check orders table to verify order is allowed to be picked up through kiosk” step 915 executes, wherein the orders table is queried and checked via the relationship with the conveyor table. The matching order is then checked to verify that the third part software will allow the order to be picked up through the kiosk in step 920 . If the “Orders valid to be picked up, step 920 finds that none of the orders are authorized to be picked up, control is returned to the customer user interface 950 , otherwise the “Orders Ready to be picked up” screen 922 is displayed and the customer is told that they have orders ready to be picked up and asks if they want to pick them up now. If they respond in step 924 with “no” or choose the “Express Drop Off” button, control is passed to the customer user interface step 950 . If “yes” is selected, then the “Create command to pick up orders” step 925 follows, and the list of valid orders is generated and sorted based on the most efficient grouping to expedite off loading by the system. The off load commands are then placed in a queue to be processed by the system. The “Create pickup file for Third Party Software” step 930 creates a file and passes it to a third party software point of sale system, in a format that has been pre-agreed upon.
Referencing FIG. 7 , in step 950 , a routine checks to see whether or not the customer has selected “express drop off”. If yes, control passes to the “Process Drop Off” routine, step 1200 . If no, then in the “Display drop off screen” step 1000 a screen is displayed on the kiosk touch screen 12 asking the customer if they will be dropping off items for cleaning. The instructions are also read aloud to them through the use of the computer synthesized voice on speaker 16 . In the “Dropping Off” step 1100 the customer responds to the drop off screen by touching the “Yes”, “No”, or “Express” button displayed on the touch screen. If the customer responds with a “no,” then control is passed to step 1300 detailed below. If either a “yes” or “Express” is selected in step 1100 , or if “Express” was selected in step 950 , the “Process Drop Off Routing” step 1200 ( FIG. 12 ) proceeds. Routine 1200 interacts with the customer to gather information about the order being dropped off, prints receipts and creates the necessary records needed for the transaction.
If in step 1210 ( FIG. 12 ) it is determined that “Express” was selected, then control is passed to step 1250 .
If in step 1210 ( FIG. 12 ) it is determined that “Express” was not selected, then during the “Ask user how many items they are dropping off” step 1220 , the kiosk touch screen 12 displays, and the speaker 16 verbally announces, asking how many items the customer/user will be dropping off. The customer then enters the number of items they are dropping off through an on screen keyboard. The customer presses “continue” to move to the “Display ‘need a bag’ screen” step 1225 ( FIG. 12 ). The kiosk touch screen 12 displays a screen informing the customer that all items dropped off will need to be in a bag, and asks if they will need a bag. This information is also read verbally to the customer. In the succeeding “Ask user if they need a bag” step 1230 , the user/customer will answer “yes” or “no” using the touch screen 12 and the indicated yes or no buttons. In step 1235 , if they answer no, control is passed to step 1250 , but if they answer “yes,” the “Activate bag dispenser” step 1240 follows, sending a command to the kiosk's machine control unit PLC 31 ( FIGS. 2 & 3 ) to dispense one bag from the bag vending device attached to the kiosk. The following “Display bag instructions” step 1245 ( FIG. 12 ) causes the kiosk touch screen 12 to display a message informing the customer to place all items in a bag and to place the bag inside of the kiosk cabinet. In the “Print 2 copies of the receipt” step 1250 two copies of the receipt is printed via the kiosks' built-in printer. One copy is for the customer to keep for a record, the other copy is placed inside the bag with the items to identify the order to the third party software. The “Display receipt printing screen” step 1255 ( FIG. 12 ) displays a screen on the kiosk's touch screen 12 informing the customer that receipts are being printed and instructing them to place one receipt in the bag and keep the other. The “Ask user if reprint is needed” step 1260 provides an option to print another copy of the receipt. The customer responds to the question in step 1265 via the touch screen and yes/no buttons. If they answer “yes” then control is passed back to step 1250 . The “Create drop-off record in database” step 1270 follows if step 1265 results in a “no.” In step 1270 , a record is created in the drop-off table in the database containing the customer ID, the number of items they are dropping off, the date and time, promise date on the order and other miscellaneous information. The “Create drop-off file for third party software” step 1275 creates a file and passes it to a third party software point of sale (POS) system, in a format that has been pre-agreed upon. Step 1300 , the “Finish Transaction” step, ( FIG. 7 ) follows.
The “Finish transaction” step 1300 of FIG. 7 is detailed in FIG. 13 . This routine delivers the completed orders to the customer, asks the customer if they would like to reject an order, and handles the reject operation. The “Orders to be delivered” step 1305 ( FIG. 13 ) checks the results from step 900 ( FIG. 7 ); if there are no orders to be delivered, control is passed to step 1360 . If step 1305 determines that orders are ready to be delivered, then the commands are executed and sent to the machine control unit 31 ( FIGS. 2 & 3 ) for retrieval.
The “Wait for a Batch of Orders to be Ready” step 1310 organizes batches of cleaned garments. Orders are picked up in batches to accommodate the size of the pickup cabinet. Excessively large orders will be delivered in several successive batches. The “Batch ready” step 1315 checks a register in the machine control unit 31 ( FIGS. 2 & 3 ) to see if a batch of orders is ready. If the batch is not ready, control is sent back to step 1310 . If a batch is ready, the “Rotate rotary door” step 1320 which is detailed in FIG. 17 follows.
During the “Rotate rotary door” routine ( FIG. 17 ), step 17 . 20 checks a register in the machine control unit PLC 31 ( FIGS. 2 & 3 ) to determine if the kiosk's front door 11 ( FIG. 1 ) is locked. If “yes”, then control proceeds to step 17 . 40 . If “No”, then in step 17 . 30 , a command is executed by the machine control unit 31 ( FIGS. 2 & 3 ) to lock the front door. Then in step 17 . 40 , a register in the machine control unit 31 ( FIGS. 2 & 3 ) is checked to determine if the rotary door 35 ( Fig.5 ) is locked. If “No”, then control proceeds to step 17 . 60 . If “Yes”, then a command is executed in step 17 . 50 by the machine control unit 31 ( FIGS. 2 & 3 ) to unlock the rotary door. In step 17 . 60 , a command is executed by the machine control unit 31 ( FIGS. 2 & 3 ) to rotate the rotary door, then is step 17 . 70 a command is executed by the machine control unit 31 to lock the rotary door. Then in step 17 . 80 , a register in the machine control unit is checked to determine if the rotary door is in the “hook-out” position. If “No”, then control passes to step 1325 ( FIG. 13 ). If “Yes”, then in step 17 . 90 a command is executed by the machine control unit 31 ( FIGS. 2 & 3 ) to unlock the front door before proceeding to step 1325 ( FIG. 13 ).
Next, referencing FIG. 13 , step 1325 entitled “Display prompt for user to remove orders from cabinet,” follows, and the kiosk's touch screen 12 ( FIG. 1 ) displays a message telling the user/customer to open the front door 11 , reach in and remove their order, and then press the “continue” button. Then in step 1327 , a routine checks to determine if the customer has removed the items from the kiosk. The routine repeats until that is confirmed, and then the “More orders to be delivered” step 1330 checks to see if all orders for that customer have been delivered, or if more orders remain. If more orders remain then the commands are sent to the machine control unit 31 ( FIGS. 2 & 3 ) to extract and deliver the next batch or orders and control is passed to step 1335 , otherwise control goes to step 1340 . In step 1335 ( FIG. 13 ) the kiosk's touch screen 12 ( FIG. 1 ) displays an instruction, and the speaker 16 ( FIG. 1 ) verbally announces, that the customer should wait for the next batch of orders that will be delivered, control passes to step 1337 and the rotate rotary door routine runs per the steps previously described in FIG. 17 , then control is returned to step 1310 . In step 1340 the customer is visually and audibly instructed to inspect all of their orders via touch screen 12 and the speaker 16 ( FIG. 1 ) respectively. The customer is then asked if they would like to return or reject any of their orders in step 1345 .
The “Reject order” step 1347 ( FIG. 13 ) requires the customer to indicate a “yes” or “no” by pressing corresponding buttons on the kiosk's touch screen 12 . If the answer is “no,” then control is passed to step 1360 . If the answer is “yes”, and an order is to be rejected, the “Process reject of an order” step 1350 runs. Referencing FIG. 14 , the “Display message for user to enter a daytime phone number” step 1351 causes the kiosk touch screen to display instructions for the customer/user to enter a daytime phone number. The latter instruction is announced orally on speaker 16 . The “User inputs phone number” step 1352 instructs the customer to input a phone number through the kiosk's touch screen and on screen number pad. The customer chooses “continue” on the touch screen display when done entering the requested phone number. In the “Reject record is created in database” step 1353 a record is created in the “rejects table” in the database. This record contains the customer ID, phone number, date and time of the transaction and other miscellaneous information. The “Display instructions for user to place order on hook inside of cabinet and close door” step 1354 is facilitated by the touch screen display and verbal system, presenting instructions for the customer to place the order they are returning inside the cabinet on the hook, close the door, and then press the continue button on the screen 12 . The routine is then complete and control passes to step 1360 where a routine runs to check whether or not the rotary door 35 ( FIG. 5 ) is in the hook-in position. If “yes”, control is passed to step 1395 . If “no”, then the rotate rotary door routine, step 1390 ( FIG. 17 ) is executed, then control is passed to step 1395 . In step 1395 , a routine checks to determine if the rejected clothes sensor 33 ( FIG. 5 ) has been tripped. If “No”, control is passed to step 1400 ( FIG. 7 ). If “Yes”, step 1397 process rejected/left behind orders routine ( FIG. 18 ) is run.
In FIG. 18 , the Process Rejected/Left Behind Orders routine begins with step 18 . 10 in which an available slot on a hanger bracket 47 ( FIG. 4 ) on the electric storage conveyor 48 ( FIGS. 4 , 5 & 6 ) is found on which to hang the rejected/left behind order. Then in step 18 . 20 , the machine control unit PLC 31 ( FIGS. 2 & 3 ) moves the electric storage conveyor to position that available slot at a point where it can be loaded by the garment transfer unit 38 ( FIG. 5 ). Then in step 18 . 30 , the garment transfer unit removes the rejected/left behind order from the delivery hook 52 ( FIG. 5 ) and places it onto the available hanger bracket slot on the conveyor. A record is then created in the database in step 18 . 40 for the order and slot number. Then in step 18 . 50 , a routine is run to determine if the order was a rejected order (per step 1347 , FIG. 13 ). If “Yes”, a rejected order record is created in the database in step 18 . 60 and a message is sent to kiosk management that an order has been rejected. Control then passes to step 1400 ( FIG. 7 ) where a finish screen is displayed on the touch screen monitor 12 ( FIG. 1 ). If “No”, then in step 18 . 70 a left behind order message is created in the database and a message is sent to kiosk management that an order has been left behind by a customer. An order record is then created in the database for the last customer to use the system in step 18 . 80 enabling the order to be retrieved again in the event the customer returns to do so. The routine is then complete and control then passes to step 1400 ( FIG. 7 ) where a finish screen is displayed on the touch screen monitor 12 ( FIG. 1 ).
After checking registers on the machine control unit 31 ( FIGS. 2 & 3 ) to verify that the door is closed and locked, audible “thank you” message is played and control is sent to step 100 .
Load Station User Interface
The load station consists of a secondary computer monitor 20 ( FIG. 4 ) which is touch screen enabled. A serial barcode scanner 21 is used as an input device to supplement the touch screen. Operation commences with the “Display operator load screen” step 2000 ( FIG. 15 ). The main load station User Interface (UI) screen is displayed on the monitor 20 ( FIG. 4 ). This screen has an input box allowing for the entry of an order number. The “Operator scans or types order number” step 2005 ( FIG. 15 ) allows the order number to be entered using the onscreen number pad, or scanned using the attached serial scanner. The “Verify order” step 2010 compares the order number entered in step 2005 against the orders table in the database. The “Valid order?” step 2015 looks for an order entry corresponding to that found in the database in step 2010 , and control is sent to step 2020 , otherwise control is passed to 2025 .
The “Find optimal load position” step 2020 insures maximum time efficiency by arranging delivery of orders for the same customers as close together as possible. This is determined through the algorithm of FIG. 16 .
In FIG. 16 , a routine in step 2020 . 2 determines if the customer who owns the order that was just entered has any other orders already hanging on the conveyor. If no, the nearest empty slot (or hook) is assigned to the order in step 2020 . 7 . If yes, then the nearest hanging order is determined in step 2020 . 3 and then in step 2020 . 4 a routine runs to determine if there is an empty slot next to the order found in step 2020 . 3 If yes, then that slot is assigned to the order being loaded. If not, another routine runs in step 2020 . 5 to determine if there are additional orders belonging to the same customer that are already hanging on the conveyor. If yes, then in step 2020 . 6 the nearest of those orders is determined and control is passed back to step 2020 . 4 . If no, then in step 2020 . 8 the closest empty slot on the conveyor is determined and is assigned to the order being loaded. Control then returns to step 2030 ( FIG. 15 ).
The target load position is displayed on the load station monitor. Control is then passed to the “Move conveyor to load position” step 2030 that issues a command to the machine control unit 31 ( FIGS. 2 & 3 ) to rotate the conveyor to the correct load position. This is done by moving the conveyor in the direction that yields the shortest travel distance. The operator confirms the load operation in step 2035 , i.e., the operator is given the choice of loading and confirming the placement of the order, or manually entering a new location and confirming the new location. Placement of the order onto the conveyor is confirmed either by a sensor located on the load shroud 42 ( FIG. 4 ), or by the operator pressing a confirmation button on the load station touch screen monitor 20 ( FIG. 4 ).
In the event a new location is selected by the operator, a command is sent to the machine control unit 31 ( FIGS. 2 & 3 ) to rotate the conveyor to the new position. If step 2040 confirms a “yes”, steps 2045 and 2050 follow, otherwise the program returns to step 2000 .
If no order was found in step 2015 , the “Display order not found to Operator” step 2025 provides a message displayed to the operator that the order was not found, and requests that he or she please retry. Control is then passed to step 2000 , which results in rescanning and another verification attempt.
The “Create conveyor record in database for order” step 2045 ( FIG. 15 ) creates a record in the conveyor table in the database for the order. The location, order number, time of load, customer ID and other miscellaneous information is contained in this record. Finally, the “Create load file for Third Party Software” step 2050 creates a file and passed it to a third party software point of sale system, in a format that has been pre-agreed upon. Control is then passed back to step 2000 .
Garment Transfer Unit
The garment transfer unit 38 is depicted in FIG. 19 and consists of a vertical actuator 92 , horizontal actuator 93 , rotary actuator 94 , reach actuator 95 , angular gripper 96 , and two gripper fingers 97 . Each of these components may be either pneumatic or electric.
In FIG. 20 , when transferring orders from the electric garment storage conveyor 48 ( FIG. 5 ) to the rotary door order delivery hook 52 ( FIG. 5 ), the garment transfer unit is first positioned to the home position step 20 . 10 with the angular gripper 96 open, rotary actuator 94 is rotated so as to align the gripper fingers 97 perpendicularly with the storage conveyor 48 ( FIG. 5 ), vertical actuator at it's bottom position, horizontal actuator 93 at its most forward position and reach actuator 95 retracted. The reach actuator 95 is then extended in step 20 . 20 , and the angular gripper 96 is closed in step 20 . 30 to grip the neck of the garment hangers containing the order in the conveyor bracket 47 ( FIG. 4 ) slot, the vertical actuator 92 is moved to its top position in step 20 . 40 to lift the hangers out of the slot and the horizontal actuator 93 is then moved to its middle position in step 20 . 50 pulling the order away from the conveyor 48 ( FIGS. 4 & 5 ). The rotary actuator 94 is then rotated 90 degrees in step 20 . 60 to align the order so that it's parallel to the rotary door 35 ( FIG. 5 ). The horizontal actuator 93 is then moved to its most reverse position (closest to the kiosk cabinet 54 ( FIG. 5 )) in step 20 . 70 . The vertical actuator 92 is then moved to its bottom position in step 20 . 80 , setting the order's garment hanger hook(s) on the rotary door order delivery hook 52 ( FIG. 5 ). The angular gripper 96 is open in step 20 . 90 to release the garment hangers, then the reach actuator is retracted in step 20 . 100 to move the gripper fingers 97 clear of the garment hangers. The horizontal actuator 93 is then moved back to its middle position in step 20 . 110 , then the rotary actuator 94 is rotated 90 degrees in step 20 . 120 to position the gripper fingers perpendicular to the garment storage conveyor 48 ( FIG. 5 ), and the finally in step 20 . 130 the horizontal actuator 93 is moved to its most forward position in order to complete the return of the garment transfer unit to its home position.
In FIG. 21 , when transferring orders from the rotary door order delivery hook 52 ( FIG. 5 ) to the electric garment storage conveyor 48 ( FIG. 5 ), the garment transfer unit is first positioned to the home position step 20 . 10 with the angular gripper 96 open, vertical actuator at it's bottom position, rotary actuator 94 is rotated so as to align the gripper fingers 97 perpendicularly with the storage conveyor 48 ( FIG. 5 ), the horizontal actuator 93 at its most forward position and reach actuator 95 retracted. The horizontal actuator 93 is then moved to its middle position in step 21 . 20 , then in step 21 . 30 the rotary actuator 94 is rotated 90 degrees to align the gripper fingers to be parallel with the rotary door 35 ( FIG. 5 ). The horizontal actuator 93 is then moved to its most reverse position (closest to the kiosk cabinet 54 ( FIG. 5 )) in step 21 . 40 and then is step 21 . 50 the reach actuator 19 is extended. Then in step 21 . 60 the angular gripper 96 is closed so that the gripper fingers 97 grip the neck of the garment hanger(s) containing the order and then the vertical actuator 19 is moved to its top position in step 21 . 70 to lift the garment order off the rotary door order delivery hook 52 ( FIG. 5 ). Then in step 21 . 80 the horizontal actuator is moved to its middle position and then the rotary actuator 94 is rotated 90 degrees in step 21 . 90 to align the garment order perpendicularly to the garment storage conveyor 48 ( FIG. 5 ).
The horizontal actuator 93 is then moved to its most forward position in step 21 . 100 and the vertical actuator 92 is then moved in step 21 . 110 to its bottom position. The garment order's hanger(s) are then released onto the storage conveyor hanger bracket slot when the angular gripper 96 is opened in step 21 . 120 . The reach actuator is then retracted in step 21 . 130 to return the garment transfer unit to its home position, thus completing the process.
From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | An automated, self-service dry cleaning delivery system accepts and records items dropped off through a kiosk for cleaning, and returns cleaned items to the same kiosk for customer pick-up. A computer software program operates the conveyors, the loading doors, and material transporting equipment. To facilitate maximum customer satisfaction, numerous customer feedback choices are displayed to maximize system dexterity. | 3 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a method for operating a switching system for data packets having inputs and outputs, with temporary storage of the data packets at the input. Such switching systems for data packets are used, by way of example, for the design of local data networks (LAN=Local Area Network). An example of such a local data network is known by the name “ETHERNET” as a technical standard.
In such data networks, it is necessary for the data to be routed from a source to a destination in the form of data packets. This requires an appropriate switching system. On the basis of the prior art, the only solution there was for such switching systems for data packets in networks was either for the data packets to be temporarily stored at the input (INPUT BUFFERED) or for the data to be temporarily stored at the output (OUTPUT BUFFERED). Both solutions based on the prior art have considerable disadvantages. When the data packets are temporarily stored at the input, the system can be blocked by so-called “HEAD-OF-LINE BLOCKING”. In addition, traffic control by allocating different priorities to different data packets, and hence preferential switching of particular, especially urgent data packets, is possible only with great difficulty.
In the case of temporary storage at the output, a very large bandwidth is required for the buffer at the output, and such a system with temporary storage at the output additionally requires a very rapid decision about the data path to be used (routing).
Systems having a common memory, which represent a combination of a buffer at the input and a buffer at the output, also require a high bandwidth for the memory.
To date, the only switching systems on the market with a high bandwidth are those with temporary storage at the output, for example from Texas Instruments, or very complicated systems having a common memory.
SUMMARY OF THE INVENTION
The object set by the present invention was therefore that of providing a method for operating a switching system for data packets having inputs and outputs, with temporary storage of the data packets at the input, which combines the advantages of temporary storage at the input with the advantages of temporary storage at the output without having their respective disadvantages.
The invention achieves this object by virtue of the feature that, when each data packet arrives, a message is merely sent to the output and is placed into the queue there. In this way, the transmission of data and the transmission of the information for defining the sequence for transmission of the data are independent of one another. The necessary bandwidth for the internal connections in the switching system is now determined exclusively by the bandwidth of the local physical inputs, with a small addition for the logical channel for the messages. Hence, the bandwidth of the internal connections is defined and is not dependent on the total data throughput of the system.
Further advantages of the invention are that it enables the outputs to be prevented from becoming overloaded or from idling unnecessarily. To this extent, the method according to the invention acts in the manner of a data flow controller. In addition, the invention makes it possible to direct and organize traffic in a switching system with temporary storage at the input in the same way as would otherwise be possible only with temporary storage at the output.
Thus, the invention enables the advantages of temporary storage at the input and at the output to be combined and, at the same time, enables the disadvantages of each of the two systems to be avoided.
A further preference of the invention is that the message contains a reference, information about the priority for correct marshaling of the data packet and information about the length of the packet. This allows traffic to be directed and organized exactly in the data network.
A particularly simple hardware implementation of the present invention is possible if the message is transmitted via the same physical transmission path, but via a separate logical channel, as the data packets.
One preference of the invention is for a further message to be returned to the input memory from the output as soon as the data packet can be dispatched via the output, and only then for the data packet to be transmitted to the appropriate destination. It is then particularly preferred if the further message contains information about the destination of the data packet.
In order to reduce further the bandwidths necessary for transmitting the individual messages, it is particularly preferable according to the invention for the messages to be combined into message packets which are transmitted together via the switching system. It is then also preferable to use a data flow controller to handle transmission of the messages.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is explained in more detail below with the aid of the appended drawings, in which:
FIG. 1 shows a block diagram for an inventive switching system for data packets using the ETHERNET standard;
FIG. 2 shows a flowchart for a switching procedure within a module; and
FIG. 3 shows a switching procedure between two modules.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is described below with the aid of an illustrative embodiment which is in the form of a switching system for data packets for the ETHERNET standard.
As FIG. 1 shows, this switching system 10 is designed as follows:
The local area network is connected by means of the connection block (PORTS-BLOCK) 12 . This connection block comprises twelve access control devices on lines with a data rate of 100 megabit/s and an access control unit for a data rate of 1 gigabit/s. The access controllers on the individual lines are denoted by MAC (Medium Access Control). The access controller designed for one gigabit/s is denoted by GMAC, and the access controllers designed for 100 megabit/s are denoted by FEMAC. The outputs of these access controllers are connected to the bus 1 via a respective FIFO (First-In-First-Out) memory 14 . The bus 1 is additionally connected to a crossbar interface 16 and to a memory management unit 18 . In this arrangement, the crossbar interface 16 and the memory management unit 18 are also connected by further buses 2 and 3 . In addition, bus 2 is also connected to first-in-first-out memories 20 which collect the outgoing data packets and supply them either to one FEMAC each or to the GMAC together. The bus 1 is also connected to a header FIFO 22 . This header FIFO 22 (First-In-First-Out memory for the address part of the data packet) stores a maximum of 128 bytes of the address range of each data packet. The header FIFO 22 is connected to the address evaluation circuit 24 , 26 denoted by L2+ and L3 Interface.
Additionally connected to the bus 1 is the transmit buffer (TB) 28 , which carries out the direct memory access operations from the main memory of the connected microprocessor or computer via an interface DMUT 30 .
The bus 2 is likewise connected to the receive buffer (RB) 32 , which carries out the corresponding write access operations directly to the main memory of the connected microprocessor or computer via a corresponding interface DMUR 34 . Since, in this case, access operations are carried out using direct access (DMA—Direct Memory Access), an interrupt controller 36 and a PCI-FPI bridge 38 are also provided for synchronization with the microprocessor or computer. In addition, a protocol unit 40 is provided which is connected to the bus 2 and to a further bus 3 , which in turn connects the memory management unit 18 and the crossbar interface 16 . The protocol unit 40 is additionally connected to the queue manager 42 .
The switching system shown in FIG. 1 essentially has five tasks:
1. To match the data rates, the switching system needs to store data and deliver it on request. 2. The switching system must be able to work with comprehensive time-consuming table references (Lookup) used by higher-level protocols. It is therefore necessary for the complete data packet to be temporarily stored before a decision can be made about the destination for forwarding the data packet. This means that the data packets need to be temporarily stored at the input. 3. Under some circumstances, the time taken for processing the table references, measured in clock cycles, may not be constant. This produces the need for temporary storage of the address parts of the data packets in a FIFO memory (Header FIFO) 22 . 4. If data streams are to be processed in real time, it is necessary to define a sequence on the output side, in order to control the throughput as a function of the bandwidth per connection. Similarly, simple allocation of priorities during the data switching needs to be assured, and blocking (Head of line blocking) needs to be precluded. 5. Modification of the addresses must be possible, where not only can particular address fields be changed, but also parts of the address range can be added or erased.
On the basis of these requirements, the way in which the switching system for data packets shown in FIG. 1 works is described below:
An access controller receives a data packet on a line (Medium Access Control MAC) from the network (LAN) and writes it via the internal bus 1 to the packet memory 44 , which is likewise connected to the memory management unit 18 . To match the data rate between the input and the internal bus 1 , a bus access controller and a first-in-first-out memory 14 need to be provided. The respective access controller also handles the tasks associated with the transmission protocol, such as throughput control. Connected to the bus 1 are twelve access controllers for a speed of 100 megabit/s (FEMAC) and an access controller for one gigabit/s (GMAC). However, only either the twelve FEMACs or the GMAC are active in each case. Hence, all the units connected to the bus 1 perceive no difference as to whether the data arrives via the GMAC or the FEMAC. The result of this is considerable simplification.
In transmission mode, the access controllers indicate receptivity if there are more than 1536 bytes of space in the appropriate transmit FIFO memory 20 . A further data packet is then retrieved from the packet memory 44 . The packet is transmitted via the bus 2 to the appropriate FIFO 20 , and is assembled there. When the packet has been assembled completely, the access controller immediately indicates readiness to transmit again if there are still more than 1536 bytes free in its transmit FIFO memory 20 . At the same time, transmission of the data packet via the appropriate line begins.
In the case of the GMAC, the request for an appropriate data packet for a FIFO memory 20 takes too long to utilize the transmission speed of the GMAC on the line fully. In this case, all twelve transmit FIFO memories 20 request and assemble frames in parallel. After assembly, the data packets are forwarded to the GMAC in the correct sequence and are transmitted onto the GIGABIT Ethernet line by the GMAC.
The text below uses FIG. 2 to describe the path of an individual data packet through the switching system shown in FIG. 1 . All modifications of this path (local/remote, one receiver/a plurality of receivers) can be derived from this example.
When a data signal is recognized at the physical level, the start of a receive procedure is indicated to the appropriate access controller (MAC). The access controller removes preambles, limiters and the cyclic checksums after the check and adds a network address for a virtual LAN, provided that there is not already one available. The data packet is written to the receive FIFO memory 14 and, provided that the memory contains more than 128 bytes, or the entire packet comprises less than 128 bytes, the packet is written to the packet memory 44 in sections of 64 bytes via the bus 1 and the memory management unit 18 . The first two sections are additionally copied to the header FIFO memory 22 . A reference address for the data packet in the packet memory 44 is transmitted back by the memory management unit 18 and is likewise stored in the header FIFO memory 22 . The first and last sections of a packet have a special significance. If the reception procedure was erroneous, for example on account of a checksum error or a collision, this will be discernable from the last section, and the memory management unit 18 will erase the packet from the packet memory 44 and from the header FIFO memory 22 .
Once the entire packet has been received, the header FIFO memory 22 marshals the entry for processing by the address evaluation circuit 24 . As soon as the address evaluation circuit 24 has free processing capacity, it takes the first entry in the memory 22 for processing.
Address processing can result in various measures. The assumption for this data packet is that it has a new source address and a known local destination address. In addition, the address can be changed in the network. The changed address is written back to the memory management unit 18 . FIG. 2 shows the procedure after address determination as a message diagram. The address evaluation circuit 24 uses an “advertise” message 1 to instruct the protocol unit 40 to forward this message to the local queue manager 42 as message 2 . The information transmitted is the reference address, the sequence designation and a few other items of information. The sequence information implicitly contains the local output connection and the priority of the data packet. Internally, the address evaluation circuit 24 adds the new source address to its address table and produces a “learn” message in order to inform the other line units in the system of how this new address can be reached, or resets the aging counter.
When an access controller MAC is able to transmit a data packet, it signals its availability to the queue manager 42 by means of a message 3 . The queue manager 42 receives this availability information and a queue belonging to this local output connection is sought. Provided that a data packet is waiting to be transmitted there, the queue manager 42 sends the address of the reference element and the local output connection to the protocol unit 40 as message 4 . The protocol unit 40 produces a message 5 for the memory management unit 18 . The memory management unit 18 then starts to transmit the requested data packet via the bus 2 to the output FIFO memory 20 for the appropriate output connection. This procedure is denoted by 6 here. When transmission has ended correctly, the memory management unit 18 checks the counter for multiple transmissions, and, if this counter is counted down, the memory management unit 18 will enable the appropriate memory area in the data packet memory 44 . As soon as the entire data packet has been transmitted to the transmit FIFO memory 20 , the access controller begins to transmit the data packet onto the line.
If a data packet is to be transmitted via a further, remote switching system, as shown in FIG. 3 , the reception procedure is the same, up to the address determination, as for a local path of the data packet. In this case, however, resolution of the references produces a nonlocal destination specification for the data packet. The “advertise” message is transmitted, with the input address of the data packet in the data packet memory 44 plus the input chip identification, from the protocol unit 40 to the opposite station at the output. The message thus runs from the address manager 24 to the dedicated protocol unit (message 1 ), and from there to the remote protocol unit 40 ′ (message 2 ). At the output, the protocol unit 40 ′ there forwards the message as message 3 to the queue manager 42 ′ at the output. As soon as an access controller at the output is free for transmission and reports this by means of message 4 , the queue manager 42 ′ at the output requests the data packet from the memory management unit 18 at the input via protocol units 40 ′, 40 at the output and input. In this way, the messages 5 , 6 and 7 are produced. Using the chip and connection identification provided, the memory management unit 18 transmits the data packet to the connection block 12 ′ at the output via the crossbar interface (crossbar) 16 (message 8 ). The only difference in this method as compared with the local path is the different way in which the queue manager receives and requests a data packet. In the present example, the connection block 12 ′ is ready before the “advertise” message arrives in the queue manager 42 ′. This can occur with a low volume of data traffic.
The present invention thus uses an input-buffered architecture to permit detailed table references for route selection and assurance of service quality, and with regard to the reasonable demands on the memory bandwidth. According to the invention, however, in contrast to the usual prior art, a supplementary message protocol is introduced which merely transmits a reference, a sequence information item and a length information item to the output for each data packet received (called “advertise” message or announcement message). At the output, only this reference is marshaled into the queue. These messages require much less bandwidth than transmission of the entire packet to the output. The message protocol uses the same physical data link, but in a separate logical channel to the output, as the data packets. The marshaling of the references into a corresponding queue can be called virtual marshaling of the data packet. The transmitting physical output connection requests a data packet from the queue manager 42 , and the reference to this data packet is sent back to the input buffer memory (request message) in which the data packet is stored, with the information being transmitted at the same time via the destination connection. The input buffer then transmits the data packet to the destination connection. When the data packet has arrived correctly, it is transmitted on the data line and the next data packet is requested from the queue manager 42 .
Announcement and request messages going to the same chip can be combined in message packets in order to reduce the bandwidth required for transmitting them. A data flow controller can be used on the message traffic in order to prevent overload situations in the message channel and the message processing units.
The present invention separates, for the first time, the transmission of data from the transmission of the appropriate information to the sequence controller, which makes the system very open to matching. According to the invention, the necessary bandwidth of the internal data links is determined only by the bandwidth of the local physical connections plus a little surplus for the logical message channels. The bandwidth required for the internal connections is fixed and is not dependent on the total throughput of the system. The announcement/request message protocol of the present invention protects the outputs of the system against overload or unnecessary idling and, in this respect, acts in the manner of a throughput controller. The invention combines the advantages of input-buffered systems and output-buffered systems and avoids the disadvantages of these two solutions.
The announcement/request message protocol according to the invention permits input-buffered systems to perform the same traffic management as is otherwise possible only in the case of output-buffered systems.
The method according to the invention prevents blocking of the system, as can occur in input FIFO buffered systems, when the packet at the very front in the FIFO buffer cannot be switched immediately. | A method for operating a switching system for data packets includes providing a switching system having inputs and outputs, temporarily storing data packets at an input of the switching system where, when each data packet arrives, merely sending a message to an output of the switching system at the input and placing the message into a queue at the output. The method combines advantages of temporary storage at the input with the advantages of temporary storage at the output, without having to accept the disadvantages of one of such systems. | 7 |
[0001] Desired skin colour is a major unmet consumer need in Asia. Consumers particularly desire even skin colour, absence of age spots (solar lentigines) and lighter overall skin tone. One solution is to use biological actives that reduce the activity of melanocytes in skin. These cells, present in the basal layer of the epidermis, make the darkly coloured pigment melanin and export it in small export vesicles called melanosomes to the neighbouring keratinocytes. It is well described in the literature that compounds which reduce melanin synthesis when topically applied to the skin will reduce skin darkness over time.
[0002] This invention relates to a composition comprising a synergistic combination of ketoconazole and sulforaphane for use in skin lightening. This invention is based on the fact that a combination of ketoconazole and sulforaphane has been found to synergistically inhibit pigment production in B16 monolayer cultures. Thus the composition, when applied topically or imbibed over an appropriate length of time in-vivo, would be expected to cause skin lightening, or to reduce blemishes and/or hyperpigmented spots and/or solar lentigines leading to an improvement in skin tone and evenness.
[0003] Ketoconazole is sold (for example as Nizoral™ by Johnson & Johnson Inc. and Daktarin™ Gold by Janssen Pharmaceutica NV) in a topical and oral over-the-counter (OTC) preparation for the treatment of fungal diseases.
[0004] WO 2007/072216 A2 discloses a therapeutic kit including a therapeutic azole with increased solubility. The kit includes an aerosol packaging assembly having a container accommodating a pressurized product and an outlet capable of releasing the pressurized product as a foam. The pressurized product is a foamable composition including, amongst other things, a therapeutic azole. In exemplary embodiments, the therapeutic azole is an imidazole or triazole selected from a group including ketoconazole. In one or more embodiments, the foamable composition further includes at least one additional therapeutic agent selected from the group including a skin whitening agent.
[0005] In WO 02/053108 A2, retinoic acid is disclosed as having been employed to treat a variety of skin conditions including age spots and discoloration. Compounds which inhibit acyl coenzyme A (CoA): retinol acyl transferase/lecithin retinol acyl transferase (ARAT/LRAT), retinal reductase, cellular retinoic acid binding protein II (CRAB PII) and retinoic acid oxidation (the latter catalyzed by cytochrome P450 systems), and others which enhance retinol dehydrogenase are collectively termed “boosters”. The boosters, alone or in combination with each other, potentiate the action of a retinoid by increasing the amount of retinol available for conversion to retinoic acid and inhibiting the degradation of retinoic acid. Ketoconazole is identified as a retinoic acid oxidation inhibitor.
[0006] In Mun et al (Biol. Pharm. Bull., 27(6), 806-809 (2004)), the inhibitory effect of miconazole is described on melanogenesis in B16 melanoma cells. Tyrosinase activity and melanin content were dose dependently decreased by the azole as compared with untreated cells, however this is accompanied by decreased cellular viability.
SUMMARY OF THE INVENTION
[0007] In a first aspect of the invention, a skin lightening composition is provided, the composition comprising ketoconazole and sulforaphane. Ketoconazole has the following structure:
[0000]
[0008] and sulforphane has the following structure:
[0000]
[0009] It is obtained from cruciferous vegetables such as broccoli. The enzyme myrosinase transforms glucoraphanin, a glucosinolate, into sulforaphane upon damage to the plant (such as from chewing). Young sprouts of broccoli and cauliflower are particularly rich in glucoraphanin.
[0010] The skin lightening composition may comprise 0.001 to 2, preferably 0.005 to 0.5% w/w ketoconazole. The skin lightening composition may comprise 0.001 to 2, preferably 0.01 to 1% w/w sulforaphane.
[0011] The sulforaphane may be in the form of the L-isomer, preferably exclusively in the form of the L-isomer.
[0012] The skin lightening composition may be in the form of an oral or topical composition.
[0013] In a second aspect of the invention, the composition of the first aspect is provided for use in skin lightening. In one embodiment of this aspect, the composition of the first aspect is provided for use in skin lightening, wherein the composition is used such that the daily dosage for oral use of ketoconazole is 50 to 200, preferably 50 to 100 mg; and the daily dosage for oral use of sulforaphane is 50 to 600, preferably 200 to 400 mg.
[0014] In the alternative, use of ketoconazole and sulforaphane is provided in the manufacture of the composition of the first aspect for lightening skin. In a further embodiment of this alternative, use of ketoconazole and sulforaphane is provided in the manufacture of the composition of the first aspect for lightening skin, wherein the composition is administered such that the daily dosage for oral use of ketoconazole is 50 to 200, preferably 50 to 100 mg; and the daily dosage for oral use of sulforaphane is 50 to 600, preferably 200 to 400 mg.
[0015] In a further alternative, a method of lightening the skin of a human is provided, the method comprising the step of a person in need thereof imbibing the composition of the first aspect. In a further embodiment of this further alternative, a method of lightening the skin of a human is provided, the method comprising the step of a person in need thereof imbibing the composition of the first aspect such that the daily dosage of ketoconazole is 50 to 200, preferably 50 to 100 mg; and the daily dosage of sulforaphane is 50 to 600, preferably 200 to 400 mg.
SUMMARY OF THE FIGURES
[0016] The invention is illustrated with reference to the following figures wherein:
[0017] FIG. 1 shows darkly pigmented MelanoDerm™ cultures treated with 1 μM ketoconazole for 14 days (right hand side) versus DMSO control (left hand side) with melanin content visualised with Masson-Fontana staining;
[0018] FIG. 2 shows darkly pigmented MelanoDerm™ cultures treated with 1 μM ketoconazole for 14 days (righthand side) versus DMSO control (left hand side) with melanocytes visualised with MART-1 immuno-staining; and
[0019] FIG. 3 shows light microscopy images of normal human melanocytes derived from a dark skinned donor after treatment with 1 μM ketoconazole for 5 days (right hand side) versus DMSO control (left hand side).
DETAILED DESCRIPTION OF THE INVENTION
[0020] Topical Compositions
[0021] It should be known that commercially acceptable and conventional vehicles may be used in topical compositions of the invention, acting as diluents, dispersants and/or carriers for the skin lightening agents described herein and for any other optional but often preferred ingredients. Therefore, cosmetically acceptable vehicle suitable for use in this invention may be aqueous-based, anhydrous or an emulsion whereby a water-in-oil or oil-in-water emulsion is generally preferred. If the use of water is desired, water typically makes up the balance of the composition, and preferably makes up from about 5 to about 99%, and most preferably from about 40 to about 80% by weight of the topical composition, including all ranges subsumed therein.
[0022] In addition to water, organic solvents may be optionally included to act as carriers or to assist carriers within the compositions of the present invention. Illustrative and non-limiting examples of the types of organic solvents suitable for use in the present invention include alkanols like ethyl and isopropyl alcohol, mixtures thereof or the like.
[0023] Other optional additives suitable for use include ester oils like isopropyl myristate, cetyl myristate, 2-octyldodecyl myristate, avocado oil, almond oil, olive oil, neopentylglycol dicaprate, mixtures thereof or the like. Typically, such ester oils assist in emulsifying the composition of this invention, and an effective amount is often used to yield a stable, and most preferably, water-in-oil emulsion.
[0024] Emollients may also be used, if desired, as carriers within the composition of the present invention. Alcohols like 1-hexadecanol (i.e. cetyl alcohol) are often desired as are the emollients generally classified as silicone oils and synthetic esters. Silicone oils suitable for use include cyclic or linear polydimethylsiloxanes containing from 3 to 9, preferably from 4 to 5, silicon atoms. Non-volatile silicone oils useful as an emollient material in the inventive composition described herein include polyalkyl siloxanes, polyalkylaryl siloxanes and polyether siloxane copolymers. The essentially non-volatile polyalkyl siloxanes useful herein include, for example, polydimethylsiloxanes.
[0025] The ester emollients that may optionally be used are:
(1) Alkenyl or alkyl esters of fatty acids having 10 to 20 carbon atoms. Examples thereof include isoarachidyl neopentanoate, isononyl isonanonoate, oleyl myristate, oleyl stearate, and oleyl oleate. (2) Ether-esters such as fatty acid esters of ethoxylated fatty alcohols. (3) Polyhydric alcohol esters. Ethylene glycol mono and di-fatty acid esters, diethylene glycol mono- and di-fatty acid esters, polyethylene glycol (200-6000) mono- and di-fatty acid esters, propylene glycol mono- and di-fatty acid esters, polypropylene glycol 2000 monooleate, polypropylene glycol 2000 monostearate, ethoxylated propylene glycol monostearate, glyceryl mono- and di-fatty acid esters, polyglycerol poly-fatty esters, ethoxylated glyceryl mono-stearate, 1,3-butylene glycol monostearate, 1,3-butylene glycol distearate, polyoxyethylene polyol fatty acid ester, sorbitan fatty acid esters, and polyoxyethylene sorbitan fatty acid esters are satisfactory polyhydric alcohol esters. (4) Wax esters such as beeswax, spermaceti, stearyl stearate and arachidyl behenate. (5) Sterols esters, of which cholesterol fatty acid esters are examples.
[0031] Emollients when used, typically make up from about 0.1 to about 50% by weight of the composition, including all ranges subsumed therein.
[0032] Fatty acids having from 10 to 30 carbon atoms may also be included as acceptable carriers within the composition of the present invention. Illustrative examples of such fatty acids include pelargonic, lauric, myristic, palmitic, stearic, isostearic, oleic, linoleic, arachidic, behenic or erucic acid, and mixtures thereof. Compounds that are believed to enhance skin penetration, like dimethyl sulfoxide, may also be used as an optional carrier.
[0033] Humectants of the polyhydric alcohol type may also be employed in the compositions of this invention. The humectant often aids in increasing the effectiveness of the emollient, reduces scaling, stimulates removal of built-up scale and improves skin feel. Typical polyhydric alcohols include glycerol, polyalkylene glycols and more preferably alkylene polyols and their derivatives, including propylene glycol, dipropylene glycol, polypropylene glycol, polyethylene glycol and derivatives thereof, sorbitol, hydroxypropyl sorbitol, hexylene glycol, 1,3-butylene glycol, 1,2,6-hexanetriol, ethoxylated glycerol, propoxylated glycerol and mixtures thereof. For best results the humectant is preferably propylene glycol or sodium hyaluronate. The amount of humectant may range anywhere from 0.2 to 25%, and preferably, from about 0.5 to about 15% by weight of the composition, based on total weight of the composition and including all ranges subsumed therein.
[0034] Thickeners may also be utilized as part of the acceptable carrier in the compositions of the present invention. Typical thickeners include cross-linked acrylates (e.g. Carbopol 982), hydrophobically-modified acrylates (e.g. Carbopol 1382), cellulosic derivatives and natural gums. Among useful cellulosic derivatives are sodium carboxymethylcellulose, hydroxypropyl methylcellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, ethyl cellulose and hydroxymethyl cellulose. Natural gums suitable for the present invention include guar, xanthan, sclerotium, carrageenan, pectin and combinations of these gums. Amounts of the thickener may range from 0.0 to 5%, usually from 0.001 to 1%, optimally from 0.01 to 0.5% by weight of the composition.
[0035] Collectively the water, solvents, silicones, esters, fatty acids, humectants and/or thickeners will constitute the acceptable carrier in amounts from 1 to 99.9%, preferably from 80 to 99% by weight of the composition.
[0036] Surfactants may also be present in compositions of the present invention. Total concentration of the surfactant will range from about 0 to about 40%, and preferably from about 0 to about 20%, optimally from about 0 to about 5% by weight of the composition. The surfactant may be selected from the group consisting of anionic, nonionic, cationic and amphoteric actives. Particularly preferred nonionic surfactants are those with a C10-C20 fatty alcohol or acid hydrophobe condensed with from 2 to 100 moles of ethylene oxide or propylene oxide per mole of hydrophobe; mono- and di-fatty acid esters of ethylene glycol; fatty acid monoglyceride; sorbitan, mono- and di-C8-C20 fatty acids; block copolymers (ethylene oxide/propylene oxide); and polyoxyethylene sorbitan as well as combinations thereof. Alkyl polyglycosides and saccharide fatty amides (e.g. methyl gluconamides) are also suitable nonionic surfactants.
[0037] Preferred anionic surfactants include soap, alkyl ether sulfate and sulfonates, alkyl sulfates and sulfonates, alkylbenzene sulfonates, alkyl and dialkyl sulfosuccinates, C8-C20 acyl isethionates, acyl glutamates, C8-C20 alkyl ether phosphates and combinations thereof.
[0038] Perfumes may be used in the composition of this invention. Illustrative non-limiting examples of the types of perfumes that may be used include those comprising terpenes and terpene derivatives like those described in Bauer, K., et al., Common Fragrance and Flavor Materials, VCH Publishers (1990).
[0039] Illustrative yet non-limiting examples of the types of fragrances that may be used in this invention include myrcene, dihydromyrenol, citral, tagetone, cis-geranic acid, citronellic acid, mixtures thereof or the like.
[0040] Preferably, the amount of fragrance employed in the composition of this invention is in the range from about 0.0% to about 10%, more preferably about 0.00001% to about 5 wt %, most preferably about 0.0001% to about 2% by weight of the compound.
[0041] Various types of optional additional active ingredients may be used in the compositions of the present invention. Actives are defined as skin benefit agents other than emollients and other than ingredients that merely improve the physical characteristics of the composition. Although not limited to this category, general examples include talcs and silicas, as well as alpha-hydroxy acids, beta-hydroxy acids, zinc salts, and sunscreens.
[0042] Beta-hydroxy acids include salicylic acid, for example. Zinc pyrithione is an example of the zinc salts useful in the composition of the present invention.
[0043] Sunscreens include those materials commonly employed to block ultraviolet light. Illustrative compounds are the derivatives of PABA, cinnamate and salicylate. For example, avobenzophenone (Parsol 1789®) octyl methoxycinnamate and 2-hydroxy-4-methoxy benzophenone (also known as oxybenzone) can be used. Octyl methoxycinnamate and 2-hydroxy-4-methoxy benzophenone are commercially available under the trademarks, Parsol MCX and Benzophenone-3, respectively. The exact amount of sunscreen employed in the compositions can vary depending upon the degree of protection desired from the sun's UV radiation. Additives that reflect or scatter the suns rays may also be employed. These additives include oxides like zinc oxide and titanium dioxide.
[0044] Many compositions, especially those containing water, should be protected against the growth of potentially harmful microorganisms. Anti-microbial compounds, such as triclosan, and preservatives are, therefore, typically necessary. Suitable preservatives include alkyl esters of p-hydroxybenzoic acid, hydantoin derivatives, propionate salts, and a variety of quaternary ammonium compounds. Particularly preferred preservatives of this invention are methyl paraben, propyl paraben, phenoxyethanol and benzyl alcohol. Preservatives will usually be employed in amounts ranging from about 0.1% to 2% by weight of the composition.
[0045] Still other optional ingredients that may be used with the composition of this invention include dioic acids (e.g. malonic acid and sebacic acid), antioxidants like vitamin E, retinoids, including retinoic acid, retinal, retinol and retinyl esters, conjugated linoleic acid, petroselinic acid and mixtures thereof, as well as any other conventional ingredients well known for wrinkle-reducing, anti-acne effects and reducing the impact of sebum.
[0046] When making the composition of the present invention, the desired ingredients are mixed in no particular order and usually at temperatures from about 70 to about 80° C. and under atmospheric pressure.
[0047] The packaging for the composition of this invention can be a patch, bottle, tube, roll-ball applicator, propellant driven aerosol device, squeeze container or lidded jar.
[0048] Oral Compositions
[0049] Oral compositions of the invention may be in the form of capsules, pills, tablets, granules, solutions, suspensions or emulsions.
[0050] If the composition is water-based, i.e. comprises at least 70% w/w water, it has the sensation of being a regular water-based product and would thus be consumed on a regular basis as part of a consumer's normal diet. For example it could replace a fruit juice normally consumed at breakfast. Preferably the water-based composition has a viscosity of from 2 to 100 centipoise at a shear rate of 1 s-1 and at 25 degrees centigrade.
[0051] The composition may comprise from 0.2 to 10%, preferably from 0.4 to 5& w/w oil. The oil may comprise at least 12, preferably at least 20% w/w eicosapentaenoic acid (EPA) and docosahexaenoic acid (DHA), both omega 3 polyunsaturated acids and known as fish oils. Increased intake of EPA has been shown to be beneficial in coronary heart disease, high blood pressure, and inflammatory disorders such as rheumatoid arthritis.
[0052] Antioxidant is required in order to prevent or slow down the natural oxidative degradation of the fish oil. Suitable antioxidants can be selected, although not exclusively, from the following list, either singularly or in combination: tert-butylhydroquinone (TBHQ), ascorbyl esters such as ascorbyl palmitate, ascorbic acid, tocopherols, rosemary extract, fruit concentrates or extracts, black or green tea extract, propyl gallate, essential oils or oleoresins, butylated hydroxyanisole (BHA), butylated hydroxytoluene (BHT), citric acid or esters, coenzyme Q10, tocotrienols, polyphenols, phenolic compounds and flavonoids.
[0053] Especially preferred antioxidants are vitamins C and E. Not only are these effective antioxidants but they also have been shown to give skin benefits when consumed.
[0054] The amount of antioxidant should be added sufficient to prevent the fish oil from going rancid over a typical shelf-life of 6 months. Clearly the amount of antioxidant will depend on the type and activity of the antioxidant used. However, preferably the product has a ratio of antioxidant to oil of from 1:10 to 1:100 based on the antioxidant activity of vitamin C. For these purposes an antioxidant activity is as measured using an appropriate assay, for example Trolox equivalent antioxidant capacity.
[0055] At least 0.01%, preferably from 0.05 to 3%, more preferably from 0.1 to 1% w/w phospholipid emulsifier, such as lecithin, has been found to be suitable for emulsifying high quantities of fish oil.
[0056] The composition may also comprise from 0.01 to 0.5%, preferably from 0.01 to 0.3% w/w soy isoflavones. Soy isoflavones are components within soy that have a biological function similar to oestrogen, including the promotion of dermal matrix protein synthesis. In addition, they have also been shown to have anti-inflammatory properties and stimulate synthesis of hyaluronic acid, a proteoglycan in skin which can retain water and thereby influence skin firmness. Preferably the soy isoflavones are selected from genistein and daidzein.
[0057] The composition may also comprise from 0.0005 to 0.1%, preferably from 0.002 to 0.04% w/w carotenoids. The carotenoids, being oil soluble, would be comprised predominantly within the oil phase. Highly preferred carotenoids are beta-carotene, and lycopene. These carotenoids provide moderate protection from UV induced erythema, thought to be due to their antioxidant functionality including scavenging of reactive oxygen species.
[0058] The composition is prepared from separate aqueous and oil phases. In general the water-soluble ingredients are combined to form the aqueous phase and the oil-soluble ingredients combined to form the oil phase. Then the two phases are blended together to form a homogenous stable emulsion. The stable emulsion may then be packaged in a sealed container such as a metal, coated cardboard, for example as marketed by Tetra Pak™, or a plastics container. The container is then preferably sealed so as to give no headspace or a gas filled, for example nitrogen or carbon dioxide, headspace. This assists still further in preventing the fish oil oxidising. Alternatively the emulsion may be frozen and packaged and sold as a frozen consumer product.
[0059] In-Vitro Studies of the Skin Lightening Effect of Ketoconazole
[0060] Materials
[0061] MelanoDerm™ Cultures
[0062] MatTek MelanoDerm™ cultures (a pigmented 3D-Living Skin Equivalent (LSE) model) purchased from the MatTek Corporation. Dark cultures (MEL-300-B), for evaluation of skin lightening potential, were prepared in a long life maintenance medium (EPI-100-LLMM available from the MatTek Corporation) for good pigment production whilst preserving acceptable histology.
[0063] On arrival samples were replaced into growth medium and left at 37° C. for 2 hours to recover prior to the administration of test items. Test actives were applied to the samples by addition to the growth medium. Fresh growth medium containing dimethyl sulphoxide (DMSO) alone or test actives was replaced every 2-3 days and the cultures were grown in this way for 14 days prior to harvesting and analysis. Prior to extraction or fixation cultures were assayed using the WST-1 cell proliferation assay.
[0064] B16 Monolayer Cultures
[0065] B16 mouse melanoma cells were cultured in Eagle's minimal essential medium (EMEM) supplemented with 10% foetal calf serum (FCS) and 2 mM L-glutamine at 37° C., 5% CO2 in T175 tissue culture flasks and were sub-cultured twice weekly using trypsin in EDTA. For assay, 25 000 cells per well in 500 μl volume were seeded to a 48 well plate and adhered overnight. The following morning standard culture media was replaced by EMEM, 10% FCS, 4 mM L-glutamine (500 μl) and test actives added. Cells were then incubated for 72 hours. At 72 after which the supernatants were removed and analysed for melanin content by spectrophometry at 450 nm against a reference standard curve. The B16 cell monolayer was dissolved in Triton™/PBS at 4° C. for 20 minutes, centrifuged at 13 000 rpm for 5 minutes at 4° C. and analysed for total protein content using a standard bicinchoninic acid assay (BCA) assay against a reference standard curve. Melanin results were normalised to total protein.
[0066] Normal Human Melanocytes
[0067] Primary human melanocytes were obtained from Invitrogen Cascade Biologics (HEMn-DP) and grown in Cascade melanocyte media (M-254CF-500+human melanocyte growth supplement (HMGS) supplement containing phorbol myristate acetate (PMA)) according to the manufacturer's instructions. Once established, cultures were routinely grown in T175 tissue culture flasks and could generally be passaged for use up to six (P6) or seven (P7) times. Once the cells reached about 70% confluence they were treated with trypsin, spun down and re-suspended in an appropriate volume of media ready for plating out. Cells seeded at 2×10 5 cells per well in a 6-well plate and incubated in 2 ml medium per well. Cells were allowed 16 hours to settle on the cover-slips before addition of treatments. Cells were treated for 5 days with DMSO vehicle or test actives dissolved in DMSO and light microscope images captured.
[0068] Azoles
[0069] Ketoconazole, fluconazole, imidazole, oxazole and thiazole were obtained from Sigma Aldrich Company Limited.
[0070] Methods
[0071] Melanin Quantitation
[0072] Melanin content of the cultures was determined following the recommended by MatTek (solvable extraction protocol) using a proprietary solvent known as Solvable™ (available from Perkin-Elmer) as the extraction solvent. Protein was extracted as described previously and quantified using the BCA assay.
[0073] Histological Analysis
[0074] Post treatment and WST-1 analysis cultures were fixed in neutral buffered formalin (NBF) for 4 hours and processed for histology to provide formalin fixed paraffin embedded (FFPE) tissue blocks. Each culture was bisected and embedded in the same paraffin embedded block so that when sectioned, one section provided two non-serial sections. FFPE tissue was cut to provide four slides per block, each slide containing two non-serial sections per slide. Sets of slides were subject to immuno-staining with an antibody against the melanocyte marker MART-1 (Abcam Plc), or stained with Masson Fontana and representative images captured.
[0075] Results
[0076] Melanogenesis in B16 Monolayer Cultures
[0077] Each test active was applied in DMSO to n=3 cultures. The results are summarised in table 1.
[0000]
TABLE 1
Normalised melanin (per mg protein) from B16 monolayer cultures
(the first DMSO control relates to the ketoconazole results only and
the second DMSO control relates to the remaining results).
Treatment
Normalised melanin (μg/mg protein)
DMSO control
0.186 ± 0.021
5 μM ketoconazole
0.173 ± 0.032
20 μM ketoconazole
0.004 ± 0.001
50 μM ketoconazole
0.007 ± 0.003
DMSO control
0.187
0.188
0.172
20 μM flucoazole
0.232
0.214
0.229
20 μM imidazole
0.180
0.231
0.240
20 μM oxazole
0.217
0.210
0.185
20 μM thiazole
0.228
0.255
0.236
[0078] Melanogenesis in MelanoDerm™ Cultures
[0079] Ketoconazole was applied in DMSO to n=6 cultures. Three cultures from each treatment group were extracted for melanin and protein quantitation and three were fixed, wax embedded, sectioned and stained to visualise histological integrity (H&E) and melanin (Fontana-Masson). The results for normalised melanin (per mg protein) are summarised in table 2.
[0000]
TABLE 2
Normalised melanin (per mg protein) from MelanoDerm ™ cultures.
Treatment
Normalised melanin (μg/mg protein)
DMSO control
74.560
103.845
90.333
1 μM ketoconazole
59.276
57.292
58.573
[0080] The total extracted protein concentration was relatively consistent for all treatments (data not shown) suggesting that there were not any substantial cytotoxic effects on the cultures.
[0081] Histological Analysis
[0082] FIG. 1 shows that the normalised melanin extracted from the culture treated with 1 μM ketoconazole consistently reduced the levels of extractable melanin and had a marked effect on the melanin content of the basal melanocytes as shown after Masson-Fontana staining. FIG. 2 immuno-staining with an antibody against the melanocyte marker MART-1 shows that the absence of Masson-Fontana stained melanin in FIG. 1 was not due to the elimination of melanocytes from these cultures.
[0083] Evaluation of Ketoconazole on Growth and Morphology of Normal Human Melanocytes (NHM) in Monolayer Culture
[0084] NHMs grown in monolayer cultures were treated with 1 μM ketoconazole for 5 days and assessed by light microscopy. The results shown in FIG. 3 indicate that there was no evidence that treatment had an adverse effect on NHM morphology or proliferation. In particular it can be seen that the proportion of bipolar cells (normal cells) for the NHMs treated with ketoconazole is practically identical to the control.
[0085] Conclusions
[0086] Ketoconazole very effectively inhibits melanin production in B16 monolayer cultures and MelanoDerm™ cultures at 1 μM. Furthermore there is no detectable effect on the viability of either monolayer human melanocytes or epidermal cultures at this dose. Surprisingly other azoles and in particular fluconazole, imidazole, oxazole and thiazole did not effectively inhibit melanin production in B16 monolayer cultures.
[0087] In-Vitro Delivery of Ketoconazole into Human Skin
[0088] Method
[0089] This study quantified the in-vitro human skin penetration after application of a cream formulation containing 2% (w/w) ketoconazole (Daktarin™ Gold). Eight diffusion cells were prepared (using female abdominal skin from three donors) plus three undosed control cells (for assay validation purposes). Epidermal membranes were used and integrity assessed by measuring electrical resistance. Permeation of active was measured over 24 hours following application of a target 5 mg/cm2 dose. Suitable liquid chromatography analytical assays were developed, with active peaks separated from formulation, skin and tape strip derived peaks.
[0090] Distribution within the skin at 24 hours was determined by measuring the levels of active within the stratum corneum (tape strips) and the epidermis plus any remaining lower stratum corneum (following tape stripping). The skin was wiped prior to tape stripping to remove active remaining at the surface. Levels in the donor chamber sealing grease and on the donor chambers were also measured (donor chamber wash).
[0091] Results
[0092] The results are presented in table 3 below.
[0000]
TABLE 3
Recovered ketoconazole from in-vitro delivery into human skin
after 24 hours (n = 8).
Compartment
Ketoconazole (% recovered)
Surface of skin
83.6 ± 2.4
Donor chamber
4.00 ± 1.26
Strip 1
4.92 ± 2.03
Strips 2-3
0.858 ± 0.255
Strips 4-6
0.318 ± 0.062
Strips 7-10
0.192 ± 0.046
Epidermis†
2.02 ± 0.74
Permeation chamber
3.49 ± 0.26
Overall recovery
99.4 ± 1.2
†Will also include any remaining stratum corneum remaining following tape stripping
[0093] Conclusion
[0094] Ketoconazole showed low but adequate delivery into human skin.
[0095] Combination of Ketoconazole with Sulforaphane
[0096] Method
[0097] B16 F10 cells (mouse melanoma cell line) were obtained from ATCC and grown in Lonza Biowhittaker BE12-662F media. Trypsin in ethylenediaminetetraacetic acid (EDTA) (Sigma T3924) and Dulbecco's Phosphate Buffered Saline (DPBS) (Sigma D8537) were used to split the cells. Plates were set up at a concentration of 2.5×10 4 cells per well in 48 well plates in Phenol Red free media (Sigma D1145).
[0098] After overnight incubation, media was removed and media with sulforaphane (available from Sigma-Aldrich Company Limited as at least 95% L-sulforaphane) in DMSO and ketoconazole in DMSO solutions were added. 500 μl of the media and solutions were added to 4 wells of a 48 well plate and the plates incubated at 37° C. for a further 3 days. Thereafter the melanin concentration and cell numbers were measured.
[0099] Melanin concentration was measured by making up standards each day and pipetting 100 μl of each standard in duplicate onto Greiner plates. For the blank plate Phenol Red free media was used. 100 μl from each well was also pipetted in duplicate onto Greiner plates and the plates read on a Dynex plate reader at 450 nm.
[0100] Cell numbers were measured by washing the wells twice with phosphated buffer solution (PBS). Then 1 ml of trypsin EDTA diluted in PBS at 1:10 v/v was added to each well and the wells observed for cell detachment. All media from each well was then collected the media assayed by adding 100 μl of the media to 9.9 ml of Coulter Isoton II diluent. Cell numbers were assessed using the Z1 Coulter Particle Counter.
[0101] Results
[0102] The results are summarised in table 5.
[0000]
TABLE 5
Melanin (μg) per cell.
Average
μg melanin/
cell
(4 tests)
% vehicle control
10 μM L-sulforaphane
0.00026453
86.88710608
1 μM ketoconazole
0.00029155
95.76492704
10 μM L-sulforaphane +
6.8138E−05
22.38093578
1 μM ketoconazole
Media control
0.00030445
100
DMSO control
0.00028774
94.51056836
[0103] Conclusion
[0104] Significant synergy in reducing melanin content per cell is exhibited in this in-vitro assay by combining L-sulforaphane with ketoconazole. | This invention relates to a composition comprising a synergistic combination of ketoconazole and sulforaphane for use in skin lightening. This invention is based on the fact that a combination of ketoconazole and sulforaphane has been found to synergistically inhibit pigment production in B16 monolayer cultures. Thus the composition, when applied topically or imbibed over an appropriate length of time in-vivo, would be expected to cause skin lightening, or to reduce blemishes and/or hyperpigmented spots and/or solar lentigines leading to an improvement in skin tone and evenness. | 0 |
TECHNICAL FIELD
This invention relates generally to tub grinders and more particularly to an improvement to the slug bars of tub grinders.
BACKGROUND
Grinders for grinding hay or other materials to be ground are shown in U.S. Pat. Nos. 3,912,175 to Anderson, 3,966,128 to Anderson et al., 4,033,515 to Barcell et al., 4,134,554 to Morlock, 4,210,289 to Arnoldy, 4,846,411 to Herron et al., 5,419,502 to Morey, 5,626,298 to Arnoldy, and 6,412,715 to Brand et al., all of which are incorporated herein by reference in their entirety.
Tub grinders are used to reduce the size of many things such as bales of hay, tree branches, material from demolished buildings, etc. The material is placed in the top of the “tub” portion, for example with a grappling hook or front end loader on a tractor, then the tub portion rotates around a floor as can be seen in the prior art shown in FIG. 1 of the drawings. An opening in the floor as shown in prior art FIGS. 1 and 2 is provided with rotating hammers passing between slug bars, the hammers hitting the material in the tub, reducing the size to smaller particles that are delivered to an unloading conveyor to put the ground up particles in a pile or on a trailer or the like for transporting the ground material to another place. Typically the material to be ground is moving in the direction of the tub as shown by the arrow in FIG. 1 , while the hammers are rotating in the direction shown in FIG. 1 .
One of the problems associated with tub grinders is that they do not operate at optimum efficiency for all types of material to be ground.
Accordingly a tub grinder that can be easily adapted to efficiently grind different types of material is needed.
BRIEF DESCRIPTION OF THE DRAWINGS
The above needs are at least partially met through provision of the apparatus described in the following detailed description, particularly when studied in conjunction with the drawings, wherein:
FIG. 1 is a typical prior art tub grinder;
FIG. 2 is a cross sectional view taken along line 2 - 2 of the prior art device of FIG. 1 ;
FIG. 3 is a side elevational view of a slug bar with one preferred configuration of a riser bar welded to the top thereof and immediately above that integral structure is shown the riser bar alone, before it is welded onto the slug bar;
FIG. 4A is a cross sectional view similar to the prior art view of FIG. 2 , but showing a preferred embodiment of the present invention set up for grinding material that is relatively easy to grind;
FIG. 4B is a cross sectional view similar to the prior art view of FIG. 2 , but showing a preferred embodiment of the present invention set up for grinding material that is more usual or medium to grind;
FIG. 4C is a cross sectional view similar to the prior art view of FIG. 2 , but showing a preferred embodiment of the present invention set up for grinding material that is difficult or hard to grind;
FIG. 5 is a perspective view of the embodiment of FIGS. 3 and 4B as would be seen if looking at a tub grinder from the view of FIG. 1 if it had the improvement of the present invention thereon;
FIG. 6 is a side elevational view of a riser bar similar to the one shown in FIG. 3 , but having a serrated and sharpened top surface on a part thereof; and
FIG. 6A is a cross sectional view taken along line 6 A- 6 A of FIG. 6 .
Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.
DETAILED DESCRIPTION
Referring now to the drawings, wherein like reference numerals indicate identical or similar parts throughout the several views, FIGS. 1 and 2 show a typical tub grinder 10 without the improvements of the present invention thereon and explained in the third paragraph above. The tub grinder 10 has a floor 11 that is fixed with respect to the frame of the tub grinder 10 . A rotating wall 12 is provided for moving the material within the walls of the tub wall 12 in the same general direction that the tub wall 12 is moving in order to move the material to a hammer mill 13 disposed in an opening in the floor of the tub grinder 10 . Rotation of the rotor 19 and hammers 14 in the direction shown in FIG. 2 between slug bars 15 forces material above the floor 11 down into the area above screen 16 and the hammers also force the material through the screen 16 so that the ground up material can eventually be delivered to the unloading conveyor 17 for dumping the ground up material on the ground or into a trailer or wagon or the like.
FIG. 3 is a side elevational view of a slug bar 115 with one preferred configuration of a riser bar 121 welded by welds 122 to the top of prior art part 120 thereof as shown in FIG. 3A , and immediately above that integral slug bar structure 115 in FIG. 3 is shown the riser bar 121 alone, before it is welded onto the prior art slug bar 120 .
FIG. 4A is a cross sectional view similar to the prior art view of FIG. 2 , but showing a preferred embodiment of the present invention set up for grinding material that is relatively easy to grind, such as very dry or light porous material such as alfalfa hay or Styrofoam. The rotor 119 is rotated in the direction shown by the arrow in FIG. 4A and the swinging hammers 114 do not hit the material to be ground as the hammers 114 first rotate upwardly between the slug bars 120 and riser bar portions 121 a until about point A on the riser bar portion 121 a . After that the hammers 114 gradually extend above the riser bar portions 121 a more until they are only extending above the slug bars 120 .
FIG. 4B is a cross sectional view similar to the view of FIG. 4A , but showing a preferred embodiment of the present invention set up for grinding material that is average or medium to grind, such as wet or dense material like high moisture hay or fescue hay or medium porous material or the like. The rotor 119 is rotated in the direction shown by the arrow in FIG. 4B and the swinging hammers 114 do not hit the material to be ground as the hammers 114 first rotate upwardly between the slug bars 120 and riser bar portions 121 until about point B on the riser bar portion 121 . After that the hammers 114 gradually extend above the riser bar portions 121 a more until they are only extending above the slug bars 120 . Since the riser bar portion 121 is longer an higher for more of the length of the riser bar 121 than for the riser bar portion 121 a in FIG. 4A , the hammers 114 only extend above the riser bar portions 121 starting at point B where the hammer is substantially vertically oriented, therefore since the hammers 114 extend above the riser bars for less time and do not extend above the riser bars as far during such relative time, a less aggressive approach is taken which requires less horsepower to rotate the rotor 119 and doesn't slow the revolutions per minute (rpm) as much as if the same medium to grind material was in the tub grinder arrangement shown in FIG. 4A . Keeping the rpm of the rotor 119 (and therefore the rpm of an engine that rotates the rotor 119 ) above a certain predetermined level is important to the efficiency of a tub grinder and also reduces the wear and tear on such equipment such as the engine powering the tub grinder.
The hammers 114 force the material through the screen 116 similar to FIG. 2 .
FIG. 4C is a cross sectional view similar to the view of FIGS. 4A and 4B , but showing a preferred embodiment of the present invention set up for grinding material that is difficult or hard to grind, such as very dense material like wood, rubber, rubber tires or the like. The rotor 119 is rotated in the direction shown by the arrow in FIG. 4C and the swinging hammers 114 do not hit the material to be ground as the hammers 114 first rotate upwardly between the slug bars 120 and riser bar portions 121 c until about point C on the riser bar portion 121 c . After that the hammers 114 gradually extend above the riser bar portions 121 c more until they are only extending above the slug bars 120 . Since the riser bar portion 121 c is longer an higher for more of the length of the riser bar 121 c than for the riser bar portion 121 a in FIG. 4A or riser bar portion 121 of FIG. 4B , the hammers 114 only extend above the riser bar portions 121 starting at point C where the hammer 114 is substantially past vertically oriented, therefore since the hammers 114 extend above the riser bars 121 c for less time than when riser bars 121 or 121 a are used and do not extend above the riser bars 121 c as far during such relative time, a less aggressive approach is being taken than when the riser bars 121 or 121 a are used, which requires less horsepower to rotate the rotor 119 and doesn't slow the revolutions per minute (rpm) as much as if the same easy to grind or medium to grind material was in the tub grinder arrangement shown in FIG. 4A or FIG. 4B respectively.
FIG. 5 is a perspective view of the embodiment of FIGS. 3 and 4B as would be seen if looking at a tub grinder 10 from the view of FIG. 1 if it had the improvement of the present invention thereon. Slug bars 120 have riser bar portions 121 welded to the top thereof and the hammers 114 are shown passing between the slug bars 120 and riser bar portions 121 to gradually begin grinding material as the hammers 114 move to the right in the direction of the arrow shown in FIG. 5 .
FIG. 6 is a side elevational view of a riser bar 221 similar to the riser bar 121 shown in FIG. 3 , but having a serrated and sharpened top surface 222 on a part thereof. FIG. 6A is a cross sectional view taken along line 6 A- 6 A of FIG. 6 and shows how the serrated part 222 is also sharpened to an edge. Using this alternate embodiment will provide additional cutting action as the hammers 114 force the material against the sharpened serrated edge 222 .
Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the spirit and scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept as expressed by the attached claims. | A tub grinder has a rotor with hammers that pass between adjacent slug bars. The slug bars have a riser bar portion disposed on the top of the slug bars, the riser bar portions extending vertically higher on one end of each respective slug bar than on the other end of each respective slug bar so that the hammers extend farther beyond the top of the riser bar and slug bar when they pass by first end than when they pass by the second end of the riser bar. | 1 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to document feeders for conveying document originals from a document placement location, along a predetermined conveyance path, and to a document information-capturing location, and also relates to image-capturing devices—such as facsimile machines, scanners, and photocopiers—furnished with such document feeders.
2. Description of the Related Art
Automatic document feeders (ADFs) that send out one-by-one and convey to a document information-capturing location document originals stacked on a document tray are long since well-known. In this class of document feeders, machines furnished with printing means that print text or other markings, such as “SCANNED” or “FAXED,” in an inconspicuous place on a document from which image information has been captured are also known.
One example of a document-information capturing device furnished with a document feeder having a printing means of this kind is disclosed in, for instance, Japanese Unexamined Pat. App. Pub. No. H09-18631. This document-information capturing device is equipped with, as a printing means, a stamper that stamps post-image-capturing documents with a mark. The stamper is supported on a guide rail stretching along the widthwise direction of the document (direction orthogonal to the document conveyance direction). Accordingly, a user can manually shift the stamper to any desired location in the document widthwise direction.
With the configuration disclosed in Pat. App. Pub. No. H09-18631, however, if the stamper is not set into an appropriate location, specifically, if a user makes an error as to the size of a document original—for example, if he or she mistakes the conveyed document to be in A4 landscape, even though it is in A4 portrait, orientation—and ends up situating the stamper in a position where the edge of a landscape-oriented A4 document would pass, because the document does not actually traverse the position where the stamper has been situated, a site where there is no document gets stamped in vain (gets empty-stamped) by the stamper, whereby the conveyance path is left gummed with ink, which leads to incidents of subsequent documents becoming splotched with the ink. Moreover, this problem is linked to ink wastage.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention, brought about focusing attention on the circumstances just described, is to make available a document feeder and image capturing device whereby empty stamping associated with improper positioning of the printing means is prevented.
In order to resolve the aforementioned issues, the present invention affords a document feeder that is for conveying document originals from a document placement location, along a predetermined conveyance path, and to a document information-capturing location, and that is furnished with: printing means, shiftable along the document widthwise direction being approximately orthogonal to the document conveyance direction, for carrying out predetermined printing onto conveyed documents; and detection means, provided in the conveyance path further upstream in the document-conveyance direction than the printing means, for detecting whether a conveyed document will pass inside the limits of the range in which the printing means prints.
Furthermore, the present invention also affords an image capturing device equipped with a document feeder of the above-described configuration, and an image capturing means for capturing image information from a conveyed document, in the document information-capturing location.
According to the present invention, within the conveyance path further upstream in the document-conveyance direction than the printing means, a detection means is provided to detect whether a conveyed document will traverse the printing range delimited by the printing means, thanks to which empty stamping associated with improper positioning of the printing means can be prevented.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a sectional view illustrating an image capturing device furnished with a document feeder involving one embodiment of the of the present invention;
FIG. 2 is an oblique view illustrating the configuration of a printer unit and its environs;
FIG. 3 is an oblique view illustrating the configuration of a printer sensor and its environs, in a state in which a metal frame and plastic head-guide member fixed to the frame have been removed;
FIG. 4 is a block diagram representing the gross configuration of a CPU; and
FIG. 5 is a flowchart of operations in the image capturing device involving one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the present invention will now be explained based on the drawings provided.
FIG. 1 is a sectional view of an image capturing device 100 equipped with a document feeder of the present invention. The image capturing device 100 , which adopts the present invention, will now be explained with reference to FIG. 1 . The image capturing device 100 can be used as a stand-alone scanner connected to a PC or network, or as part of an MFP (multi-function peripheral) connected to an image-forming apparatus such as a printer or the like. Reference mark A labels a document feeder installed on the image capturing device 100 . The document feeder A conveys a document original (simply “original” hereinafter) along a predetermined conveyance path to pass the original over a first contact glass 1 surface of the image capturing unit H used as the image capturing means. Note that the image capturing device 100 has a CPU 150 used as the control means that controls operations of the document feeder A and the image capturing unit H.
The image capturing unit H is equipped with a first reading unit 3 that reads images on an original by irradiating light from a light source such as a lamp or the like onto an original conveyed via the first contact glass 1 ; reflecting the reflected light by a plurality of mirrors via a lens and then photoelectrically converting that by photoelectric conversion means such as CCD or the like. Note that the top surface of the first contact glass 1 composes the first reading position 5 (a document information-capturing location of the document feeder A) of the image capturing unit H.
Also, the image capturing unit H is equipped with a second contact glass 2 where an original can be set. A thick original, such as a book or the like, can be placed on the second contact glass 2 by opening the document feeder A, and then moving a first reading unit 3 in a sub-scanning direction to read images on that original on the second contact glass 2 .
The document feeder A is equipped with a feeder tray T that stacks a plurality of originals using a center alignment; and a discharge tray 11 disposed under the feeder tray T to store read originals. Two guide members 901 are mounted on the feeder tray T to enable their movement in a width direction (a direction substantially perpendicular to the direction of original conveyance) of the feeder tray T based on substantially the center thereof. The originals in the feeder tray T are set aligned to the center of the feeder tray T by these two guide members 901 touching both sides of the originals stacked in the feeder tray T. Therefore, originals are aligned to the center while being conveyed through the entire conveyance from the feeder tray T to the discharge tray 11 . Specifically, the guide member 901 is composed of center-referent delivery means that feeds an original P so that a centerline L 2 of the original P width direction X is aligned substantially to a centerline L 1 of the conveyance path (see FIG. 2 ) for both rollers 21 and 22 described below. Furthermore, a pressing cover 13 composed of a porous member such as sponge or the like and a film member such as white Mylar that presses against the second contact glass 2 , and a U-shaped conveyance path 12 that conveys an original from the feeder tray T to the discharge tray 11 are provided.
A second reading unit 4 (at a document information-capturing location of the document feeder A) for reading an original is provided at the bend of a U-shaped conveyance path 12 . The second reading unit 4 is composed to read original images by irradiating light from a light source such as a lamp or the like on an original conveyed via a third contact glass 7 that forms part of the conveyance path 12 as a second reading position 6 , then to photoelectrically convert that light, reflected by a plurality of mirrors into a lens, using photoelectric conversion means such as a CCD or the like. Specifically, to greatly shorten the image reading process times of both sides of an original, this apparatus is configured to read one side of an original that passes over the second reading position 6 of the conveyance path 12 using the second reading unit 4 described above, and to read the other side of the original at the first reading position 5 using the first reading unit 3 .
The U-shaped conveyance path 12 is equipped with kick roller 21 that kicks out an original from the feeder tray T; separating means composed of a feed roller 22 and separating pad 23 that separate originals conveyed from the kick roller 21 into single sheets to be fed; a pair of registration rollers 24 that remove any skewing in the original by aligning the leading edge of the original when it is fed from the feed roller 22 and the leading edge of the original engages the pair of registration rollers 24 and then drive to convey the original to a downstream side; a pair of feed rollers 25 that feed the original from the registration rollers 24 toward the second reading position 6 and the first reading position 5 ; a pair of first reading rollers 26 that convey the original from the pair of feed rollers 25 to the second reading position 6 ; a pair of second reading rollers 27 that convey the original one side thereof read at the second reading position 6 to the first reading position 5 ; a pair of third reading rollers 28 that convey out from the first reading position 5 the original the other side thereof read at the first reading position 5 ; a pair of first discharge rollers (conveyance rollers) 29 that receives the original both sides thereof read from the pair of third reading rollers 28 and conveys the original toward the discharge tray 11 ; and a pair of second discharge rollers (conveyance rollers) 30 that discharge the original into the discharge tray 11 . The pair of first discharge rollers 29 and the pair of second discharge rollers 30 are positioned at an upstream side and a downstream side of conveyance direction of the printer unit 8 to grip both sides of the original traversing the printer unit 8 for conveyance.
The following will now explain original conveyance operations using the document feeder A configured as described above. First, originals are detected to be stacked on the feeder tray T by an empty sensor S 1 . If a paper feed instruction is received from the image capturing unit H, the kick roller 21 and feed roller 22 are driven. This kicks out originals which are separated to feed a single sheet by the separating means. Also, when a registration sensor S 2 detects a leading edge of the fed original, the original is fed a predetermined amount from the point that the original was detected to engage the leading edge of the original at a nipping point of the pair of registration rollers 24 . This aligns the leading edge of the original to remove any skew of the original. Then, the pair of registration rollers 24 , the pair of feed rollers 25 and the pairs of reading rollers 26 , 27 , and 28 are driven. This conveys the original along the U-shaped conveyance path 12 to feed it to a downstream discharge tray, turning the original over from front to back in the process. In the U-shaped conveyance path, the original passes by the second reading position 6 and the first reading position 5 in that order. In the process to pass through the second reading position 6 and the first reading position 5 , one surface of the original is read at the second reading position 6 , and the other side of the original is read at the first reading position 5 .
The leading edge of the original is detected by a discharge sensor unit S 3 , and the pair of the first discharge rollers 29 and the pair of the second discharge rollers 30 drive up to the point where the leading edge of the original reaches the pair of the first discharge rollers 29 . This operation reads both sides of the original at the second reading position 6 and the first reading position 5 , then the pair of first discharge rollers 29 and the second discharge rollers 30 discharge the original to the discharge tray 11 . Note that the discharge sensor unit S 3 is disposed near the center of the conveyance path to detect any size of originals. This sensor unit is composed of a lever 9 that is rotated by the leading edge of the original coming into contact therewith, and a sensor 10 that detects the leading edge of the original by detecting a member mounted to the shaft of the lever 9 . Specifically, the discharge sensor unit S 3 functions as an original passing detection means that detects the passing of a conveyed original. Then, after a predetermined amount of time after the trailing edge of the original is detected by the discharge sensor unit S 3 , the drives of the first discharge rollers 29 and the second discharge rollers 30 are stopped and the reading operation is ended. Note that the discharge sensor unit S 3 is used as a sensor that detects the leading edge of the original to measure the timing to drive the printer head 800 , as described in detail below.
Note that a shingle-feed detection sensor (shingle-feed detection means) GS that detects a “shingle-feeding” of a plurality of overlapped originals is provided in the conveyance path 12 between the registration rollers 24 and the feed roller 25 , in the document feeder A according to this embodiment of the present invention. This shingle-feed detection sensor GS is configured to detect a shingle-feed of originals by a received vibration level of ultrasonic waves. The sensor GS disposes an emitter that emits ultrasonic waves, and a receiver that receives the ultrasonic waves opposite to each other to sandwich the path. The printer unit 8 is disposed in the conveyance path 12 between the first discharge rollers 29 and the second discharge rollers 30 (in other words further downstream than the document information-capturing location 5 ) as the printing means. The printer unit 8 prints a maximum of 40 characters on the original surface of the original conveyed by the first discharge rollers 29 and second discharge rollers 30 , and prints characters to notify the user whether shingle-feeding of originals has occurred when shingle-feeding of originals has been detected. A printer sensor S 4 (detection means) is provided at an upstream side of the printer unit 8 and the first discharge rollers 29 , to detect whether an original is at the print head printing position, or more specifically whether the conveyed original has passed inside a range of a printing region (inside are range for printer head movement) for printing by the printer head (printer unit 8 ). The printer sensor S 4 is composed of a reflective type sensor, and is installed to move along with the movement of the printer unit 8 in the original width direction.
The printer unit 8 will now be explained in detail with reference to FIG. 2 .
As shown in the drawing, the printer unit 8 has an ink-jet type printer head 800 , and a head support portion 801 that detachably mounts and supports the printer head 800 . A cable 812 is connected to the printer head 800 to receive a print start command or character data and to supply power.
The head support portion 801 is supported by a resin head guide member 802 fastened to a metal frame 803 and moves in a width direction (shown as the arrows X in the drawing) of the original over a conveyance guide 805 that forms an original conveyance path. The head guide member 802 has a substantially rectangular opening 804 formed along the Xdirection of the width of the original from substantially the center to one side (the front side in the drawing) of the apparatus. Two screw holes are formed in the head support portion 801 . By inserting and tightening screws 811 into the screw holes in the head support portion 801 from above the opening 804 , the head support portion 801 can be movably supported by the head guide member 802 . Note that the opening 804 is formed to be only half of the original conveyance path so the range of movement it is only approximately half of the original conveyance path. A projection 810 is formed on the head support portion 801 so the user can grip that projection 810 and move the head support portion 801 . Note that the opening 813 that guides the printer sensor S 4 when the printer sensor S 4 is moved in the width direction of the original, described in further detail below, is formed in the frame 803 . In the same way as the opening 804 is formed to guide the printer head 800 , the opening 813 is approximately half the size of the original conveyance path along the original width in the Xdirection.
A plurality of printing openings 806 formed to match printing positions of each size of the originals is formed in the conveyance guide 805 . There is a rib 807 formed along the original width in the Xdirection downstream of the printer head 800 . A plurality of grooves 808 is formed in the rib 807 to correspond to each original size. A groove engaging portion 809 that engages the grooves 808 is formed on the head support portion 801 . The printer head 800 is fastened to predetermined printing positions that correspond to the original sizes by the engagement of the grooves 808 and groove engaging portion 809 . (Specifically, the grooves 808 and groove engaging portion 809 compose positioning means 814 that selectively positions (to fasten the printer head 800 at predetermined printing positions that correspond to the original sizes) the printer head 800 (printing means) at a plurality of positions along the original width direction.) Also, characters and the like are printed on the original via the printing opening 806 at each printing position. Note that by setting the original size (for example A4 or A3) that the grooves 808 corresponded to, near the grooves 808 , it is convenient for the user because it is possible to know where the printer head 800 should be fastened.
The printer sensor S 4 will now be explained in detail with reference to FIG. 3 .
A sensor support portion 815 , made of a synthetic resin (plastic), that supports the printer sensor S 4 is fastened to the upstream side (in the direction of conveyance) of the head support portion 801 . (The printer sensor S 4 and the printer unit 8 are integrated.) A reflective type sensor is mounted to the sensor support portion 815 , and the printer head 800 and printer sensor S 4 shift unitarily. The printer sensor S 4 detects the passing of the conveyed original via the opening 816 formed in the conveyance guide 805 , but the detection position of the original in the width direction of the printer sensor S 4 is set to be several millimeters to the outside of the conveyance width direction than the printing position of the printer head 800 . For that reason, a determination of whether the original is at the printing position of the printer head 800 is securely performed. (This is to determine whether an original has been conveyed to the printing position of the printer head 800 ; specifically whether the conveyed original is within the print region of the printer head 800 .) Also, screw holes are formed in the sensor support portion 815 for the insertion of screws 14 . By tightening screws 14 from above the opening 813 shown in FIG. 2 , that is guided in the opening 813 and movement is more stable. Note that the distance between the printer sensor S 4 and printer head 800 should be as short as is possible to reduce the affects of original skewing and to increase the detection accuracy. Also, the first discharge rollers 29 are disposed near an upstream side of the printer head 8 ; the second discharge rollers 30 are disposed near a downstream side thereof. These pairs of rollers nip the printed original at the upstream and downstream sides of the printing position thereby reducing shaking of the original that occurs during its conveyance and contributing to a good quality printed image.
FIG. 4 shows a schematic configuration of the CPU 150 (see FIG. 1 , control means) that controls the overall image capturing device 100 that includes the image capturing unit H and the document feeder A. The CPU 150 calls up an execution program for the reading process from the ROM. Then, the CPU 150 controls the apparatus according to the execution program to convey the original and read images on the original. Particularly, in this embodiment, the CPU 150 controls the printing operation of the printer head 800 . Note that each of the sensors described above, namely sensors GS, S 3 and S 4 are electrically connected to the CPU 150 . Also, a warning unit (warning means) 190 such as an LCD panel or PC screen or the like, is electrically connected to issue a warning when the position along the original width direction of the printer head 800 is improper. As a more detailed example of the warning unit, a PC is the monitor when it is possible to operate the system via a PC driver, if, for example, the image capturing device 100 is connected to a PC or network. Also, if a liquid crystal display panel is equipped on the image capturing device 100 , that liquid crystal display panel can be implemented to be a monitor.
The operations of the image capturing device 100 having the configuration described above will now be explained in detail with reference to the flowchart of FIG. 5 .
Initially, the user moves the printer head 800 to a predetermined position according to the original size prior to reading the original at the image capturing device 100 . Along with this, the printer sensor S 4 also shifts with it unitarily. Also, the characters and numbers to be printed are predetermined as default, but they can be freely changed using a driver screen on the PC for example to provide further convenience for the user.
Next, when the start button on the image capturing unit H is pressed, conveyance of the original on the feeder tray Twill begin when by selecting start key on the PC screen (Step ST 1 ). The original on the feeder tray T is kicked out by the kick roller 21 and conveyed by the feed roller 22 . Then, it is conveyed by the registration rollers 24 and feed rollers 25 . The shingle-feed detection sensor GS detects whether a plurality of originals have been shingle-fed (Step ST 2 ). If shingle-feeding is not detected, the conveyance of the original is continued according to the normal reading mode. After the original is read at the first reading position 5 and/or the second reading position, the original is discharged to the discharge tray 11 .
If shingle-feeding is detected, the system enters the shingle-feed detection mode. In the same way as with the normal reading mode, the feed rollers 25 , first reading rollers 26 , second reading rollers 27 and the third reading rollers 28 are rotated to continue feeding the original, but reading is not performed on the originals at either of the reading positions 5 or 6 . Next, the system determines whether the leading edge of the original has reached the lever 9 (that is, whether the leading edge of the original has been detected by the discharge sensor unit S 3 ) (Step ST 3 ). When the leading edge of the original has been detected, it means that it has passed the position of the lever 9 . If the leading edge of the original is not detected, the original stopped somewhere in the conveyance path up to the lever 9 , so the drive of each roller is stopped and the user is notified of a jam. Next, the printer sensor S 4 detects the presence of the original (Step ST 4 ). If the original is detected by the printer sensor S 4 (in other words, if the conveyed original has passed within a range of the print head 800 print region) and the original has passed the printing position, it means that the printer head 800 is set the proper position for the size of the original, so the control from the CPU 150 drives the printer head 800 to print characters on the original (Step ST 5 ). Note that printing is set to start after a predetermined amount of time has passed after detection of the leading edge of the original by the discharge sensor unit S 3 at step ST 3 , by measuring from the detection of the discharge sensor unit S 3 . (In other words, printing is performed by the printer head 800 at a predetermined timing based on detection by the discharge sensor unit S 3 .) This configuration allows for the starting time to be set freely from the detection of the leading edge of the original to the start of printing allowing the user to freely change the position to print characters in the original conveyance direction, further increasing user convenience.
At step ST 4 , if the original is not detected by the printer sensor S 4 , it means that the original is not at the printing position of the printer head 800 (the conveyed original has not passed within the range of the printing region of the printer head 800 ). In other words, this means that the setting position of the original size and the printer head 800 are incorrect. For example, the conveyed original is A4 portrait, but the printer head 800 is positioned for A4 landscape. In such cases, the CPU 150 does not drive the printer head 800 , but displays an error message that the setting position of the printer head 800 is incorrect on the warning unit 190 such as a PC screen or the operation panel on the image capturing unit H (Step ST 6 , or a warning sound can be issued).
As another preferred embodiment, a printer drive unit 500 such as a motor for automatically moving the printer head 800 as shown with the dashed lines of FIG. 4 , can be provided to automatically move the printer head 800 rather than manually move it. The printer drive unit 500 can be configured to be controlled by the CPU 150 . Also, as shown at the dashed lines in FIG. 5 , when a determination is performed at step ST 4 , the CPU 150 automatically moves the printer head 800 to the proper position to enable it to print onto the conveyed original (Steps ST 7 and ST 8 ).
As described above, with this embodiment, the printer sensor S 4 is provided in the conveyance path upstream in the direction of conveyance of the printer unit 8 , as detection means to detect whether a conveyed original has passed within a range of the printer unit 8 printing region, so it is possible to prevent improper printing that occurs when the position of the printer unit 8 is incorrect. In other words, it is possible to prevent mis-printing or the wasted consumption of ink that occurs when the printer head 800 because the setting positions of the conveyed original size and printer unit 8 are incorrect.
Furthermore, with this embodiment, the printer sensor S 4 is integrated to the printer unit 8 and is configured to travel unitarily with the printer unit 8 along the width direction of the original, so the detection position of the printer sensor S 4 varies along with the movement of the printer unit 8 , and therefore not only is it possible to efficiently and accurately detect according to original size, no interlocking mechanism is required to interlock the printer sensor S 4 to the movement of the printer unit 8 . This contributes to a simplified structure, a lower number of components and to a more compact overall apparatus. Also, in addition to this configuration, with this embodiment, the printer sensor S 4 is positioned further outside of the width direction of the original than the printer unit 8 , so not only is the passage of the original detected by the printer sensor S 4 , but it is possible to accurately determine whether the original is within the printing range of the printer unit 8 .
The embodiment equips the warning unit 190 that warns when the position of the printer unit 8 is improper so mis-printing of the printer head 800 is further prevented. Particularly, as with the other preferred embodiment described above, if the printer unit 8 is automatically moved to the proper position when the printer unit 8 position is incorrect, mis-printing of the printer unit 8 can be securely prevented.
Also, with this embodiment, a detection sensor unit S 3 that detects the passing of the original is equipped in addition to the printer sensor S 4 , so it is possible to attain accurate determinations by a determining unit 150 B. In other words, if the discharge sensor unit S 3 is equipped substantially in the center of the conveyance path that conveys originals using a center reference, any size of original is detected by the sensor 10 of the sensor unit S 3 making it possible to accurately convey the original. Therefore, if the setting position of the printer head 800 is incorrect, the original will not be detected by the printer sensor S 4 , even though it was detected by the sensor 10 , making it possible to determine that the setting position of the printer head 800 is incorrect, and to output an error message. However, if the sensor 10 did not exist, when the original is not detected by the printer sensor S 4 , it cannot be determined whether the original was actually not conveyed or the setting position of the printer head 800 is incorrect. Therefore, it would not be possible to output an error message that the setting position of the printer head 800 is incorrect.
Also, the original is conveyed based on a center reference so the printer sensor S 4 and the printer unit 8 only have to move substantially half the width direction of the conveyance path. Therefore, the apparatus is more compact, power consumption is conserved and the forming is simplified.
Note that the present invention is not limited to the aforementioned embodiment; It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention. For example, this embodiment equips upstream of the printer sensor S 4 a discharge detection sensor S 3 that detects the leading edge of the original. The drive timing (print start timing) for the printer head 800 is set based on the detection time of the discharge sensor S 3 , but it is also acceptable to determine the drive timing of the printer head 800 by the printer sensor S 4 and not equip the discharge sensor unit S 3 . (In other words, printing is performed by the printer head 800 at a predetermined timing based on detection by the printer sensor S 4 .) According to the embodiment described, in the event a shingle-feed of originals is detected by the shingle-feed detection sensor GS, printing is performed on the original by the printer head 800 but this is not to be construed as a limitation. To simply print characters to confirm that the original has been read, or if using a facsimile machine to print characters indicating that the original has be faxed, it is acceptable to set characters to print on an operation panel disposed on a PC screen or image capturing device. Also, according to the embodiment described, originals are conveyed based on a center alignment, but this is not to be construed as a limitation. Originals can also be conveyed along a side position of the conveyance path. Still further, the embodiment positions a discharge sensor unit S 3 upstream of the printer sensor S 4 . However, the discharge sensor S 3 can also be disposed at a downstream side of the printer sensor S 4 . | Document feeder and image capturing device preventing empty stamping associated with improper positioning of printing unit. Document feeder A, conveying document originals from a document placement location, along a predetermined conveyance path ( 12 ), and to a document information-capturing location ( 5, 6 ), is furnished with: a printing unit ( 8 ), which is shiftable along the document widthwise direction approximately orthogonal to the document conveyance direction, and is for carrying out predetermined printing onto conveyed documents; and a detection unit (S 4 ), provided in the conveyance path further upstream in the conveyance direction than the printer unit ( 8 ), that detects whether a conveyed document will pass inside the limits of the range in which the printer unit ( 8 ) prints. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a U.S. National Stage of International Application No. PCT/DE2010/000087 filed Jan. 27, 2010, which published as WO 2010/094253 A2 on Aug. 26, 2010, the disclosure of which is expressly incorporated by reference herein in its entirety. Further, this application claims priority under 35 U.S.C. §119 and §365 of German Application No. 10 2009 009 896.8 filed Feb. 20, 2009.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and a system for detecting target objects using an imaging electro-optical image sensor.
2. Background Description
To detect target objects inside a monitoring area, combinations of different sensors are particularly advantageous, in that a first sensor device with at least one first sensor, for example, a radar system and/or a passive or active laser sensor, detects a target object and determines a first target parameter therefor, and further information is obtained by a second sensor device with at least one second sensor, wherein the second sensor is formed by a different sensor type than the first sensor. In particular, electro-optical imaging image sensors are becoming increasingly important as second sensors of this type due to the possibility, by evaluating an image obtained thereby, of classifying more narrowly target objects that cannot be distinguished with other sensors. Such electro-optical image sensors are designed in particular for the visible or the infrared spectral range.
Electro-optical image sensors of this type represent an important aid for identifying and classifying targets especially in the military field and in the case of sovereign functions such as, e.g., police monitoring and border security.
In systems with electro-optical sensors, methods are known in which these sensors in all-round search operation scan a predetermined search region in order to detect targets therein and to display/represent them to the operator in order then to automatically continue searching or, upon a command from an operator, to wait to continue the search. Electro-optical sensors have also hitherto been manually controlled by an operator, who aligns the electro-optical sensor manually to targets of interest based on the current situation display based on other available sensors and situation information from tactical data links.
It is also known to carry out an optimization of drones equipped with electro-optical sensors or the like unmanned aircraft such that an optimum flight path is calculated for the drone based on the tactical ground situation and the optimum flight path is selected from several possible flight paths in order to update the ground situation with the sensor data.
It is also known that with a stationary or in a manned flying platform (e.g., police helicopter) in which an electro-optical sensor is fixedly aligned or manually aligned by an operator, the current image information is fed to an automatic image evaluation and the targets detected therewith are classified and this information is displayed in the image information so that the operator is alerted to potential objects of interest or the detection ability of the operator is supported.
The informational content of an image recorded by an image sensor of this type is a priori high and the automatic image evaluation of an individual image is computer-intensive and time-consuming, so that with an all-round search operation by an optical image sensor typically only slow-changing scenarios can be usefully detected and optically evaluated.
It is therefore known that a situation display based on different sensors, e.g., active and/or passive radar and laser sensors, is displayed to a viewer and the viewer aligns an electro-optical image sensor to target objects discernible in this situation display, which is also referred to as assigning the image sensor to a target object. However, the evaluation of the displayed situation display and the selection of the target objects is highly subjective and, particularly in threat scenarios, cannot cope with a possibly quickly changing situation and a suitable reaction.
SUMMARY OF THE INVENTION
The aim of the present invention is therefore to disclose a method and a system for detecting target objects with a second sensor, in particular an electro-optical image sensor, which renders possible a better detection of even quickly-changing scenarios.
Solutions according to the invention are described in the independent claims. The dependent claims contain advantageous embodiments and further developments of the invention.
The invention combines a monitoring of a monitoring area by a first sensor device with at least one first sensor which is not an electro-optical image sensor and preferably carries out with respect to the second sensor a quick detection of target objects inside the monitoring area, with an automated evaluation of individual target objects detected thereby, with an automatic determination of a highest priority target object and with an automatic assignment of a second sensor of a second sensor device to the highest priority target object.
The determination of the highest priority target object among several currently detected target objects is carried out by the application of stored evaluation criteria to the at least one target parameter and/or other data available on the target object, which have been obtained and stored on the respective target objects by the at least one first sensor of the first sensor device. Different parameters can be available for different target objects. Different evaluation criteria can advantageously be directed at different parameters. Parameters can also contain the lack of detectable variables, for example, as zero value of a parameter describing a laser emission of a target object when the target does not show any such laser emission.
Advantageously, with the automated evaluation based on stored evaluation criteria on each or at least on several target objects respectively a prioritization value individually assigned thereto can be determined as a value on a one-dimensional scale. From the prioritization values a ranking can be compiled which is headed by the highest priority target object. The prioritization values are continuously updated so that the ranking can change dynamically. Typically, a target object detected by the second sensor as the highest priority target object will thereafter fall in the ranking, since an immediately new detection by the second sensor as a rule does not produce a major increase in information and therefore does not have a high priority. A target object newly detected by the first sensor device can skip over target objects already previously detected in the ranking, depending on the result of the application of the stored evaluation criteria. A target object detected by the second sensor can thereafter be more quickly subjected to a new detection than a target object with detection carried out earlier. The order of the assignment of the second sensor to the different target objects thus generally deviates from the order of the chronological detection by the first sensor device. Target objects can also be dropped from the automated evaluation if, e.g., a target object leaves the monitoring area or if a target object is classified as definitively no longer of interest.
The automated evaluation based on stored evaluation criteria and the assignment of the second sensor to a target object determined as the highest priority in the evaluation renders possible an acquisition of information optimized within the scope of the stored evaluation criteria for the totality of the target objects, wherein the contribution of an individual target object to the total information can depend on the ability of the second sensor to extract further target parameters in an assignment to a target, on the input of the assignment of the second sensor to the target object and the importance of the target within the overall situation in the monitoring area, which is predefined by the stored evaluation criteria and in particular can be advantageously realized by the cited prioritization values.
The first sensor device for detecting target objects as the at least one first sensor or several first sensors can contain sensors known per se, such as, e.g., active radar sensors or active laser sensors for the determination of a solid angle and the distance of a target object by emitting electromagnetic waves and receiving portions backscattered by target objects, which optionally can also carry out a first classification. First sensors can also be passive receivers of electromagnetic radiation, which pick up radiation emitted by a target object, in particular radar, radio or laser radiation, and carry out a direction determination or location determination.
Preferably, at least one first sensor of the first sensor device is arranged in a fixed spatial allocation to the second sensor. In particular, the second sensor can be arranged on a land vehicle, water craft, aircraft or spacecraft. A first sensor of the first sensor device can also be further distant from the second sensor of the second sensor device and can also be arranged outside the detection zone of the second sensor and also changeable in terms of distance and/or direction relative thereto and transmit the target parameter or target parameters of a detected target object via a data connection to the location of the evaluation device. A target object can thereby be located in an overlapping region of the monitoring area of the first sensor of the first sensor device and the monitoring area of the second sensor or also just reach the monitoring area of the second sensor. Unless explicitly stated otherwise, without loss of generality it is assumed below to simplify matters that in a preferred embodiment the at least one first sensor of the sensor device and the at least one second sensor of a second sensor device are arranged in fixed spatial allocation to one another and the monitoring angle ranges of the first sensor and the second sensor essentially coincide. The first sensor device can contain several first sensors, in particular, of a different functional type. The concept of the first sensor should distinguish it or them from the second sensor, in particular, with respect to the sensor type.
Without loss of generality, to simplify matters the at least one second sensor of the second sensor device is assumed below to be an imaging sensor, in particular an electro-optical image sensor, and the first sensor device is also referred to simply as the sensor device.
The sensor device determines in a known manner, depending on the functional type of the first sensor, the direction of a detected target object relative to the image sensor, and in addition at least one target parameter of the target object. The target direction as an azimuthal and/or elevational angle can be obtained directly from the direction information of the first sensor if the image sensor and first sensor are arranged close together or, in the case of greater distance between the image sensor and first sensor, can be derived from a target position detected by the sensor device and the position of the image sensor. A first target parameter can be, for example, the target distance and/or a movement variable of the target object, such as, e.g., speed and/or direction of movement. The direction of movement can be detected for example by trace-forming. The speed can be determined depending on the amount and direction of movement from a Doppler signal of an active sensor or likewise by trace-forming. Another target parameter can be the distance of the target object from the image sensor.
An aspect angle of the image sensor to the target object can be determined as a further derived first target parameter, which can be evaluated in a manner to be explained in greater detail for an estimate of the usable information content of an image to be recorded by the image sensor.
The emission of radio or radar waves or laser radiation by a target object can be determined as a target parameter in particular by a passive sensor of the sensor device, wherein optionally in addition a certain signature, e.g., as modulation, of an emission of this type can be established by a signature recognition device and can form a rear target parameter.
The target parameters determined by one or more first sensors of the sensor device are referred to as first target parameters. There can be several first target parameters for a target object.
Of the target objects detected in the sensor device, not necessarily all of the target objects are already fed with the first detection to a further detection by the image sensor. It can also be provided that firstly a signal processing, for example, with trace-forming, is carried out in the sensor device itself and/or detected target objects are ruled out from the further image sensor processing from the start, for example, target objects unequivocally recognized as friend target objects.
The target objects provided for further detection by the image sensor are respectively stored with direction information giving a solid angle regarding the image sensor and with target parameters available for the respective target object and subjected to further processing in an evaluation device. In the evaluation device evaluation criteria are stored, to which the target direction as well as individual target parameters as well as combinations or derived values from these values can be subjected.
The criteria can represent absolute criteria, which if they are not met results in a target object being excluded from further processing. An absolute criterion of this type can be, for example, the distance of the target object from the image sensor, wherein from a maximum distance preset as a threshold value, targets that are further distant from the image sensor are excluded from further processing, because if the distance is too great, the target resolution in the image recorded by the image sensor is too low to be able to obtain reliable information about the target object in an image evaluation. Another absolute criterion can be given, for example, for a spatial direction angle range when an obstacle lies in the line of sight of the image sensor in this solid angle range, for example, ship superstructures of a ship carrying the image sensor in maritime use. A target object, the spatial direction of which falls in this type of shaded angle range, cannot be detected by the image sensor, so that a further evaluation and an alignment of the image sensor to a target object of this type is not feasible either. Furthermore, for example, area ranges or spatial ranges can be predefined inside the monitoring area of the image sensor in which definitively no critical target is to be expected and in which detected targets are classified from the start as non-critical and are not further processed.
Target objects which are not excluded at an early stage by such absolute criteria are subjected to an evaluation in the evaluation device, wherein respectively one value designated as the prioritization value, in particular a numerical value on a one-dimensional scale, is determined for target objects and assigned to the target object. Typically, several target parameters including the spatial direction information can be used for the determination of the prioritization value and subjected individually or in combination to predetermined evaluation criteria.
Advantageously, at least one evaluation criterion is provided which provides a binary value as an output value. This can be carried out in particular by comparison of a target parameter to a threshold value or a value range as criterion, wherein the binary value output with this criterion, for example, is given the value zero (or incorrect) when a predetermined criterion, for example, exceeding a threshold value by a target parameter or the location of a target parameter within a range is not met and otherwise is given the value one (or correct).
Also at least one criterion can be provided which as an output value provides a multi-digit binary value, in that, for example, a scale for a target parameter is subdivided into four ranges, and binary value combinations of two binary digits are assigned to the four ranges.
The binary values thus obtained from evaluation criteria in this manner can be combined in a particularly advantageous embodiment to form a multi-digit binary index value, the individual binary digits of which are assigned unequivocally to certain criteria. However, the position of the individual binary digits thereby has no significance for the extent to which the respective criterion influences a prioritization value to be determined. The multi-digit binary index value thus obtained can be used as an address value for addressing a table in which a prioritization value is stored for all possible bit combinations of the index value. In this manner a prioritization value can be obtained via the index value, which is also referred to below as a table index, which prioritization value is also referred to below as a table prioritization value.
In another advantageous embodiment it can be provided that a prioritization value is obtained through weighted combination of values of target parameters or combinations of target parameters or values derived therefrom. A prioritization value obtained in this manner is also referred to below as a weighted prioritization value.
To obtain a weighted prioritization value, in particular target parameters can be used which can adopt a plurality of different values on a one-dimensional scale and thereby in preferably monotonic correlation influence the quality of a digital evaluation of an image recorded by the sensor. The values for the target parameters can thereby be given on a few discrete values according to a scale subdivision into a few ranges.
For example, in an advantageous embodiment the optical quality in the direction of a target object can be subdivided into several quality steps, to which a discrete numerical value is assigned in each case, wherein with monotonic sequence a better visibility leads to a higher prioritization value than a poorer visibility. The target distance can likewise as a target parameter be subject to this type of evaluation criterion, in that a small target distance indicates more reliable information from the automatic image evaluation than a greater target distance, and therefore a smaller target distance leads to a higher prioritization value than a large distance. In particular in the case of ships as maritime target objects, the aspect angle as the angle between the line of sight and the longitudinal direction of the ship plays an important role for the automatic evaluability of an image recorded by the image sensor, wherein a higher reliability of a target classification can be achieved with an aspect angle of 90° than with an aspect angle of 0° or 180°. As a further example of a weighted criterion in obtaining a weighted prioritization value in a recurring target object, the time between the current occurrence and the last classification of this target object in the automatic image evaluation can be used, wherein a longer time interval leads to a higher overall prioritization value than a short time interval. Finally, as a further example, the time used for a realignment of the image sensor to a target object compared to a previous alignment can also be used, wherein an angle difference in azimuth and/or elevation can be used as a gauge. Since this type of realignment due to motor-driven panning of the image sensor can easily take several seconds, it may be more favorable to prefer a target with an otherwise lower prioritization value but lower differential angle to a target object with an otherwise higher prioritization value but larger differential angle.
In obtaining the weighted prioritization value, it can also be provided that with one or more criteria or target parameters, the amount of the partial contribution to the total weighted prioritization value increases monotonically with decreasing reliability of the image evaluation, such a contribution to the overall prioritization value then being included as reducing the prioritization value, for example by a minus sign with a summation or as a denominator or part of a denominator in a ratio formation.
In general, the sensor assignment can be interpreted as an optimization problem in which the yield of information to be expected is maximized over all targets. The yield of information to be expected with a single target is a function of the ability of the sensor in an assignment to recognize the target, to carry out an assignment to the input and the threat to be expected from the target which is described by the weighted prioritization values by way of example.
In a particularly advantageous simple embodiment, a combination of a table prioritization value and a weighted prioritization value can be used to obtain a prioritization value. The stored target objects, to which new ones can be added constantly, are divided into a ranking based on the prioritization values assigned thereto, wherein without loss of generality it is assumed below that a higher prioritization value indicates a better ranking, i.e., a higher priority in the ranking of the successive processing of the target objects by the image sensor.
A control device controls the alignment of the image sensor to the respective target objects in that the target objects are processed in the order of the ranking generated from the prioritization values. A target object detected in this manner by the image sensor is subsequently deleted from the list, but upon renewed detection can again be specified as a target to be processed by the image sensor and again evaluated in the evaluation device.
A digital image generated by the image sensor for a target object is subjected to an automatic digital image evaluation. One or more further target parameters can be extracted from the automatic image evaluation. In particular, a further target parameter of this type can represent one of several predefined target classes. Another further target parameter can form information on visibility conditions in a particular spatial direction, for example.
In an advantageous further development, the further target parameters obtained in the automatic image evaluation in addition to the first target parameters determined in the sensor device can be assigned to the respective target objects and stored, if these target objects are to be subjected several times in chronological succession to an evaluation and an image evaluation. Direction-dependent target parameters obtained from the image evaluation, such as in particular, visibility conditions, glare conditions due to the position of the sun etc., can also be taken into account for other targets in the same or adjacent spatial directions in the evaluation as criteria.
In an advantageous further development it can be provided that the information obtained from the image evaluation, in particular the further target parameters extracted thereby, can be used to adaptively track individual criteria in the evaluation device and to hereby further improve the quality of the additional information from the image evaluation for the overall evaluation of the situation. The contribution to be expected from an individual target object to the total yield of information through sensor observations can hereby be acquired, as it were, and the function of the ability of the sensor to recognize the target in an assignment can thus be approximated.
In embodiments, the invention is directed to a method for detecting target objects by a first sensor device containing at least one first sensor and a second sensor device containing at least one second sensor, wherein the second sensor can be aligned by a control device in different spatial directions, with the following process steps: a) target objects are detected by the first sensor device; b) for the target objects respectively at least one first target parameter is determined; c) at least a part of the target objects is stored with the at least one first target parameter and information on the spatial direction of the target object relative to the position of the second sensor; d) the stored target objects are assessed based on target parameters and assessment criteria stored thereon and a highest priority target object is determined thereby; e) the second sensor is aligned to the highest priority target object determined in step d) and a sensor signal of the second sensor to the target object is obtained; f) by automatic evaluation of the sensor signal obtained on a target object in the second sensor at least one further target parameter is extracted; and g) the steps d) through f) are carried out repeatedly, optionally with the addition of newly added target objects according to a) through c).
In further embodiments, the at least one further target parameter is used to classify the target object in one of several classes of a classification.
In additional embodiments, the direction of movement of the target object relative to the image sensor and/or the speed of the target and/or the distance of the target is determined as a first target parameter.
In embodiments, the emission of radar or laser radiation by the target object is determined as a first target parameter.
In further embodiments, a recognizable signature of a radar or laser radiation emitted by the target object is determined as a first target parameter.
In additional embodiments, the target position of a target object is determined as a first target parameter.
In embodiments, at least one angle range of the alignment of the second sensor is predefined and reviewed as an assessment criterion, whether the target direction falls in this angle range.
In further embodiments, at least one partial area within the detection zone of the second sensor is predefined and reviewed as an assessment criterion, whether the target position lies in this partial area.
In additional embodiments, the time expenditure for the realignment of the second sensor to a target object is determined and taken into account in the assessment as a criterion.
In embodiments, a further target parameter extracted from the evaluation of the sensor signal of the second sensor to a target object is taken into account in the assessment as a criterion.
In further embodiments, at least one assessment criterion is adaptively changed taking into consideration the image evaluation.
In additional embodiments, respectively one prioritization value is generated in the application of the stored assessment criteria to the several target objects and the target object with the highest prioritization value is selected as the highest priority target object.
In embodiments, at least in one of the assessment criteria a first target parameter is compared to a threshold value and a binary value is generated.
In further embodiments, a multi-digit binary value is generated in at least one of the assessment criteria.
In additional embodiments, several binary values generated according to different assessment criteria are combined to form a table index and that with this table index as address, a prioritization table value is read out of a table.
In embodiments, a weighted prioritization value is determined by summation of weighted target parameters.
In further embodiments, a prioritization value is determined by the combination of a prioritization table value and a weighted prioritization value.
In additional embodiments, at least one absolute assessment criterion is applied to a first target parameter, with the non-satisfaction of which the target object is excluded from the current further processing.
In embodiments, an imaging electro-optical image sensor is used as a second sensor.
In further embodiments, a sensor that can be mechanically pivoted about at least one pivot axis is used as a second sensor.
In embodiments, the invention is directed to a system for detecting target objects, with a first sensor device containing at least one first sensor and a second sensor device with at least one second sensor, which can be aligned by a control device in different spatial directions, wherein: the first sensor device detects target objects and determines for them respectively a spatial direction regarding the position of the second sensor and at least one of several first target parameters; an assessment device determines a highest priority target object among several target objects on the basis of target parameters and stored assessment criteria; the control device aligns the second sensor to the highest priority target object previously determined; and an evaluation device extracts at least one further target parameter from the sensor signal of the second sensor
In further embodiments, the second sensor is arranged on a vehicle.
In additional embodiments, at least one first sensor of the first sensor device is arranged at a fixed spatial assignment to the second sensor.
In embodiments, at least one sensor of the sensor device is an active radar or laser sensor
In further embodiments, at least one sensor of the sensor device is a passive radar or laser detector.
In additional embodiments, a signature recognition device is assigned to the passive sensor.
In embodiments, the assessment device contains a binarily addressable table with prioritization table values.
In further embodiments, at least one assessment criterion can be adaptively adjusted in the assessment device.
In additional embodiments, the second sensor can be changeably aligned in azimuth and/or elevation in a motor-driven manner regarding a sensor carrier.
In embodiments, the second sensor is an image sensor.
In further embodiments, the image sensor is designed for the visible or the infrared spectral range.
In additional embodiments, the focal length of an optical system of the image sensor is changeable.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated further below based on advantageous exemplary embodiments. They show:
FIG. 1 A diagram of a detection system according to the invention;
FIG. 2 A diagrammatic structure of an evaluation device;
FIG. 3 A target from different aspect angles; and
FIG. 4 A range subdivision.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows in a diagrammatic representation essential components of a system according to the invention.
A sensor device SE contains one or more sensors S 1 , S 2 , . . . , which are designed for detecting target objects in a detection zone. A target object is designated by Z in FIG. 1 . The sensors S 1 , S 2 can be active radar sensors, for example, or laser sensors or can also be formed by purely passive sensors, which detect only electromagnetic radiation that is actively emitted by the target Z. SK is used to designate a further sensor which can be arranged at a distance from the sensor device SE and connected via a data connection to the sensor device SE or the evaluation device.
The sensor device SE detects target objects in its detection zone and generates target reports thereon and determines first target parameters assigned to the respective target objects. Several target parameters can be determined hereby for one target object.
The sensor device SE transmits reports on target objects together with information on the spatial direction in which the target is located, and with the first target parameters determined, to an evaluation device BE. The transmitted spatial direction information and first target parameters PA n are individually assigned to the individual target objects ZO n . Several first parameters can be assigned to each target object.
The evaluation device BE, which is shown in more detail diagrammatically in FIG. 2 , carries out an intermediate storage of the transmitted information while retaining the assignment to a certain target object and evaluates each target object ZO i , ZO i-1 , ZO i-2 , . . . based on the target parameters PA i , PA i-1 , PA i-2 , . . . stored therefor. The totality of the evaluation criteria is indicated overall by K m as an evaluation stage in the evaluation device.
The evaluation stage assigns a prioritization value PW n to each target object ZO n , based on which in a ranking register RR target information on the individual target objects is stored in an order determined by the respective prioritization values PW n , the first place of which being taken by the respectively highest priority target object. The ranking is not static and can change during the successive processing, in particular by newly detected target objects. Instead of the ranking, only one highest priority target object can also be respectively determined. The formation of a ranking has the advantage that only target objects to be newly evaluated have to be newly classified in the priority rank. The direction information R q of the respectively highest priority target object given to a sensor control SS, which aligns a second sensor mechanically and/or electronically alignable changing direction according to the direction information transmitted by the evaluation unit in the direction of this target object, i.e., assigns the second sensor to this target object. The target object hereby detected and evaluated by the second sensor can be evaluated anew and included in the ranking. In a preferred embodiment an electro-optical image sensor is assumed to be the second sensor below.
After the alignment of the image sensor in the desired spatial direction, the image sensor records a digital image and transmits it to an image evaluation device BA, which in a manner known per se extracts from the image information on a target object contained therein, for example, assigns such a target object with a certain probability to one of several target classes. The target class ZK n assigned to a target object ZO n in the image evaluation device BA in the image evaluation is fed to an evaluation device AE, which links the target class, if applicable, to further information, for example, the information transmitted by the sensor device SE.
In the image evaluation device BA, in addition to the assignment of a class, other target parameters PZ n can also be extracted and fed to the evaluation device BE, in order to take into account such a further target parameter as well with a new processing of the same target object.
In an advantageous further development it can be provided that the evaluation device AE evaluates the assigned target class and/or the overall situation so that the criteria stored in the evaluation unit BE can be modified to further improve the recognition of the overall situation. In FIG. 1 this is indicated by a path from the evaluation device AE to the assessment device BE and via this transmitted adaptation data AD.
The realignment of the image sensor including the recording of a digital image of the target typically takes several seconds. In successive processing of targets in the order of detection by the sensor device there would therefore be a danger that in this sense important targets that a quick reaction is necessary are reviewed too late by the image sensor. The assessment and assignment of a prioritization value and the processing in the order of the ranking of the prioritization values thus provides an automated and rapid processing with reproducible preference of targets with objectified importance for the overall situation.
An approach in the compilation of a prioritization value is described below in which two methods for generating a prioritization value are combined.
The following in particular can be reasons for an assignment (alignment) of the image sensor to a target object detected by the sensor device and the digital evaluation of a digital image of the target object recorded by the image sensor:
A detected target object has not previously been subjected to a detection by the image sensor and an automatic image evaluation, so that no further parameters extracted during the image evaluation are yet available; A target object that has been reported via a communications device, but could not yet be identified or classified by the originator thereof, comes into the detection zone of the electro-optical sensor; An already detected target object has been classified as (potentially) particularly threatening, because e.g.,
The target object is moving towards a protection object at high speed The target object has penetrated a special protection zone The target object emits an electromagnetic emission which is considered typical of an attack based on its characteristics, e.g., missiles (radar search head for missiles, fire-control radar of a combat aircraft, warship); and/or The target object is the source of a laser emission, e.g., a laser range finder, laser target designator or laser beam rider;
An already detected target object classified as non-threatening suddenly changes its behavior; A new target has been detected by a different sensor and is likewise to be detected by this sensor in order to complete the position information based on the image evaluation; and/or For an action against a target object not hitherto classified, the type of measure against the target is to be quickly optimized with the aid of the automatic image evaluation.
A first method for an evaluation with generation of a prioritization value is to use each of the cited points as an evaluation criterion K m , with the satisfaction of which, by a target object ZO n a partial value TW m stored for this criterion provides, as an addend, a contribution to a prioritization value PS formed by summation via the contributions by all M criteria K 1 through K M . Unsatisfied criteria do not make a contribution. Satisfaction or non-satisfaction of a criterion Km can be displayed in the assessment device by a binary satisfaction value E m which can have, e.g., the values 0 (zero) or 1. The prioritization value PS then results as the sum.
PS
=
∑
m
=
1
M
(
satisfactionvalue
m
*
TW
m
)
It is shown that frequently different combinations of satisfied and non-satisfied criteria have special effects on the significance of a target objet for the evaluation of the situation, which cannot be adequately taken into consideration by such a simple generation of a prioritization value as the sum.
In an advantageous further development, therefore, every evaluation criterion is not used individually as an addend of a summation, but a multi-digit binary word is formed from the satisfaction values TW m , wherein a fixed binary digit within the binary word is assigned to each criterion, in which the satisfaction value determined for this criterion is entered. A binary word of this type is then used as a key index for addressing a cell inside a table with stored prioritization values and the prioritization value stored in the addressed table cell is read out and assigned to the respective target object. The multi-digit binary word can (with m as the number of the respective criterion) also be expressed as a binary numerical value in the form
Index
=
∑
m
=
1
M
(
satisfactionvalue
m
*
2
m
)
However, the index does not have the function of a value further evaluated as a numerical value, but forms only a table address.
The prioritization value stored at the respectively associated table address forms an individual value for an individual combination of satisfied and non-satisfied criteria. With M criteria then 2 M individual prioritization values are stored as numerical values suitable for forming a ranking, of which some can be of the same size. Any interactions between individual criteria can hereby be advantageously taken into consideration in the stored priority values. There is also the possibility of assigning more than one binary digit to a criterion which cannot be usefully represented by a binary satisfaction value, so that a criterion as, e.g., a two-digit binary combination, can also assume four different values and this can be taken into consideration in the generation of the prioritization value.
Also with the first referenced embodiment, with the summation of partial values weighted with a satisfaction value over all criteria instead of a two-value satisfaction value 0/1, a greater differentiation of the satisfaction value can also be provided with more than two values.
It can also be provided for a part of the assessment criteria to carry out a weighted summation to obtain a first prioritization value and for another part of the assessment criteria to determine a second prioritization value from the table addressing with a multi-digit binary word and to link the two prioritization values, for example, to total them.
In particular with target parameters and criteria in which a greater value implies a lower prioritization value, it can be informative to consider contributions by such criteria as parts of a cost metric that has a negative effect in the generation of the prioritization value.
A cost metric of this type as a partial variable of a prioritization value can, for example, take into account the time taken for the realignment of the image sensor and possibly also the time for the image to be recorded by the sensor. The larger the panning angle for a realignment of the image sensor, the higher the contribution by the criterion of the alignment effort to a cost metric of this type, which in turn reduces the prioritization value, so that a target object otherwise of equal value with lower alignment effort is preferred. The contribution of this criterion reducing the prioritization value is expediently a function increasing monotonically with the alignment effort, for example, expressed as an amount of the panning angle necessary. A cost metric for the realignment of the image sensor to a target object can be expressed, for example, as a time effort cost metric
L time expenditure =f ( T align +T measurement )
in the total cost metric.
In the possible repetition of a measurement, that is, when a target object has already been measured once with this image sensor, another cost metric can result from the time difference to the last measurement, wherein a repeated measurement after a greater time interval compared to a repeated measurement after a shorter time interval is typically to be preferred. The contribution by this criterion then expediently forms a function monotonically decreasing with the time interval, e.g., a function decreasing in a linear or exponential manner between a maximum value and zero, and can be expressed as a repetition cost metric as a function of the time interval to the last measurement.
L repetition =f (time interval)
Further examples of criteria forming a cost metric can be parameters and factors which are of decisive importance for the quality of the image detection of the target object and the target object classification in the digital image evaluation, and thus, for the probability of success of an image detection and image evaluation, such as, in particular:
Distance of the image sensor from the target object; Light conditions; low brightness; Angular distance of the spatial direction of the target object from the current position of the sun; Visibility conditions (such as, e.g., rain, fog); and/or Movement of the target (speed, acceleration).
The above list is not to be considered complete or mandatory. Depending on the image sensor used, the list of criteria to be expediently used can vary.
Each of these criteria is weighted per se as an individual value and is included in the total cost metric as an individual cost metric, wherein the values are favorably restricted to a few discrete values.
Advantageous embodiments for discretization can be comparisons to predetermined threshold values (e.g., for the output of a brightness sensor or fog sensor used for support), wherein the several threshold values delimit value ranges adjoining one another. Exceeding one of the limit values generates the assigned discrete value.
The evaluation of all chances of success is taken into account with a cost metric for a possible failure. This cost metric can be advantageously realized by way of example by the following calculation:
L
failure
=
∑
m
=
1
M
(
weighting
m
*
discretizationvalue
m
)
where the following applies:
the weighting m designates the individual cost metric of a criterion “m,” the discretization value m designates a discrete value (with value range N 0 ={0, 1, 2, 3 . . . }), which increases, the more disadvantageously this criterion “m” is satisfied.
Example of discretization values of fog based on an arbitrary optical sensor:
0: clear visibility;
1: slight limitation;
2: light fog;
3: average fog;
4: poor visibility; and or
5: no visibility (sensor cannot be used).
Aspect Angle of the Target
It can be included as a further cost metric that, despite a successful assignment, the image information obtained thereby due to the unfavorable position of the target possibly renders a further automatic classification difficult or not useful at all.
By way of example, the aspect angle at which a target object is detected is cited.
If, for example, a ship is detected frontally from the front, this image of the ship is similar to many other types of ship, so that a precise classification is not possible.
However, if the target changes its position (aspect angle) relative to the line of sight between the image sensor and the ship so that the superstructures of the ship can be recognized spatially separated from one another, a more precise classification can also be carried out in an automated manner FIG. 3 shows a situation with an aspect angle of 0° ( FIG. 3 A) and a situation with an aspect angle of 90° ( FIG. 3 B), from which the influence of the aspect angle on the classification of this type of ship target MZ on an ocean surface MO is obvious.
The following definition is made to take into account the aspect angle:
If a target moves radially away from the sensor, the aspect angle is zero; If the sight connection from the sensor to the target is perpendicular to starboard, the aspect angle is 90 degrees; If a target moves radially towards the sensor, the aspect angle is 180 degrees; and/or If the sight connection from the sensor to the target is perpendicular to port, the aspect angle is 270 degrees.
A cost metric can therefore be defined, that is larger, the more unfavorable the aspect angle α.
One advantageous embodiment is a cost metric, that can be defined as follows:
L Aspect= L AspectMax*|cos α|
where LAspectMax is the maximum cost value at the most unfavorable angle directly from the front or the rear (where the aspect angle is zero or 180 degrees),
cos α is the angle function cosine for the aspect angle, and
|x| is the amount of a function or value.
The advantage of the calculation with the above-referenced formula is that for the aspect angle of 0 or 180 degrees the resulting cost metric yields the maximum, for the optimum aspect angle of 90 or 270 the function gives the value zero, that is, in this case no contribution to the total cost metric occurs.
The aspect angle, which is not usually exactly known, can be derived from the direction of the track based on the sensor position. For targets with lower to average maneuverability, this is sufficient. Otherwise, corresponding smoothing functions, such as an α-β filter, are favorable.
Based on all of the contributing factors that make an assignment appear unfavorable, a total cost metric is subsequently calculated:
L Total =L Time Expenditure +L Repetition +L Failure +L Aspect
For each target that is not already ruled out for an assignment based on a pre-selection with absolute criteria, a prioritization value is determined in the evaluation device for which the cited variants are to be understood as examples for possible approaches without loss of generality. If from parts of the evaluation criteria different contributions to a prioritization value are determined separately as partial prioritization values, the partial prioritization values are finally linked to one another, wherein an additive or subtractive as well as a ratio formation or combinations thereof are possible. For example, a first prioritization value referred to as a use value can be determined from an evaluation criteria set, such as is cited by way of example in the description of the determination of a prioritization value, and with the total cost metric described by way of example as a further prioritization value the ratio
V =Use Value/ L Total
can be determined and used as a prioritization value of the target object to be used for determining the ranking. The larger the ratio, the more suitable the target that is the next to be assigned to the sensor. Thus the target with the maximum is considered and allocated as the optimum pairing of sensor to target.
It is advantageous to already exclude those targets that in principle are not considered for an assignment of the sensor from further processing before the evaluation.
This includes in particular:
Targets in a blind spot of the sensor, e.g., regions in which the sensor has no visibility due to e.g. structural measures or due to the location (for example, ship superstructures); Targets in a No-Pointing zone, e.g., predetermined regions which are to be excluded for reasons of operational stipulations; Targets that are located outside the typical visual range (range) of the sensor; and/or Targets that are no longer visible for optical reasons, that is, outside the so-called line of sight (“behind the optical horizon”).
FIG. 4 shows in a simplified manner a plan view of a monitoring area of a system according to the invention, wherein EB designates a detection zone limited by a maximum distance for detection with the image sensor, BB designates a region that cannot be detected by the image sensor due to shading and NP designates a zone from which target reports are not processed further. The position of the image sensor is designated by SP.
The features given above and in the claims and discernible from the figures can be advantageously realized individually as well as in various combinations. The invention is not limited to the described exemplary embodiments, but can be modified within the scope of technical skill in different ways. In particular, in addition to the automated approach described, it can be provided that a measurement of a target object that can be initiated in a targeted manual manner is possible and can also have priority over the automatic handling. | Method for detecting target objects by a first sensor device containing at least one first sensor and a second sensor device containing at least one second sensor. The second sensor is alignable by a control device in different spatial directions. Method includes: detecting target objects by first sensor device, determining at least one first target parameter for target objects; and storing at least a part of target objects with at least one first target parameter and information on a spatial direction of target object relative to a position of second sensor. Method additionally includes: assessing stored target objects, and determining highest priority target object; aligning second sensor to highest priority target object, and obtaining a sensor signal of second sensor to target object; extracting at least one further target parameter by automatic evaluation of sensor signal; and performing assessing, aligning, and extracting repeatedly. | 6 |
This application is the US national phase of International Application No. PCT/CN2012/078165 filed on Jul. 4, 2012, which claims the priority of the Chinese Patent Application No. 201110288382.9, entitled “BANKNOTE INCLINATION CORRECTION DEVICE AND ATM”, filed with the Chinese Patent Office on Sep. 23, 2011, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to the technical field of paper correction, and in more to particular, to a correcting device for banknotes. The present invention also provides an automatic teller machine with the above correcting device for banknotes.
BACKGROUND OF THE INVENTION
In a deposit process via an ATM (abbreviation for the Automatic Teller Machine), banknotes are put often on the skew into a deposit opening of the ATM by a user. Therefore, the banknotes need to be corrected by a correcting device before entering into the inside of the ATM.
FIGS. 1 and 2 show an existing correcting device for banknotes with a cyclic correcting design. The process of correcting a skew banknote by the correcting device for banknotes is described as follows. After entering into the correcting device for banknotes, a banknote is transmitted to a correcting wheel 001 by a transmission wheel 007 , and in a banknote transmission passage 003 the banknote is subjected to a component force F′, parallel to the banknote transmission passage 003 and a component force F′ b perpendicular to the banknote transmission passage 003 imparted from the correcting wheel 001 . Under the action of the component force F′ a , the banknote is transmitted forward in the banknote transmission passage 003 ; meanwhile, under the action of the component force F′ b , the banknote is aligned toward a reference wall 004 . Thus, the banknote is transmitted forward in the banknote transmission passage 003 while being aligned by taking the reference wall 004 as a reference. A sensor 005 is used for detecting the obliquity of the banknote. If the obliquity of the banknote does not meet a requirement, the banknote may enter again into the correcting device for banknotes under the guiding of a reversing block 006 . The above process is repeated until the obliquity of the banknote meets the requirement. Then, the reversing block 006 is activated to change the direction of the passage, so that the banknote is transmitted out of the correcting device. Thus, the correcting process is completed.
The existing correcting device for banknotes adopts correcting wheels 001 singly arranged in three rows, and driven pressure wheels 002 corresponding to the correcting wheels 001 . Such a design aims to avoid the occurrence of banknote jam in the banknote transmission passage 003 as a forward corner of the banknote comes into contact with the reference wall 004 due to an excessive component force F′ b or a long-time action of the correcting wheel 001 . However, this design has the following disadvantages. When a small-dimension banknote (i.e. a banknote with both a small length and a small width) is transmitted longitudinally, the banknote moves to the reference wall 004 by a relatively long distance due to the small width of the small-dimension banknote itself, and the correcting wheel 001 acts on the banknote for a shortened time because of the small length of the small-dimension banknote. For the above two reasons, the small-dimension banknote may not be able to move to the reference wall 004 . Although the cyclic correcting design used in the existing correcting device for banknotes can overcome this problem, the next banknote can enter into the correcting device only after a previous banknote has been corrected and left the correcting device based on the cyclic correcting design, resulting in the discontinuousness of banknote transmission. The discontinuousness of banknote transmission will affect the working efficiency of the ATM, and then a functional requirement of transmitting banknotes at a high velocity continuously cannot be satisfied.
In sum, how to provide a correcting device for transmitting various-dimension banknotes at a high velocity continuously is a problem to be overcome presently by the skilled in the art.
SUMMARY OF THE INVENTION
In view of this, the present invention provides a correcting device for banknotes which can transmit various-dimension banknotes at a high velocity continuously.
In order to achieve the above object, the invention provides technical solutions as follows.
A correcting device for banknotes includes:
an inner passage plate and an outer passage plate, wherein a banknote transmission passage is formed between the inner passage plate and the outer passage plate;
a reference wall disposed on one side of the inner passage plate and the outer passage plate;
a transmission wheel located at the entrance of the banknote transmission passage and disposed on one of the inner passage plate and the outer passage plate;
a plurality of correcting wheel sets disposed on one of the inner passage plate and the outer passage plate, wherein each of the plurality of correcting wheel sets includes at least one correcting wheel oriented toward the reference wall; and
a transmission side wheel located between the reference wall and the plurality of correcting wheel sets, the transmission side wheel being parallel to the reference wall, wherein the rim linear velocity of the transmission side wheel is greater than the rim linear velocity of the at least one correcting wheel in each of the plurality of correcting wheel sets.
Preferably, in the above correcting device for banknotes, both the inner passage plate and the outer passage plate are an arc with a radian less than 360° in shape.
Preferably, the above correcting device for banknotes further includes a transmission floating pressure wheel mounted on the other one of the inner passage plate and the outer passage plate opposite to the transmission wheel, wherein the transmission floating pressure wheel is disposed such as to be in rolling contact with the transmission wheel.
Preferably, the above correcting device for banknotes further includes a correcting floating pressure wheel mounted on the other one of the inner passage plate and the outer passage plate opposite to the at least one correcting wheel in each of the plurality of correcting wheel sets, wherein the correcting floating pressure wheel is disposed such as to be rolling contact with the at least one correcting wheel in each of the plurality of the correcting wheel sets.
Preferably, the above correcting device for banknotes further includes the transmission floating pressure wheel, and the transmission side wheel is polygonal in shape.
Preferably, the above correcting device for banknotes further includes the transmission floating pressure wheel. The correcting wheel sets are four in number, and are disposed successively from the entrance of the banknote transmission passage and then away from the entrance.
Preferably, the above correcting device for banknotes further includes the transmission floating pressure wheel, and the correcting wheel set close to the transmission wheel includes two or more correcting wheels.
Preferably, the above correcting device for banknotes further includes the transmission floating pressure wheel, and multiple transmission wheels are provided on a drive shaft perpendicular to a banknote transmission direction such as to be spaced equidistantly with each other along the drive shaft.
Preferably, the above correcting device for banknotes further includes the transmission floating pressure wheel, and the transmission wheel is threaded such as to drive a banknote to move away from the reference wall.
Based on the above correcting device for banknotes, the present invention further provides an automatic teller machine including the correcting device for banknotes described above.
In the correcting device for banknotes according to the present invention, during the operation, the rim linear velocity of the transmission side wheel is greater than the rim linear velocity of the correcting wheel of the correcting wheel sets. Under the action of the transmission side wheel, the side of the banknote close to the transmission side wheel moves faster than the other side of the banknote close to the correcting wheel. The deflection of the banknote is achieved due to the velocity difference between the two sides of the banknote, so as to correct a banknote more efficiently and to more effectively prevent a forward corner, which is close to the correcting wheel, of the banknote from colliding with the reference wall to otherwise cause the banknote jamming or blocking phenomenon. Moreover, multiple correcting wheel sets are employed in the correcting device for banknotes, and each of the correcting wheel sets includes at least one correcting wheel. The multiple correcting wheels can increase the transverse component force of the correcting device perpendicular to the banknote transmission passages, so that a small-dimension banknote can reach the reference wall under the action of the transverse component force. Accordingly, the correcting device for banknotes according to the present invention improves the correcting effect, thereby increasing the probability of correcting banknotes in one cycle, and the probability of correcting various-dimension banknotes. Therefore, the correcting device for banknotes according to the present invention can transmit various-dimension banknotes continuously at a high velocity.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to more clearly illustrate the embodiments of the invention or the technical solutions of the prior art, drawings needed to be used in the description of the embodiments or the prior art will be introduced briefly as follows. It is obvious that the drawings described below are only some embodiments of the invention, and other drawings can be occurred to those skilled in the art based on these drawings without any creative effort.
FIG. 1 is a front view of an existing correcting device;
FIG. 2 is a top sectional view of an existing correcting device;
FIG. 3 is a front view of a correcting device for banknotes according to an embodiment of the present invention;
FIG. 4 is a side view of a correcting device for banknotes according to an embodiment of the present invention;
FIG. 5 is a sectional view taken along line A-A in FIG. 3 according to the embodiment of the present invention, showing a working state where a transmission side wheel presses a banknote so as to impart a force to the banknote;
FIG. 6 is a sectional view taken along line A-A in FIG. 3 according to the embodiment of the present invention, showing a working state where the transmission side wheel keeps away from the banknote so as to allow the banknote to be aligned to a reference wall successfully;
FIG. 7 is an outline view of a transmission side wheel according to an embodiment of the present invention;
FIG. 8 shows configuration and features of a transmission wheel and a process of correcting a banknote state according to an embodiment of the present invention;
FIG. 9 shows a correcting process in the case where a banknote in a first state enters into the correcting device and a force analysis of the banknote during the correcting process according to an embodiment of the present invention;
FIG. 10 shows a correcting process in the case where a banknote in a second state enters into the correcting device and a force analysis of the banknote during the correcting process according to an embodiment of the present invention; and
FIG. 11 shows a correcting process in the case where a banknote in a third state enters into the correcting device and a force analysis of the banknote during the correcting process according to an embodiment of the present invention.
REFERENCE NUMERALS IN FIGS. 3 TO 11
008 Inner Passage Plate,
009 Outer Passage Plate,
010 drive shaft,
011 transmission wheel,
012 belt pulley,
013 transmission floating pressure wheel,
014 transmission wheel set,
014 a first correcting wheel set,
014 b second correcting wheel set,
014 c third correcting wheel set,
014 d fourth correcting wheel set,
015 pulley,
016 gear,
017 rotating shaft,
018 transmission pulley,
019 transmission side wheel,
020 correcting floating pressure wheel,
021 banknote separating roller,
022 transmission device,
023 passage wheel.
DETAILED DESCRIPTION OF THE INVENTION
An object of the present invention is to disclose a correcting device for banknotes for transmitting continuously various-dimension banknotes at a high velocity. Another object of the present invention is to disclose an automatic teller machine with the correcting device.
The technical solutions in the embodiments of the present invention will be described clearly and completely in conjunction with the accompanying drawings in the embodiments of the present invention as follows. It is apparent that the described embodiments are only a part of and not all the embodiments of the present invention. All the other embodiments occurred by the skilled in the art based on the embodiments in the present invention without any creative effort fall within the scope of protection of the present invention.
Reference is made to FIGS. 3 and 4 . FIG. 3 is a front view of a correcting device for banknotes according to an embodiment of the present invention, and FIG. 4 is a side view of the correcting device for banknotes according to an embodiment of the present invention.
The embodiment of the present invention discloses a correcting device for banknotes including an inner passage plate 008 , an outer passage plate 009 , a reference wall 008 a , a transmission wheel 011 , a correcting wheel set 014 and a transmission side wheel 019 .
A banknote transmission passage, in which a banknote is transmitted, is formed between the inner passage plate 008 and the outer passage plate 009 .
The reference wall 008 a is disposed on one side of the inner passage plate 008 and the outer passage plate 009 . The banknote is aligned by taking the reference wall 008 a as a reference while it is conveyed forward in the banknote transmission passage. The correcting device for banknotes according to the embodiment of the present invention corrects a skew banknote depending on the reference wall 008 a as a reference. Specifically, the alignment of a banknote is achieved by lining up one side edge of the banknote against the reference wall 008 a . Therefore, the banknote must be fully moved to the reference wall 008 a.
The transmission wheel 011 is located at the entrance 1 of the banknote transmission passage, and is disposed on the inner passage plate 008 or the outer passage plate 009 . Multiple correcting wheel sets 014 are disposed on the inner passage plate 008 or the outer passage plate 009 . Each correcting wheel set includes at least one correcting wheel oriented toward the reference wall 008 a . The correcting wheels in respective correcting wheel sets 014 are mounted such as to be directed toward the reference wall 008 a at the same installation angle θ. The installation angle θ is an angle between the plane on which the correcting wheel is located and the plane on which the reference wall 008 a is located. In this way, the banknote is allowed to move toward the reference wall 008 a . The installation angle θ of the correcting wheel and the design rule of the correcting device are determined depending on the minimum-dimension banknote.
The installation angle θ of the correcting wheel in the correcting wheel sets 014 can be calculated by the following formulas:
V a =V *Sin θ (1)
V 1 =V *Cos θ (2)
S/V 1 =L/V a (3)
L=W 1 −W 2 (4)
It can be derived from formulas (1), (2), (3) and (4) that: θ=TAN −1 [(W 1 −W 2 )/S].
In these formulas, V a is the component velocity of a banknote; V 1 is the transmission velocity of a banknote in the banknote transmission passage; V is the transmission velocity of a correcting wheel in a correcting wheel set 014 ; S is the length of a banknote in a banknote transmission direction from the transmission wheel 011 to the passage wheel 023 in the correcting device; L is the distance by which a banknote moves in the direction perpendicular to the banknote transmission passage in the correcting device; W 1 is the width dimension of the correcting device; and W 2 is the width of a minimum-dimension banknote.
The installation angle θ of the correcting wheel must be determined such as to ensure that the minimum-dimension banknote (having a minimum width) moves to the reference side within a time T from the side of the correcting device opposite to the reference side. The time T is the time that a banknote passes through the correcting device at a component velocity V 1 in a direction perpendicular to the banknote transmission passage.
The transmission side wheel 019 is located between the reference wall 008 a and the correcting wheel sets 014 , and is installed at one end of a rotating shaft 017 . At the other end of the rotating shaft 017 a transmission pulley 018 is provided to supply with power to the rotating shaft 017 . The transmission side wheel 019 is parallel to the reference wall 008 a , and has a rim linear velocity greater than that of the correcting wheel of the correcting wheel sets 014 . In the case that banknote is wrinkled or turned up and thus cannot be transmitted forward, since the rim linear velocity of the transmission side wheel 019 is faster than that of the correcting wheel of the correcting wheel sets 014 , the transmission velocities on both sides of banknotes are not the same. That is, the transmission velocity of the side of the banknote at the transmission side wheel 019 is faster than that of the other side of the banknote at the correcting wheel sets 014 , so that the banknote may be deflected away from the reference wall 008 a . When the side edge of the banknote near the reference wall 008 a is deflected to lean against the reference wall 008 a , and thus is blocked by the reference wall 008 a . At this time, even under the action of the transmission side wheel 019 , the banknote will not be deflected so as to achieve a correcting effect.
In the correcting device for banknotes according to the present invention, during the operation, the rim linear velocity of the transmission side wheel is greater than the rim linear velocity of the correcting wheel of the correcting wheel sets. Under the action of the transmission side wheel, the side of the banknote close to the transmission side wheel moves faster than the other side of the banknote close to the correcting wheel. The deflection of the banknote is achieved due to the velocity difference between the two sides of the banknote, so as to correct a banknote more efficiently and to more effectively prevent a forward corner, which is close to the correcting wheel, of the banknote from colliding with the reference wall to otherwise cause the banknote jamming or blocking phenomenon. Moreover, multiple correcting wheel sets are employed in the correcting device for banknotes, and each of the correcting wheel sets includes at least one correcting wheel. The multiple correcting wheels can increase the transverse component force of the correcting device perpendicular to the banknote transmission passages, so that a small-dimension banknote can reach the reference wall under the action of the transverse component force. Accordingly, the correcting device for banknotes according to the present invention improves the correcting effect, thereby increasing the probability of correcting banknotes in one cycle, and the probability of correcting various-dimension banknotes. Therefore, the correcting device for banknotes according to the present invention can transmit various-dimension banknotes continuously at a high velocity.
To further optimize the above technical effect, as shown in FIG. 4 , both the inner passage plate 008 and the outer passage plate 009 are of an arc shape with a radian less than 360°. The existing correcting device for banknotes is of a closed circular shape, and operates in a cyclic correcting process in which, only after a previous banknote has been corrected and moved away from the correcting device, the next banknote can enter into the correcting device. In the correcting device according to the present invention, the various-dimension banknotes can be aligned to the reference wall 008 a to achieve the correction in one cycle, without the need of adopting the banknote cyclic correcting process. Therefore, the device of the present invention is designed such as to be in an arc shape with a radian less than 360°.
The correcting device for banknotes according to the invention further includes a transmission floating pressure wheel 013 . The transmission floating pressure wheel 013 is mounted on the inner passage plate 008 or the outer passage plate 009 opposite to the transmission wheel 011 , and is disposed in rolling contact with the transmission wheel 011 . The correcting device for banknotes further includes a correcting floating pressure wheel 020 . The correcting floating pressure wheel 020 is mounted on the inner passage plate 008 or the outer passage plate 009 opposite to the correcting wheel, and is disposed in rolling contact with the correcting wheel of the correcting wheel set 014 . If the transmission wheel 011 is installed on the inner passage plate 008 , there is a need for a certain space in the inside of the inner passage plate 008 to accommodate a power source and associated transmission structures; accordingly, a transmission floating pressure wheel 013 is installed on the outer passage plate 009 opposite to the inner passage plate 008 . In an alternative way, if the transmission wheel 011 is installed on the outer passage plate 009 , there is a need for a certain space in the inside of the outer passage plate 009 to accommodate a power source and associated transmission structures; accordingly, the transmission floating pressure wheel 013 is installed on the inner passage plate 008 opposite to the outer passage plate 009 . Under the tension action of the spring force, the transmission floating pressure wheel 013 always is in rolling contact with the transmission wheel 011 , and presses banknotes to transmit the banknotes. Similarly, the correcting floating pressure wheel 020 is installed and transmits banknotes in the same processes as that of the transmission floating pressure wheel 013 , which will not be repeatedly described herein.
The transmission side wheel 019 of the correcting device for banknotes according to the invention is polygonal in shape. Referring to FIGS. 5 to 7 , FIG. 5 is a sectional view taken along line A-A in FIG. 3 according to an embodiment of the invention, showing a working state where the transmission side wheel presses a banknote so as to impart a force on the banknote; FIG. 6 is a sectional view taken along line A-A in FIG. 3 according to an embodiment of the invention, showing a working state where the transmission side wheel keeps away from a banknote so as to allow the banknote to be aligned against a reference wall successfully; and FIG. 7 is an outline view of a transmission side wheel according to an embodiment of the present invention.
Considering that the banknote must pass through the transmission side wheel 019 before moving to the reference wall 008 a , the transmission side wheel 019 in the present invention is designed to be polygonal in shape. Referring to FIG. 5 , when the transmission side wheel 019 is in contact with the banknotes, the arc face 3 at the maximum diameter of the transmission side wheel 019 is lower than the arc face 4 of the inside passage of the outer passage plate 009 . The transmission side wheel 019 applies a resistance force to the banknote moving towards the reference wall 008 a while pressing the banknote downwards, so that the banknote no longer moves towards the reference wall 008 a . Referring to FIG. 6 , after the arc face 3 at the maximum diameter of the transmission side wheel 019 moves away from the banknote, there is a certain gap between a side 5 of the polygonal transmission side wheel 019 and the banknote, that is, the transmission side wheel 019 may not contact with the banknote. Thus, the transmission side wheel 019 no longer prevents the banknote from aligning to the reference wall 008 a . In this way, the transmission side wheel 019 can not only apply transmission force in transmission direction to the banknote, but also enable the banknote to move toward the reference wall 008 a . Referring to FIG. 7 , the transmission side wheel 019 is pentagonal in shape, but the design of the transmission side wheel 019 is not limited to the pentagonal shape. The transmission side wheel 019 can be made of rubber materials to increase the friction force between the transmission side wheel 019 and the banknote, and to improve the efficiency of the device transmitting banknotes.
Referring to FIG. 3 , the correcting wheel sets 014 of the correcting device for banknotes according to the present invention are four in number, and are disposed successively from the entrance of the banknote transmission passage in a direction away from the entrance. The number of the correcting wheels in the correcting wheel set 014 close to the transmission wheel 011 is two or more. The correcting wheel sets 014 are located in middle of the banknote transmission passage, and are four in number, i.e. a first correcting wheel set 014 a , a second correcting wheel set 014 b , a third correcting wheel set 014 c and a fourth correcting wheel set 014 d . The correcting wheel set close to the transmission wheel 011 , i.e. the first correcting wheel set 014 a , includes two or more correcting wheels. After the power is transmitted to the second correcting wheel set 014 b through a pulley 015 , the second correcting wheel set 014 b in turn transmits the power to the subsequent correcting wheel sets through a gear 016 so as to ensure that the correcting wheels rotate in the same direction at the same velocity. It should be noted that one correcting wheel may be included in the correcting wheel set close to the transmission wheel 011 . However, in the case that the correcting wheel set close to the transmission wheel 011 is configured with only one correcting wheel, the banknote may be deflected greatly about a holding point under the holding action of single correcting wheel so that the banknote can not be efficiently corrected. Therefore, two or more correcting wheels are preferably provided in the first correcting wheel set 014 a close to the transmission wheel 011 . This configuration can ensure that multiple correcting wheels synchronously act on the banknote when the various-dimension banknote enters into the correcting wheel sets 014 to be hold, so as to prevent the excessive deflection of the banknote which would be caused by the single correcting wheel acting on the banknote, thereby enabling the banknote to be effectively corrected and then depart from the exit 2 of the correcting device.
Under the action of the multiple correcting wheels, a force Fa perpendicular to the banknote transmission passage to which the banknotes are subjected increases, ensuring that minimum-dimension banknotes can be aligned with the reference wall 008 a in the correcting device, so as to correct banknotes in one cycle.
Referring to FIG. 3 , there are multiple transmission wheels 011 in the correcting device for banknotes according to the present invention. The multiple transmission wheels 011 are disposed on a drive shaft 010 perpendicular to the transmission direction of the banknotes and are arranged and spaced with equal distance along the drive shaft 010 . The transmission wheel 011 is provided with threads so as to drive the banknote to move away from the reference wall 008 a . A wheel outer circumferential surface of the transmission wheel 011 is configured with a spiral flange with a certain helix lead angle. According to the spiral configuration direction of the transmission wheel 011 , the banknote moves away from the reference wall 008 a . Therefore, the transmission wheel 011 has a role of appropriate adjustment to the skew extent of the banknote. This adjustment not only can prevent in advance the banknote from being turned up by the forward corner of the banknote early contacting with the reference wall 008 a , but also can facilitate subsequent movement of the banknote.
Preferably, the reference wall 008 a and the inner passage plate 008 are designed into one-piece structure, so as to eliminate the jamming of the banknote resulting from a joint gap between the reference wall 008 a and the inner passage plate 008 .
The present invention discloses an automatic teller machine including a correcting device for banknotes as described above. The automatic teller machine according to the invention also has the technical effects mentioned above by adopting the above correcting device for banknotes, which will not be described herein.
In sum, the invention discloses a working process of a correcting device for banknotes.
Referring to FIGS. 4 and 8 to 11 , FIG. 8 shows configuration and features of a transmission wheel and a process of correcting a banknote state according to an embodiment of the present invention; FIG. 9 shows a correcting process in the case where a banknote in a first state enters into the correcting device and a force analysis of the banknote during the correcting process according to an embodiment of the present invention; FIG. 10 shows a correcting process in the case where a banknote in a second state enters into the correcting device and a force analysis of the banknote during the correcting process according to an embodiment of the present invention; and FIG. 11 shows a correcting process in the case where a banknote in a third state enters into the correcting device and a force analysis of the banknote during the correcting process according to an embodiment of the present invention.
Referring to FIG. 4 , after passing through the separating roller 021 , the banknotes are continuously separated one after another, pass through the transmission device 022 , and are arranged on the banknote transmission passage with the same intervals so as to enter into the correcting device. After entering the correcting device, the banknotes is clamped by a row of transmission wheels 011 disposed on the banknote transmission path at the entrance of the correcting device and the transmission floating pressure wheels 013 disposed on the other side of the passage corresponding to the transmission wheel 011 . As shown in FIG. 8 , the banknote moves away from the reference wall 008 a under a force F1 of the transmission wheels 011 depending on the direction of configuration of the threads on the transmission wheels 011 .
Referring to FIGS. 9 , 10 and 11 , a banknote in different form enters into the correcting wheel sets 014 of the correcting device. The following description is only made with reference to the limit positions illustrated in FIG. 9 . FIGS. 10 and 11 show the banknote states where the banknote may be corrected by the existing correcting device, which will not be discussed particularly. After a banknote in a banknote state c shown in FIG. 9 enters into the correcting device, the spiral transmission wheel 011 at the entrance is unable to deflect a forward corner of the banknote away from the side wall. The banknote in a banknote state c shown in FIG. 9 enters into the correcting wheel sets 014 of the correcting device, and under a clamping component Fa of the correcting wheel sets 014 , the banknote begins to be aligned with the reference. At this time, the banknote which has already been in contact with the reference wall is subjected to a resistance force f of the reference wall. The banknote continues to move toward the reference wall under a transverse component Fa of the correcting wheel 014 . If the process goes on, the forward corner of the banknote is wrinkled or turned up in the case of insufficient rigidity, causing banknote jamming or blocking. The transmission side wheel 019 designed to be polygonal will press downwardly the side of the banknote close to the reference wall, which can loose the forward corner of the banknote contacting with the reference wall, with the resistance force f disappearing. Because the transmission side wheel 019 applies a resistance force f′ to the banknote moving toward the reference wall 008 a while pressing the banknote downwards, the banknote no longer moves toward the reference wall 008 a . At this time, since the rim linear velocity of the transmission side wheel 019 is greater than the rim linear velocity of the correcting wheel, that is, V2>V1, the banknote can be deflected, so that the forward corner of the banknote will gradually move away from the reference wall 008 a . After the forward corner of the banknote moves away from the reference wall 008 a , the banknote is subject to the actions of the correcting wheel sets 014 and the transmission side wheel 019 at the same time. The rim linear velocity of the transmission side wheel 019 is greater than the rim linear velocity of the correcting wheel, resulting in the different transmission velocities at both sides of the banknote. In other words, the side of the banknote at the transmission side wheel 019 is transmitted at a greater velocity than the side of the banknote at the correcting wheel, that is, V2>V1, and thus the banknote may be deflected. The banknote leaves the correcting device after the side edge of the banknote is deflected to be aligned with the reference wall 008 a.
The above description of the embodiments of the disclosure enables the skilled in the art to implement or use the present invention. Numerous modifications to these embodiments will be apparent for the skill in the art. The general principle defined herein can be applied to other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to these embodiments shown herein, but is to comply with the widest range coincident with the principle and novel characteristics of the disclosure. | A banknote inclination correction device and an ATM (Automatic Teller Machine) including the banknote inclination correction device. The banknote inclination correction device includes: an inner channel board ( 008 ); an outer channel board ( 009 ); a banknote transfer channel formed between the inner channel board ( 008 ) and the outer channel board ( 009 ); a reference wall ( 008 a ) arranged on one side of the inner channel board ( 008 ) and the outer channel board ( 009 ); a transfer wheel ( 011 ) located at the inlet of the banknote transfer channel, and arranged on the inner channel board ( 008 ) or the outer channel board ( 009 ); multiple inclination correction wheel groups ( 014 ) configured on the inner channel board ( 008 ) or the outer channel board ( 009 ); and a transfer side wheel ( 019 ) located between the reference wall ( 008 a ) and the multiple inclination correction wheel groups ( 014 ), the transfer side wheel ( 019 ) is parallel to the reference wall. Each inclination correction wheel group ( 014 ) includes at least one inclination correction wheel, and the inclination correction wheel is inclined towards the reference wall ( 008 a ). The edge line speed of the transfer side wheel ( 019 ) is larger than that of the inclination correction wheel of the inclination correction wheel groups ( 014 ). The multiple inclination correction wheels of the transfer side wheel ( 019 ) improve the effect of inclination correction, so that the banknote can reach a corrected state at a time, and various types of banknotes can be transferred continuously and at high speed. | 1 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.